Kaysun KEM-75 DRS5 KH Modular Full DC Inverter Chillers with Hydraulic

Kit

Product Information

Specifications

• Model: DC Inverter Air-cooled Modular Chiller
• Available Models: KEM-75 DRS5 KH, KEM-90 DRS5 KH, KEM-140 DRS5 KH, KEM-180 DRS5 KH
• Power Supply: 380-415V 3N~50Hz
• Operating Temperature Range:
  • KEM-75 DRS5 KH & KEM-140 DRS5 KH: Cooling 55°C, Heating 50°C
  • KEM-90 DRS5 KH & KEM-180 DRS5 KH: Cooling 55°C, Heating 50°C

Product Usage Instructions

1. Safety Considerations

Follow the safety precautions mentioned in the manual to avoid any potential hazards. Pay attention to the DANGER, WARNING, CAUTION, and NOTE symbols for different levels of risk.

2. Before Installation

Before installation, read the manual carefully and ensure you have all the necessary accessories. Check the power supply voltage requirements and the operating temperature ranges for optimal performance.

3. Installation Site Selection

Choose a suitable installation site that meets the requirements outlined in the manual. Consider factors like ventilation, space, and access for maintenance.

4. Precautions on Installation

Follow the connection drawing of the pipeline system provided in the manual for correct installation. Ensure all connections are secure and proper insulation is in place.

5. Start-Up and Configuration

Follow the instructions for start-up and configuration to ensure the unit functions correctly. Set up any required components as per the installation manual.

6. Test Run and Final Check

After installation, perform a test run to check the unit’s operation. Verify all connections, settings, and components for proper functioning.

7. Maintenance and Upkeep

Regular maintenance is essential for optimal performance. Refer to the maintenance section in the manual for guidance on upkeep tasks.

FAQs

• Q: What should I do if the unit shows an error code?
  • A: Refer to the troubleshooting section of the manual to identify the error code and follow the recommended steps to resolve it.
• Q: Can I install the unit myself?
  • A: It is recommended to hire a professional HVAC technician for installation to ensure proper setup and avoid any potential issues.

OWNER’S & INSTALLATION MANUAL
DC Inverter Air-cooled Modular Chiller

KEM-75 DRS5 KH KEM-90 DRS5 KH

KEM-140 DRS5 KH

KEM-180 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.

APPLICABLE MODELS AND MAIN PARAMETERS

13 INFORMATION REQUIREMENTS 46

ACCESSORIES

Unit Quantity

Installation & Operation Manual
1

Water Temperature Sensor
2

ErP Information
1

Temperature testing components of total
water outlet 1

Transformer

Installation manual of wired controller

1

1

Shape

Purpose

/

KEM-180 DRS5 KH, 4pcs

/

Use for installation (only need for setting the main module)

INTRODUCTION

11 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.

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
55

HEATING
50

50

45

45

40

40

35

outdoor temperature (°C)

outdoor temperature (°C)

35 30 25 20 15 10
5 0
0 -5 -10 -15

5

10 15

20 25 30

Outlet water temperature (°C)

30 25 20 15 10
5 0
20 -5 -10 -15 -20 -25

25 30

35

40

45

50

Outlet water temperature (°C)

55 60

Fig. 1-1-1 Cooling operating range

Fig. 1-1-2 Heating operating range

KEM-90 DRS5 KH&KEM-180 DRS5 KH

KEM-90 DRS5 KH&KEM-180 DRS5 KH

COOLING
55

HEATING
50

50

45

45

40

40

35

outdoor temperature (°C)

outdoor temperature (°C)

35 30 25 20 15 10
5 0 -5 -10 -15
0

5

10

15

20

25

30

Outlet water temperature (°C)

30 25 20 15 10
5 0 -5 -10 -15 -20 -25
20 25 30 35 40 45 50 55 60
Outlet water temperature (°C)

Fig. 1-2-1 Cooling operating range

Fig. 1-2-2 Heating operating range

Low leaving water temperature mode can be set by wired controller, please refer to the Operation Manual(select “LOW OUTLETWATER CONTROL” under “SERVICE MENU” page) for details. If low leaving water temperature function is effective, the operation range will extend to the shadow area. When the setting water temperature is less than 5°C, antifreeze liquid (concentration above 15%) should be added in the water system, otherwise the unit and the water system will be damaged.

01

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.
i 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. 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 professional installers.
· All the activities described in this manual must be carried out by a licensed technician. Be sure to wear adequate personal protection equipments such as gloves and safety glasses while installing the unit or carrying out maintenance activities.
· Contact your dealer for any further assistance.

DANGER
Indicates an imminently hazardous situation which if not avoided, will result in serious injury.
————————————————————————————————-
WARNING
Indicates a potentially hazardous situation which if not avoided, could result in serious injury.
————————————————————————————————-
CAUTION
Indicates a potentially hazardous situation which if not avoided, may result in minor or moderate injury. It is also used to alert against unsafe practices.
————————————————————————————————-
NOTE
Indicates situations that could only result in accidental equipment or property damage.

Explanation of symbols displayed on the indoor unit or outdoor unit

WARNING

This symbol shows that this appliance used a flammable refrigerant. If the refrigerant is leaked and exposed to an external ignition source, there is a risk of fire.

CAUTION This symbol shows that the operation manual should be read carefully.

CAUTION

This symbol shows that a service personnel should be handling this equipment with reference to the installation manual.

CAUTION

This symbol shows that a service personnel should be handling this equipment with reference to the installation manual.

CAUTION

This symbol shows that information is available such as the operating manual or installation manual.

DANGER
· Before touching electric terminal parts, turn off power switch. · When service panels are removed, live parts can be easily touched by accident. · Never leave the unit unattended during installation or servicing when the service panel is removed. · Do not touch water pipes during and immediately after operation as the pipes may be hot and could burn your hands. To
avoid injury, leave the piping drip to room temperature or be sure to wear protective gloves. · Do not touch any switch with wet fingers. Touching a switch with wet fingers can cause electrical shock. · Before touching electrical parts, turn off all applicable power to the unit.

02

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 by suffocation.
· Safely dispose of packing materials such as nails and other metal or wood parts that could cause injuries.
· Ask your dealer or qualified personnel to perform installation work in accordance with this manual. Do not install the unit yourself. Improper installation could result in water leakage, electric shocks or fire
· Be sure to use only specified accessories and parts for installation work. Failure to use specified parts may result in water leakage, electric shocks, fire, or collapse from its mount.
· Install the unit on a foundation that can withstand its weight. Insufficient physical strength may cause the equipment to fall and possible injury.
· Perform specified installation work with full consideration of strong wind, hurricanes, or earthquakes. Improper installation work may result in accidents due to equipment falling.
· Make sure that all electrical work is carried out by qualified ersonnel according to the local laws and regulations and the manual switch should be installed individual circuit separate circuit. Insufficient capacity of the power supply circuit or improper electrical construction may lead to electric shocks or fire.
· Be sure to install a ground fault circuit interrupter according to local laws and regulations. Failure to install a ground fault circuit interrupter may cause electric shocks and fire.
· Make sure all wiring is secure. Use the specified wires and ensure that terminal connections or wires are protected from water and other adverse external forces. Incomplete connection or affixing may cause a fire.
· When wiring the power supply, tidy the wires so that the front panel can be securely fastened. If the front panel is not in place there could be overheating of the terminals, electric shocks or fire.
· After completing the installation work, make sure that there is no refrigerant leakage.
· Never directly touch any leaking refrigerant as it could cause severe frostbite.Do not touch the refrigerant pipes during or soon after operation as the refrigerant pipes may be hot or cold, . Burns or frostbite are possible if you touch the refrigerant pipes. To avoid injury, leave the pipes return to normal temperature or, wear protective gloves if you have to touch the piping.

· Do not touch the internal parts (pump, backup heater, etc.) during or soon after operation. Touching the internal parts can cause burns. To avoid injury, leave the internal parts return to normal temperature or, wear protective gloves if you have to touch the piping.
· Do not accelerate the defrosting process or clean manually, unless those recommended by the manufacturer.
· The appliance shall be stored in a room without continuously operating ignition sources (for example: open flames, an operating gas appliance or an operation electric heater.)
· Do not pierce or burn the unit.
· Be aware that refrigerants may not contain an odour.

Caution: Risk of fire/ flammable materials

CAUTION
· Ground the unit.
· Grounding resistance should be according to local laws and regulations.
· Do not connect the ground wire to gas or water pipes, lightning conductors or telephone ground wires. Incomplete grounding may cause electric shocks.
– Gas pipes: Fire or an explosion might occur if the gas leaks. – Water pipes: Hard vinyl tubes are not effective grounds. – Lightning conductors or telephone ground wires: Electrical threshold may rise abnormally if struck by a lightning bolt.
· Install the power wire at least 3.3 feet (1 meter) away from televisions or radios to prevent interference or noise. (Depending on the radio waves, a distance of 3.3 feet (1 meter) may not be sufficient to eliminate the noise.)
· Do not wash the unit by water. This may cause electric shocks or fire. The appliance must be installed in accordance with national wiring regulations. If the supply cord is damaged, it must be replaced.

03

· 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. – Where there is machinery which emits electromagnetic waves. Electromagnetic waves can disturb the control system and cause equipment malfunction. – Where flammable gases may leak, where carbon fiber or ignitable dust is suspended in the air or where volatile flammables such as paint thinner or gasoline are handled. These types of gases might cause a fire. – Where the air contains high levels of salt such as near the seaside. – Where voltage fluctuates a lot, such as in factories. – In vehicles or vessels. – Where acidic or alkaline vapors are present.
· Children should not play with the unit. Cleaning and user maintenance should not be done by children without supervision.
· This appliance is intended to be operated by expert or trained users in shops, in light industry and on farms, or for commercial use by lay persons
· If the supply cord is damaged, it must be replaced by the manufacturer or its service agent or a similarly qualified person in order to avoid a hazard.
· DISPOSAL: Do not dispose this product as unsorted municipal waste. Collection of such waste seperatelly for special treatment is necessary. Do not dispose of electrical appliances as municipal waste, use seperate collection facilities. Contact your local goverment for information regarding the collection systems available. If electrical appliances are disposed of in landfills or dumps, hazardous substance can leak into the groudwater and get into the food chain, damaging your health and well-being.
· The wiring must be performed by professional technicians in accordance with national wiring regulation and this circuit diagram. An all-pole disconnection device which has at least 3mm seperation distance in all pole and a residualcurrent device (RCD) with the rating not exceeding 30mA shall be incorporated in the fixed wiring according to the national rule.
· Confirm the safety of the installation area ( walls, floors, etc. ) without hidden dangers such as water, electricity, and gas before the wiring and piping works.
· Before installation, check whether the user’s power supply meets the electrical installation requirements of unit ( including reliable grounding , leakage , and wire diameter electrical load, etc. ). If the electrical installation requirements of the product are not met, the installation of the product is prohibited until rectified.
· When installing multiple units in a centralized manner, please confirm the load balance of the three-phase power supply, and multiple units are prevented from being assembled into the same phase of the three-phase power supply.
· Product installation should be fixed firmly, Take reinforcement measures, if necessary.
NOTE
· About Fluorinated Gasses – This air-conditioning unit contains fluorinated gasses. For specific information on the type of gas and the amount, please refer to the relevant label on the unit itself. Compliance with national gas regulations shall be observed. – Installation, service, maintenance and repair of this unit must be performed by a certified technician. – Product uninstallation and recycling must be performed by a certified technician. – If the system has a leak-detection system installed, it must be checked for leaks at least every 12 months. When the unit is checked for leaks, proper record- keeping of all checks is strongly recommended.

BEFORE INSTALLATION

31 Handling of the unit
The angle of inclination should not be more than 15º when carrying the unit in case of overturn of the unit. 1) Rolling handling: several rolling rods of the same size are placed under the base of the unit, and the length of each rod must be more than the outer frame of the base and suitable for balancing of the unit.
04

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. It is strictly forbidden to stand under the machine when it is hoisted.

Lifted cable

the angle of inclinaton
4 protective blocks should be placed. Unilateral distance should be 50mm or more.

Lifted hook

Lifted hook Fig. 3-1 lifting of the unit

4 IMPORTANT INFORMATION ON REFRIGERANT

This product contains fluorinated greenhouse gases covered by the Kyoto Protocol. Do not vent gases into the atmosphere. Refrigerant type: R32 GWP value: 675 GWP : global warming potential The refrigerant volume is indicated on the unit nameplate · Add the refrigerant
Amount of factory-charged refrigerant and tonnes CO2 Equivalent is Table 4-1

Model KEM-75 DRS5 KH KEM-90 DRS5 KH KEM-140 DRS5 KH KEM-180 DRS5 KH

Refrigerant(kg) 9 16
15.5 32.0

Tonnes CO2 equivalent 6.08 10.80 10.46 21.60

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.
4. If the unit can be achieved by unauthorized personnel, take protective measures for safety considerations, such as installing a fence. These measures can prevent man-caused or accidental injuries, and can also prevent the electrical parts in operation from being exposed when the main control box is opened.
5. Install the unit on a foundation at least 200 mm high above the ground, where the floor drain is needed, to ensure that no water accumulate.
6. If installing the unit on the ground, put the steel base of the unit on the concrete foundation, which must be as deep as into the solid soil layer. Ensure the installation foundation is separated from buildings, as the noises and vibration of the unit may adversely affect the latter. By means of the installation holes on the unit base, the unit can be fastened on the foundation reliability.
7. If the unit is installed on a roof, the roof must be strong enough to bear the weight of the unit and the weight of maintenance personnel. The unit can be placed on the concrete and groove-shaped steel frame, similar to the case when the unit is installed on the ground. The weight-bearing groove-shaped steel must match the installation holes of the shock absorber and is wide enough to accommodate the shock absorber.
8. For other special requirements for installation, please consult the building contractor, architectural designer or other professionals.
   NOTE
   The selected installation site of the unit should facilitate connection of water pipes and wires, and be free from water inlet of oil fume, steam or other heat sources. Besides, the noise of the unit and cdischarge air should not influence the surrounding environment.

05

PRECAUTIONS ON INSTALLATION

61 Outline dimensional drawing

Front view

Left view

Top view
Fig. 6-1 Outline dimensional

06

Front view

Left view

Top view

Table 6-1
Model A B C D E F

KEM-75 DRS5 KH 2000 960 1770 816 190 270

KEM-90 DRS5 KH 2220 1135 2315 910 255 270

KEM-140 DRS5 KH 2220 1135 2300 910 185 380

KEM-180 DRS5 KH 2752 2220 2413 836 356 270

NOTE
After installing the spring damper, the total height of the unit will increase by 135mm approximately.

07

62 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. If the unit needs to be provided with sunk fence, the height of the latter should not be more than that of the former; if Persian blinds are required, the total loss of static pressure should be less than the static pressure outside the fan. The space between the unit and sunk fence or Persian blinds should also meet the requirement
3. If the unit needs to operate in winter, and the installation site may be covered by snow, the unit should be located higher than the snow surface, to ensure that air flows through the coils smoothy.

G

Input of airow

B

A

D

Main unit

Input of airow

Main unit

Input of airow

C

Input of airow Fig. 6-3 single unit installstion

B

Input of airow

Main unit

E Main unit

E Main unit

F

F

A

Main unit

E Main unit

E Main unit

D

F

F

Main unit

E Main unit

E Main unit

C

Input of airow

Fig. 6-4 multiple units installstion

Table 6-2
A B C D

1500 1500 1500 1500

Installation space (mm) E F G /

800 1100 3000
/

WARNING
When the number of units installed in the same place is greater than 40 units, please contact professionals to confirm the installation method.

08

63 Installation foundation
631 Base structure
Outdoor unit base structure design should take account of the following considerations:

1. A solid base prevents excess vibration and noise. Outdoor unit bases should be constructed on solid ground or on structures of sufficient strength to support the units’ weight.

Inlet and outlet pipe side
Drainage channel

Anchor bolt

(unit: mm)

Electric control box side

2. Bases should be at least 200mm high to provide sufficient access for installation of piping.Snow protection should also be considered for the base height.
3. Either steel or concrete bases may be suitable.

Fig. 6-7 Top view of schematic diagram of installation dimension of KEM-90 DRS5 KH&MC-SU140M -RN8L-B

4. A typical concrete base design is shown in Fig. 6-5. A typical concrete specification is 1 part cement, 2 parts sand and 4 parts crushed stone with steel reinforcing bar. The edges of the base should be chamfered
5. To ensure that all contact points are equally secure, bases should be completely level. Base design should ensure that the points on the units’ bases designed for weight-bearing support are fully supported.

Rubber anti-vibration pads

Solid ground / surface

Outdoor unit

Concrete base h200mm

Inlet and outlet pipe side
Drainage channel

Electric control box side

Anchor bolt

(unit: mm)

200mm
PP
Fig.6-5 Front view of base structure

Fig. 6-8 Top view of schematic diagram of installation dimension of KEM-180 DRS5 KH
64 Installation of damping devices

632 Location drawing of installation foundation of the unit: (unit: mm)

1. If the unit is located so high that it is inconvenient for maintenance personnel to conduct maintenance, the suitable scaffold can be provided around the unit.
2. The scaffold must be able to bear the weight of maintenance personnel and maintenance facilities.
3. The bottom frame of the unit is not allowed to be embedded into the concrete of installation foundation.
4. A drainage ditch should be provided to allow drainage of condensate that may form on the heat exchangers when the units are running in heating mode. The drainage should ensure that condensate is directed away from roadways and footpaths, especially in locations where the climate is such that condensate may freeze.
   (unit: mm)

Inlet and outlet pipe side
Drainage channel

Anchor bolt

Electric control box side

641 Damping devices must be provided between the unit and its foundation
By means of the 15mm diameter installation holes on the steel frame of the unit base, the unit can be fastened on the foundation through the spring damper. See Fig.6-6, 6-7 (Schematic diagram of installation dimension of the unit) for details about center distance of the installation holes. The damper does not go with the unit, and the user can select the damper according to the relevant requirements. When the unit is installed on the high roof or the area sensitive to vibration, please consult the relevant persons before selecting the damper.
642 Installation steps of the damper
Step 1. Make sure that the flatness of the concrete foundation is within ±3mm, and then place the unit on the cushion block.
Step 2. Raise the unit to the height suitable for installation of the damping device.
Step 3. Remove the clamp nuts of the damper. Place the unit on the damper, and align the fixing bolt holes of the damper with the fixing holes on the unit base.
Step 4. Return the clamp nuts of the damper to the fixing holes on the unit base, and tighten them into the damper.
Step 5. Adjust the operational height of the damper base, and screw down the leveling bolts. Tighten the bolts by one circle to ensure equal height adjustment variance of the damper.
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

09

Anchor bolt Nut Ferrol
Damping device

651 Measures used to prevent problems caused by snow

1. Measures to prevent build-up of snow The base height should be as least the same as the predicted snow depth in the local area.

Fig. 6-9 Installation of the damper
65 Installation of device to prevent snow build-up and strong breeze
When installing an air-cooled heat pump chiller in a place with heavy snow, it is necessary to take snow protection measures to ensure trouble-free operation of the equipment. Otherwise, accumulated snow will block the air flow and may cause equipment problems.
(a) Buried in the snow
(b) Snow accumulated on the top plate
(c) Snow falling on the equipment

Outdoor unit
Base height
Fig. 6-11 Snow prevention base height
2) Lightning protection and snow protection measures Check the installation site thoroughly; do not install the equipment under awnings or trees or a place where snow is piled up.
652 Precautions for designing a snow cover

1. To ensure a sufficient air flow required by the air-cooled heat pump chiller, design a protective cover to make the dust resistance 1 mm H2O or less lower than the allowable external static pressure of air-cooled heat pump chiller. 2) The protective cover must be strong enough to withstand the snow weight and the pressure caused by strong wind and typhoon. 3) The protective cover must not cause short circuit of air discharge and suction.

(d) Air inlet blocked by snow wind with snow
(e) Equipment covered with snow
Fig. 6-10 Types of problems caused by snow

10

CONNECTION DRAWING OF PIPELINE SYSTEM

This is the water system of standard module.

Terminal Two-way valve

Plate heat exchanger

Water charge valve
0.15MPa<Water replenishing pres<0.6MPa

Three-way valve

Stop valve
Y-shaped filter Expansion vessel

Drain valve

Drain valve Drain valve Auxiliary electric heater

Pressure gauge

15100103000389
Symbol explanation Water flow switch

Gate valve

Thermometer

Circulating pump

Check valve

Safety valve

Flexible joint

Fig.7-1 Connection drawing of pipeline system

Differential pressure by-pass valve
Automatic discharge valve

NOTE
· The ratio of the two – way valves on the terminal shall not exceed 50 percent.

OVERVIEW OF THE UNIT

81 Main parts of the uint

Table 8-1

NO.

NAME

1

Air outlet

2

Top cover

3

Electric control box

4

Compressor

5

Plate heat exchanger

6

Condenser

7

Water intlet

NO.

NAME

8

Air inlet

9

Water outlet

10

wire controller (It can be placed indoors)

11

Expansion tank

12

Gas-liquid separator

13

Induction pump

11

1 1
2 2
6

8 6

8 4

3

5

7

7

5

3

9

9

Fig. 8-1 Main parts of KEM-75 DRS5 KH (Picture just use to show the key component relative position) 1 2
6
8

Fig. 8-2 Main parts of MC SU90M-RN8L-B (Picture just use to show the key component relative position)
15100103000389

3

4

4 7
5 9

Fig. 8-3 Main parts of KEM-140 DRS5 KH (Picture just use to show the key component relative position)
MODEL B

1
MODEL B 2

6
8
10 5 11 4 12 13
7 9
3 Fig. 8-4 Main parts of KEM-180 DRS5 KH (Picture just use to show the key component relative position)
12

MODEL A

82 Opening the uint

Cover 1 Cover 2

Cover 3

Cover 6 Cover 5

Fig. 8-6 Doors of KEM-75 DRS5 KH
Cover 1/2/3 give access to the compartment of water pipes and water side heat exchanger. Cover 4 give access to the electrical parts. Cover 5/6 give access to the hydraulic compartment.

Cover 4

Cover 1 Cover 2

Cover 3

Cover 6 Cover 5

Fig. 8-7 Doors of KEM-90 DRS5 KH&KEM-140 DRS5 KH
Cover 1/2/3 give access to the compartment of water pipes and water side heat exchanger. Cover 4 give access to the electrical parts. Cover 5/6 give access to the hydraulic compartment.

Cover 4

13

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 exchange Door 4/5 give access to the hydraulic compartment. Door 6/7/8 give access to the electrical parts.

14

83 Outdoor unit PCBs
831 MAIN PCB
Label descriptions are given in Table 8-2

Table 8-2

Fig. 8-9 Main board of KEM-75 DRS5 KH and KEM-140 DRS5 KH

NO. 1 CN32: Main board power supply. 2 CN99: slave board power supply. 3 CN68: Pump(220-240V control power supply )

Detail information

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.

2. In case of refrigerating or heating shutdown, the pump will be shut down 2 minutes after all modules stop operating.

3. In case of shutdown under the pump mode, the pump can be directly shut down. 4 CN74/CN67: CCH, Crankcase heater 5 CN75/CN66: EVA-HEAT, Electric of water side heat exchanger heaters connection 6 CN48: ST1, Four-way valve 7 CN47: SV6, Liquid bypass solenoid valve 8 CN49: SV5, Multi-function solenoid valve 9 CN84: SV8A, Injection solenoid valve of compressor system A 10 CN83: SV8B, Injection solenoid valve of compressor system B 11 CN93: The alarm signal output of the unit(ON/OFF signal)

Attention: the control port value of the alarm actually detected is ON/OFF but not 220-240V control power supply, so special attention should be paid when installing the alarm signal output.

15

NO.

Detail information

12 CN65: Program burn in port(USB).

13 CN28: Three-phase protector output switch.(Protection code E8)

14 CN22: Outdoor units communication and wired controller conmunication port

15 CN46: The power supply port of the wired controller (DC12V)

16 CN26: Compressor inverter module and Fan inverter module communication ports

17 CN300: Program burn in port(WizPro200RS programming device).

18 CN33: Conmunicate with slave board

19 CN41: System low pressure sensor

20 CN40: System high pressure sensor

21 CN45: Taf2: Water side antifreeze temperature sensor

22 CN37: T3A: pipe temperature sensor of the condenser

23 CN30: T4: outdoor ambient temperature sensor

24 CN16: T3B: pipe temperature sensor of the condenser

25 CN38: Tp2: DC inverter compressor B discharge temperature sensor

26 CN27: TP-PRO, Discharge temperature switch protection (protection code P0, provent the compressor from over

temperature 115°C)

27 CN42: Low pressure protection switch.(Protection code P1)

28 CN16:

T6A: Refrigerant inlet temperature of EVI plate heat exchanger T6B: Refrigerant outlet temperature of EVI plate heat exchanger

29 CN4: Temperature sensors input port

Twi: Unit water inlet temperature sensor Th: System suction temperature sensor Two: Unit water outlet temperature sensor Tz/7: coil final outlet temperature sensor Tp1: DC inverter compressor A discharge temperature sensor

30 CN72: EXVC, EVI electronic expansion valve.Used for EVI.

31 CN70: EXVA, System electronic expansion valve1.

32 CN71: EXVB, System electronic expansion valve2.Used for cooling.

33 SW3: Up button

a) Select different menus when enter menu selection.

b) For spot Cinspection in conditions.

SW4: Down button

a) Select different menus when enter menu selection.

b) For spot inspection in conditions. SW5: Menu button

Press to enter menu selection, short press to return to the previous menu. SW6: OK button

Enter the submenu or confirm the function selected by short pressing.

34 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.

35 ENC1: NET_ADDRESS

DIP switch 0-F of outdoor unit network address is enabled, which represent address 0-15.

36 S1: Dip switch

S1-1: Normal control, valid for S1-1 OFF(factory default).

Remote control, valid for S1-1 ON.

S1-3: Single water pump controll, valid for S1-3 OFF (factory default)

Multiple water pumps controll, valid for S1-3 ON.

37 S2: Dip switch(reserve)

38 S3: Dip switch

S3-1: Valid for S3-1 ON (factory default).

39 S4: POWER

DIP switch for capacity selection. (KEM-75 DRS5 KH defaults 0011, KEM-140 DRS5 KH defaults 0111)

16

Fig. 8-10 Slave board of MC-SU75-RN8L-B and MC-SU140-RN8L-B

NO.

Detail information

1 CN140: Power supply, 220-240VAC input

2 CN115: W-HEAT, Electric heater of water flow switch

3 CN125: Three-way valve(hot-water valve)

4 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.

2. In case of refrigerating or heating shutdown, the pump will be shut down 2 minutes after all modules stop operating.

3. In case of shutdown under the pump mode, the pump can be directly shut down.

5 CN121: 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.

6 CN119: HEAT1: Pipeline Auxiliary Heater;

HEAT2: Tank Auxiliary Heater;

Attention: the control port value of the HEAT1 actually detected is ON/OFF but not 220-240V control power supply, so

special attention should be paid when installing the pipeline auxiliary heater.

7 CN108: Inverter pump 0-10V output control singnal

8 CN110: W.P-SW, Water pressure switching port.

TEMP-SW, Target water temperature switching port.

9 CN138: COOL/HEAT, Remote function of cool/heat signal

ON/OFF, Remote function of on/off signal

10 CN114: Water flow switch signal

11 CN105: Taf1: Water tank antifreeze temperature

12 CN101: Tw: Total water outlet temperature sensor when several units are connected in parallel

13 CN103: T5: Water tank temperature sensor

14 CN300: Program burn in port(WizPro200RS programming device).

15 CN109: Conmunicate with main board

CAUTION
· Faults When the main unit suffers faults, the main unit stops operating, and all other units also stop running; When the subordinate unit suffers faults, only the unit stops operating, and other units are not affected.
· Protection When the main unit is under protection, only the unit stops operating, and other units keep running; When the subordinate unit is under protection, only the unit stops operating, and other units are not affected.

17

832 MAIN PCB

1. Label descriptions are given in Table 8-3

45

46 47

44 43
42 41
40 39
38 37
36
35
34 33

1

2 3
4 65

87

10

9 11

12

13
14 15 16

17

32

31 30 28 27 24 22 20 19 18

29 26 25 23 21

Fig. 8-11 Main PCB of KEM-90 DRS5 KH and KEM-180 DRS5 KH

Table 8-3

NO.

Detail information

1 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° among them. If the conditions are not met, fault

of phase sequence or phase lack may occur, and fault code will be displayed. When the power supply returns to normal

condition, fault is removed. Attention: phase lace and phase dislocation of power supply are detected only in the early period

after the power supply is connected, and they are not detected while the unit is in operation.

2 CN12: Quick return oil solenoid valve

3 CN80: Injection solenoid valve of compressor system B

4 CN47: Injection solenoid valve of compressor system A

5 CN5: Water side heat exchanger heaters connection

6 CN40: Multi-function solenoid valve

7 CN13: Electric of water side heat exchanger heaters connection

8 CN41: Liquid bypass solenoid valve

9 CN42: Crankcase heater

10 CN6: Four-way valve

11 CN43: Crankcase heater

12 CN4/CN11: Electric heater of water flow switch

13 CN27: Three-way valve(hot-water valve, reserve)

14 CN86: SV2, Spray cooling valve(reserve)

15 CN25: 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.

2. In case of refrigerating or heating shutdown, the pump will be shut down 2 minutes after all modules stop operating.

3. In case of shutdown under the pump mode, the pump can be directly shut down.

18

NO.

Detail information

16 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.

17 CN2: HEAT1.Pipeline Auxiliary Heater HEAT2: Water Tank Auxiliary Heater;
Attention: the control port value of the HEAT1 actually detected is ON/OFF but not 220-240V control power supply, so special attention should be paid when installing the pipeline auxiliary heater.

18 CN24: The alarm signal output of the unit(ON/OFF signal) Attention: the control port value of the alarm actually detected is ON/OFF but not 220-240V control power supply, so special attention should be paid when installing the alarm signal output.

19 CN20: TP-PRO, Discharge temperature switch protection (protection code P0, provent the compressor from over temperature 115°C)

20 CN71: EXVB,System electronic expansion valve2.Used for cooling.

21 CN72: WXVC,EVI electronic expansion valve.Used for EVI.

22 CN70: EXVA,System electronic expansion valve1.

23 CN60: Outdoor units communication or wired controller conmunication port

24 CN61: Outdoor units communication or wired controller conmunication port

25 CN64: Fan inverter module communication ports

26 CN65: Compressor inverter module communication ports

27 CN300: Program burn in port(WizPro200RS programming device).

28 IC10: EEPROM chip

29 CN1: temperature sensors input port. T4: outdoor ambient temperature sensor T3A/T3B: pipe temperature sensor of the condenser T5: wtater tank temperature sensor T6A: Refrigerant inlet temperature of EVI plate heat exchanger T6B: Refrigerant outlet temperature of EVI plate heat exchanger

30 CN16: System pressure sensor

31 CN31: Temperature sensors input port Th: System suction temperature sensor Taf2: Water side antifreeze temperature sensor Two: Unit water outlet temperature sensor Twi: Unit water inlet temperature sensor Tw: Total water outlet temperature sensor when several units are connected in parallel

32 CN69: Temperature sensors input port Tp1: DC inverter compressor A discharge temperature sensor Tp2: DC inverter compressor B discharge temperature sensor Tz/7: coil final outlet temperature sensor Taf1: Water tank antifreeze temperature

33 CN19: Low pressure protection switch.(Protection code P1)

34 CN91: Three-phase protector output switch.(Protection code E8)

35 CN58: Fan realy driver port.

36 CN8: Remote function of cool/heat signal

37 CN8: Remote function of on/off signal

38 CN8: Water flow switch signal 39 SW3: Up button
a) Select different menus when enter menu selection. b) For spot inspection in conditions. SW4: Down button a) Select different menus when enter menu selection. b) For spot inspection in conditions. SW5: Menu button Press to enter menu selection, short press to return to the previous menu. SW6: OK button Enter the submenu or confirm the function selected by short 40 CN18: Program burn in port(USB).

19

NO.

Detail information

41 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.

42 S5: Dip switch

S5-3: Normal control, valid for S5-3 OFF(factory default).

Remote control, valid for S5-3 ON.

43 CN7: TEMP-SW, Target water temperature switching port.

44 ENC2: POWER

DIP switch for capacity selection. (KEM-90 DRS5 KH defaults 2, KEM-180 DRS5 KH defaults 6)

45 CN74: The power supply port of the HMI .(DC9V)

46 ENC4: NET_ADDRESS

DIP switch 0-F of outdoor unit network address is enabled, which represent address 0-15.

47 S12: Dip switch

S12-1: Valid for S12-1 ON (factory default).

S12-2: Single water pump controll, valid for S12-2 OFF (factory default)

Multiple water pumps controll, valid for S12-2 ON.

CAUTION
· Faults When the main unit suffers faults, the main unit stops operating, and all other units also stop running; When the subordinate unit suffers faults, only the unit stops operating, and other units are not affected.
· Protection When the main unit is under protection, only the unit stops operating, and other units keep running; When the subordinate unit is under protection, only the unit stops operating, and other units are not affected.

84 Electric wiring
841 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. · The power wire and the grounding wire must be connected to the suitable terminals. · The power wire and the grounding wire must be fasten up by suitable tools. · The terminals connected the power wire and the grounding wire must be fully fastened and regularly checked, in case to
become loose. · Only use the electric components specified by our company, and require installation and technical services from the
manufacturer or authorized dealer. If wiring connection doesn’t conform to electric installation specification, it may cause many troubles like failure on controller, electronic shock and so on. · The connected fixed wires must be equipped with full switching-off devices with at least 3mm contact separation. · Set leakage protective devices according to the requirements of national technical standard about electric equipment. · After completing all wiring construction, conduct careful check before connecting the power supply. · Please carefully read the labels on the electric cabinet. · Please don’t repair the controller by yourself, since improper operation may cause electric shock, damages to the controller and other bad results. If the unit need repair, please contact the maintenance center., since improper repair may cause electric shock, damages to the controller, and so on. If the user has any requirement of repair, please contact the maintenance center. · The power cord type designation is H07RN-F.

20

842 KEM-75 DRS5 KH and KEM-140 DRS5 KH
DIP switch, buttons and digital display positions of uints.

ENC1 S1

S2

S3

S4

843 DIP switch instructions
Table 8-5 KEM-75 DRS5 KH and KEM-140 DRS5 KH

ENC1 S1-1 S1-3

0-F valid for uint address setting on the DIP switches 0-F 0 indicates the master unit and 1-F the auxiliary uints (parallel connection) (0 by default)

Normal control OFF
Valid for S1-1 OFF(factory default)

Remote control ON
valid for S1-1 ON

OFF

Single water pump control Valid for S1-3 OFF (factory default)

ON

Multiple water pumps control Valid for S1-3 ON

S3-1

ON Valid for S3-1 ON (factory default)

DSP1

DSP2

0011

DIP switch for capacity selection (KEM-75 DRS5 KH defaults 0011)

S4

0011

DIP switch for capacity selection (KEM-140 DRS5 KH defaults 0111)

Fig. 8-13 Display positions
842 KEM-90 DRS5 KH and KEM-180 DRS5 KH
DIP switch, buttons and digital display positions of uints.

843 DIP switch instructions
Table 8-5 MC-SU90-RN8L-B and MC-SU180-RN8L-B

ENC2

DIP switch for capacity selection 2 (KEM-90 DRS5 KH defaults 2)
(KEM-180 DRS5 KH defaults 6)

ENC4 S5-3

0-F valid for uint address setting on the DIP switches 0 indicate master unit 0, 0-F 1 indicate auxiliary unit 1, 2 indicate auxiliary unit 2, …, F indicate auxiliary unit 15.(parallel connection)

OFF

Normal control Valid for S5-3 OFF(factory default)

ON

Remote control valid for S5-3 ON

S12-1

ON Valid for S12-1 ON (factory default)

S12-2

OFF

Single water pump control Valid for S12-2 OFF (factory default)

ON

Multiple water pumps control Valid for S12-2 ON

Fig. 8-14 Display positions

21

844 Electrical wiring percautions
a. On-site wiring, parts and materials must comply with the local and national regulations as well as relevant national electrical standards.

c. It is advisable to use 3-core shielded cables for uint to minimize interference. Do not use the unshielded multicore conductor cables.

National standard

Fig. 8-15-1 Electrical wiring precaution (a) b. Copper core wires must be used

Fig. 8-15-3 Electrical wiring precaution (c)
d. Power wiring must be entrusted to professionals with electrician qualification.

Fig. 8-15-2 Electrical wiring precaution (b)

8.4.5 Power supply specification
Table 8-4

Item Model KEM-75 DRS5 KH KEM-90 DRS5 KH KEM-140 DRS5 KH KEM-180 DRS5 KH

Power supply 380-415V/3N~50Hz 380-415V/3N~50Hz 380-415V/3N~50Hz 380-415V/3N~50Hz

Fig. 8-15-4 Electrical wiring precaution (d)

Outdoor power supply

Manual switch

Fuse

100A

63A

125A

100A

200A

160A

250A

200A

Wiring 16mm2 X5(<20m) 25mm2 X5(<20m) 50mm2 X5(<20m) 70mm2 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 wire diameter should be larger in accordance with the relevant regulations.

22

846 Requirements for power supply wiring
Correct

Power distribution transformer

Manual switch Fuses

Power

380-415V

3N~50Hz

Uint

Lightning arrester
Building

Grounding wire

Grounding 1

Grounding 2

Grounding 3

Wrong

Power distribution transformer

Manual switch

Fuses

Power 380-415V 3N~50Hz

Lightning arrester

Grounding wire

Uint

Surge

current

Grounding 1

Grounding 2

Grounding 3

Fig. 8-16 Requirements of power supply wiring
NOTE
· Do not connect the grounding wire of the lightning arrester to the unit shell. The grounding wire of the lightning arrester and the power supply grounding wire must be configured separately.

847 Requirements for power cord connection
Correct

Wrong

L1 L2 L3 N L1 L2 L3 N

L1 L2 L3 N L1 L2 L3 N

Fig. 8-17 Requirements for power cord connection
23

NOTE
Please use the round-type terminal with correct specifications to connect the power cord.
848 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 CN22 at XYE on main board inside the electric control box. For specific wiring, see chapter 8.4.14
CN22(main board)

CN119(Slave board) CN121(Slave board) CN123(Slave board) HEAT2 HEAT1 COMP- STATE PUMP

Coil of 3 phase AC contactor
L1/L2/L3 220-240V~
50Hz N

Coil of 3 phase AC contactor
Max voltage: 240VAC Max current: 5A

The wired controller Uint communication communication

Fig. 8-19 Wiring of water pump and pipeline auxiliary heater and ac light of the state of compressor(only for KEM-75 DRS5 KH and KEM-140 DRS5 KH )

Blue Black Brown

As shown in the figure below, For KEM-90 DRS5 KH and KEM180 DRS5 KH: the uint communication signal 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. For specific wiring, see chapter 8.4.14
XT2

CN26(Main board) CN33(Main board) CN25(Main board) HEAT1HEAT2COM COMP-STATE PUMP

CN27(Main board) NO NC N

Coil of 3 phase AC contactor

SV1
Coil of 3 phase AC contactor

Uint communication The wired controller communication

L1/L2/L3
220-240V~ 50Hz N

Max voltage: 240VAC Max current: 5A

Fig. 8-18 Wiring of unit communication and the wired controller communication

Fig. 8-20 Wiring of water pump and pipeline auxiliary heater and ac light of the state of compressor(only for KEM-90 DRS5 KH and KEM-180 DRS5 KH )

NOTE
For KEM-180 DRS5 KH, Model A is connected to Model B, Model B is connected to Model A in the next uint. For specific connection, see chapter 8.4.14.
When the water pump and auxiliary heater are added externally, a 3-phase contactor must be used for control. The model of contactor is subject to the power of water pump and heater power. The contactor coil is controlled by the main control board. See the figure below for coil wiring. For specific wiring, see chapter 8.4.14 . The user can connect an ac light to monitor the state of compressor.When the compressor is operating, the light will be powered on. The wiring of water pump and pipeline auxiliary heater and ac light of the state of compressor is as follows.

849 Wiring of “ON/OFF” weak electric port

The remote function of “ON/OFF” must be set by DIP switch. The remote function of “ON/OFF” is effective when S1-1 or S5-3 is chosen ON, at the same time, the wired controller is out of control. Corresponding parallel connect the “ON/OFF” port of the main unit’s electric control box, then, connect the “ON/OFF” signal (provide by user) to the “ON/OFF” port of main unit as follows.

The remote function of “ON/OFF” must be DIP switch set. Wiring method:

For KEM-75 DRS5 KH and KEM-140 DRS5 KH: Shorting the terminal block CN137 at slave board inside the electric control box to enable the remote function of “ON/OFF” .

For KEM-90 DRS5 KH and KEM-180 DRS5 KH: Shorting the terminal block XT2 at 15 and 24 inside the electric control box to enable the remote function of “ON/OFF” .

0# electric control box “ON/OFF” port

0# electric control box “ON/OFF” port

Power (DC 12V) Main control board is
provided ON
Power (DC 12V) Main control board is
provided OFF

Fig. 8-21-1 Wiring of “ON/OFF ” weak electric port
24

8410 Wiring of “HEAT/COOL” weak electric port

The remote function of “HEAT/COOL” must be set by DIP switch.The remote function “HEAT/COOL” is effective when S11or S5-3 is chosen ON, at the same time, the wire controller is out of control.

Corresponding parallel connect the “HEAT/COOL” port of the main unit’s electric control box, then, connect the “ON/OFF” signal (provide by user) to the “HEAT/COOL” port of main unit as follows.

Wiring method:

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”.

For KEM-90 DRS5 KH and KEM-180 DRS5 KH: Shorting the terminal block XT2 at 14 and 23 inside the electric control box to enable the remote function of “HEAT/COOL”.

0# electric control box
“HEAT/COOL” port

0# electric control box
“HEAT/COOL” port

If the unit is operating unnormally, the ALARM port is closed, otherwise, the ALARM port is open. The ALARM ports are on the main control board. See the wiring diagram for details.
8413 Control system and installation precautions
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
Fig. 8-24-1 Control system and installation precaution (a) b. The shielding nets at both ends of the shielded wire must be grounded. Alternatively, the shielding nets of all shielded wires are interconnected and then connected to earth through or one metal plate.

Power (DC 12V) Main control board is
provided HEAT
Power (DC 12V) Main control board is
provided COOL

Fig. 8-21-2 Wiring of “HEAT/ COOL” weak electric port

8411 Wiring of “TEMP-SWITCH” weak electric port

The function of “TEMP-SWITCH” must be set by wired controller for two setting water temperature. For cooling and heating mode. Wiring method: For MC- SU75-RN8L-B andMC-SU140-RN8L-B: Shorting the terminal block CN110 at slave board inside the electric control box to chose the target water temperature For MC-SU90-RN8L-B and MC-SU180-RN8L-B: Shorting the terminal block XT2 at 20 and 25 inside the electric control box to chose the target water temperature

0# electric control box “TEMP-SWITCH” port

0# electric control box “TEMP-SWITCH” port

Uint
Fig. 8-24-2 Control system and installation precaution (b) c. Do not bind the control wire, refrigerant piping and power cord together. When the power cord and control wire are laid parallel, they should be kept at a distance of more than 300 mm to prevent signal source interference.

Power (DC 12V) Main control board is
provided Power (DC 12V) Main control board is
provided

Uint

First target water temperature Second target water temperature Fig. 8-22 Wiring of “TEMP-SWITCH” weak electric port
8412 Wiring of “ALARM” port
Connect the device provided by user to the “ALARM” ports of the module units as follows.
electric control box “ALARM” port

Fig. 8-24-3 Control system and installation precaution (c)
d. Pay attention to the polarity of the control wire when conducting wiring operations.

Device provided by user

Fig. 8-23 Wiring of “ALARM” port

Fig. 8-24-4 Control system and installation precaution (d)
25

8414 Wiring instances
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.

MAIN CONTROL WIRECONTROLER

ENC1
MAIN (NO.0) Main board
CN22

Slave board

HEAT1 PUMP

CN119

CN123

MONITOR WIRECONTROLLER

ENC1
SLAVE (NO.1) Main board
CN22

Slave board

CN119

HEAT2HEAT1 PUMP CN123

CN46
WH BR

CN46
WH BR

( BK < YE ; RD

$& WH

$& BR

$&

$&

(

<

;

(

<

;

( BK < YE ; RD

BK

YE

RD

WH

BR

BK

YE

RD

Fig. 8-25 Networking communication schematic of main unit and auxiliary unit for KEM-75 DRS5 KH

L1 L 2 L3

;7

COMMUNICATION WITH WIRE

CONTROLLER

L1 L 2 L3

;7

26

POWER POWER 380-415V 3N~50Hz
RVV-300/500 5X16mm2
Power Transformer OUTPUT: 8.5 V~

COMMUNICATION WITH NEXT MODULE

POWER
POWER 380-415V 3N~50Hz RVV-300/500 5X16mm2

The length of wire should be shorter than 500m
The Wiring Terminal XY and E on the back of Wire Controller are corresponding to the Terminal XY and E of Wiring Board in Main Module

X

Y

MAIN CONTROL WIRE CONTROLER

Over-current

Contactor

relay

PUMP

Contactor

Over-current relay

Auxiliary heater for pipeline

Over-current Contactor relay

Auxiliary heater for pipeline

MONITOR WIRECONTROLLER

COMMUNICATION WITH NEXT MODULE

ENC1
SLAVE (NO.15) Main board
CN22

Slave board

CN119

HEAT2HEAT1 PUMP CN123

CN46
WH BR

( BK < YE ; RD

$& WH

$& BR

(

<

; RD

BK

YE

L1 L 2 L3

;7

¥

$& $&

Notes The wiring diagram of auxiliary heaters is
just forreference , please follow the instructions of corresponding auxiliary heater products.
Please choose such accessory as power wire , switch of auxiliary heater according to the actual parameter of products andnational

The metal plate of contactor installation box should be grounded

L1 L2 L3 N

POWER 380-415V 3N~50Hz

POWER POWER 380-415V 3N~50Hz
RVV-300/500 5X16mm2
COMMUNICATION WITH LAST MODULE

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.

WH
BR WH
BK BR
YE BK
RD YE
RD

Fig. 8-26 Networking communication schematic of main unit and auxiliary unit for KEM-90 DRS5 KH

COMMUNICATION WITH WIRE CONTROLLER

ENC4
MAIN (NO.0)

MAIN CONTROL WIRECONTROLLER

HEAT1 HEAT2 COM PUMP

CN60

CN61

CN74

CN26

CN25

CN30

;

;<(

<

(

$&

$&

L1 L 2 L3

;7

$& WH
$& BR ( BK < YE ; RD

WH

BR

BK

YE

RD

The length of wire should be shorter than 500m

POWER

POWER 380-415V 3N~50Hz

COMMUNICATION WITH NEXT MODULE

The Wiring Terminal X Y and E on the back of Wire Controller are corresponding to the Terminal XY and E of Wiring Board in Main Module

Over-current Contactor relay

Over-current Contactor relay

Auxiliary heater for pipeline

X

Y

Over-current Contactor relay

Auxiliary heater for pipeline

ENC4
SLAVE

MONITOR WIRECONTROLER
(NO.1)

$& WH
$& BR ( BK < YE ; RD

CN60

CN61

CN74

CN2

CN83

;<(

CN30

L1 L 2 L3

;7

COMMUNICATION WITH NEXT MODULE

POWER POWER 380-415V 3N~50Hz

ENC4
SLAVE

MONITOR WIRECONTROLER
(NO.15)

CN60

CN61

CN74

CN2

CN83

CN30

27

$& WH
$& BR ( BK < YE ; RD

Power Transformer OUTPUT: 8.5 V~

MAIN CONTROL WIRECONTROLER

$& $&

Notes The wiring diagram of auxiliary heaters is just
for reference , please follow the instructions of corresponding auxiliary heater products.
Please choose such accessory as power wire, switch of auxiliary heater according to the actual parameter of products and national

The metal plafe of contactor Installation box stould be grounded

L1 L2 L3 N POWER 380-415V 3N~50Hz

;<(
¥
COMMUNICATION WITH LAST MODULE

/ / /

;7

POWER POWER 380-415V 3N~50Hz

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.

MAIN CONTROL WIRECONTROLER

ENC1
MAIN (NO.0) Main board
CN22

Slave board

CN119

HEAT2 HEAT1 PUMP CN123

MAIN CONTROL WIRECONTROLER

ENC1
SLAVE (NO.1) Main board
CN22

Slave board

CN119

HEAT2 HEAT1 PUMP CN123

( BK < YE ; RD
CN46
WH BR
$& WH $& BR ( BK < YE ; RD

( BK < YE ; RD
CN46
WH BR
$& WH $& BR ( BK < YE ; RD

Fig. 8-27 Networking communication schematic of main unit and auxiliary unit for KEM-140 DRS5 KH
28

;7

COMMUNICATION WITH WIRE CONTROLLER

;7

POWER POWER 380-415V 3N~50Hz
RVV-300/500 5X50mm 2
Power Transformer OUTPUT: 8.5 V~

The length of wire should be shorter than 500m
The Wiring Terminal XY and E on the back of Wire Controller are corresponding to the Terminal XY and E of Wiring Board in Main Module

X

Y

COMMUNICATION WITH NEXT MODULE

Over-current Contactor relay

PUMP

Over-current Contactor relay

Auxiliary heater for pipeline

Over-current Contactor relay

Auxiliary heater for pipeline

POWER POWER 380-415V 3N~50Hz
RVV-300/500 5X50mm 2

MAIN CONTROL WIRECONTROLER

COMMUNICATION WITH NEXT MODULE

ENC1
SLAVE (NO.15) Main board
CN22

Slave board

CN119

HEAT2 HEAT1 PUMP CN123

( BK < YE ; RD
CN46
WH BR
$& WH $& BR ( BK < YE ; RD

;7
¥

$& $&

MAIN CONTROL WIRECONTROLER

The metal plate of contactor installation
box should be grounded

Notes The wiring diagram of auxiliary heaters
is just forreference , please follow the instructions of corresponding auxiliary heater products.
Please choose such accessory as power wire , switch of auxiliary heater according to the actual parameter of products and national
L1 L2 L3 N
POWER 380-415V 3N~50Hz

POWER POWER 380-415V 3N~50Hz
RVV-300/500 5X50mm 2
COMMUNICATION WITH LAST MODULE

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.

MAIN CONTROL WIRECONTROLER

MAIN (NO.0)
HEAT1HEAT2 COM PUMP

AUXILIARY (NO.1)
HEAT1HEAT2 COM PUMP

MAIN CONTROL WIRECONTROLER

AUXILIARY (NO.2)
HEAT1HEAT2COM PUMP

AUXILIARY (NO.3)
HEAT1 HEAT2 COM PUMP

WH BR BK YE RD
WH BR BK YE RD

WH BR BK YE RD
WH BR BK YE RD
Fig. 8-28 Networking communication schematic of main unit and auxiliary unit for KEM-180 DRS5 KH
29

COMMUNICATION WITH WIRE CONTROLLER
The length of wire should be shorter than 500m

Power Transformer OUTPUT: 8.5 V~

The Wiring Terminal XY and E on the back of Wire Controller are corresponding to the Terminal XY and E of Wiring Board in Main Module

POWER

POWER 380-415V 3N~50Hz
7

C O M M U N I C AT I O N WITH NEXT MODULE

POWER

POWER 380-415V 3N~50Hz
7

Contactor Over-current relay
PUMP

Over-current relay

Contactor

Auxiliary heater for pipeline

Over-current relay

Contactor

Auxiliary heater

for pipeline

Contactor Over-current relay
PUMP

Over-current relay

Contactor

Auxiliary heater for pipeline

Over-current relay

Contactor

Auxiliary heater

for pipeline

C O M M U N I C AT I O N WITH NEXT MODULE
MAIN CONTROL WIRECONTROLER
AUXILIARY (NO.14)
HEAT1HEAT2 COM PUMP

AUXILIARY(NO.15)
HEAT1HEAT2 COM PUMP

WH BR BK YE RD
WH BR BK YE RD

MAIN CONTROL WIRECONTROLER

The metal plafe of contactor Installation box stould be grounded

Notes

The wiring diagram of auxiliary heaters is just for reference , please follow the instructions of corresponding auxiliary heater products.

Please choose such accessory as power wire , switch of auxiliary heater according to the actual parameter of products and national
POWER 380-415V 3N~50Hz

The metal plafe of contactor Installation box stould be grounded
POWER 380-415V 3N~50Hz

COMMUNICATION WITH LAST MODULE

POWER

POWER 380-415V 3N~50Hz
7

NOTE
When the power cord is parallel to the signal wire, make sure that they are enclosed in respective conduits and are kept a reasonable wire spacing. (Distance between the power cord and signal wire: 300mm if below 10A, and 500mm if below 50A)

Water system installation

851 Basic requirements of connection of chilled water pipes
CAUTION
· After the unit is in place, chilled water pipes can be laid.
· The relevant installation regulations should be abided with when conducting connection of water pipes.
· The pipelines should be free of any impurity, and all chilled water pipes must conform to local rules and regulations of pipeline engineering.
Connection requirements of chilled water pipes a) All chilled water pipelines should be thoroughly flushed, to be free of any impurity, before the unit is operated. Anyimpurity should not be flushed to or into the heat exchanger. b) Water must enter the heat exchanger through the inlet; otherwise the performance of the unit will decline. c) The inlet pipe of the evaporator must be provided with a target flow controller, to realize flow-break protection for the unit. Both ends of the target flow controller must be supplied with horizontal straight pipe sections whose diameter is 5 times that of the inlet pipe. The target flow controller must be installed in strict accordance with “Installation & Regulation Guide for Target Flow Controller” (Fig.8-28, 8-29). The wires of the target flow controller should be led to the electric cabinet through shielded cable (see Electric Controlling Schematic Diagram for details). The working pressure of the target flow controller is 1.0MPa, and its interface is 1 inch in diameter. After the pipelines are installed, the target flow controller will be set properly according to the rated water flow of the unit. d) The pump installed in the water pipeline system should be equipped with starter. The pump will directly press water into the heat exchanger of the water system. e) The pipes and their ports must be independently supported but should not be supported on the unit. f) The pipes and their ports of the heat exchanger should be easy to disassemble for operation and cleaning, as well as inspection of port pipes of the evaporator.

g) The evaporator should be provided with a filter with more than 40 meshes per inch at site. The filter should be installed near to the inlet port as much as possible, and beunder heat preservation.
h) The by-pass pipes and by-pass valves as shown in Fig.8-23 must be mounted for the heat exchanger, to facilitate cleaning of the outside system of water passage before the unit is adjusted. During maintenance, the water passage of the heat exchanger can be cut off without disturbing other heat exchangers.
i) The flexible ports should be adopted between the interface of the heat exchanger and on-site pipeline, to reduce transfer of vibration to the building.
j) To facilitate maintenance, the inlet and outlet pipes should be provided with thermometer or manometer. The unit is not equipped with pressure and temperature instruments, so they need to be purchased by the user.
k) All low positions of the water system should be provided with drainage ports, to drain water in the evaporator and the system completely; and all high positions should be supplied with discharge valves, to facilitate expelling air from the pipeline. The discharge valves and drainage ports should not be under heat preservation, to facilitate maintenance.
l) All possible water pipes in the system to be chilled should be under heat preservation, including inlet pipes and flanges of the heat exchanger.
m) The outdoor chilled water pipelines should be wrapped with an auxiliary heating belt for heat preservation, and the material of the auxiliary heat belt should be PE, EDPM, etc., with thickness of 20mm, to prevent the pipelines from freezing and thus cracking under low temperature. The power supply of the heating belt should be equipped with an independent fuse.
n) The temperature sensor of the total outlet water of No. 0 master unit needs to be installed in the main outlet water pipe of the project.
WARNING
· For the water pipeline network including filters and heat exchangers, dreg or dirt may seriously damages the heat exchangers and water pipes.
· The installation persons or the users must ensure the quality of chilled water, and de-icing salt mixtures and air should be excluded from the water system, since they may oxidize and corrode steel parts inside the heat exchanger.
· When the ambient temperature is lower than 2°C, and the unit will be not used for a long time, water inside the unit should be drained.
· If the unit is not drained in winter, its power supply should not be cut off, and the fan coils in the water system must be provided with three-way valves, to ensure smooth circulation of the water system when the anti- freezing pump is started up in winter.
· For KEM-180 DRS5 KH, the temperature sensor of the total outlet water of the master unit module A (the uint address of DIP switches is 0) must be repositioned on the water outlet main of the project

30

852 Connection mode of pipe

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.
Table 8-5

Model KEM-75 DRS5 KH KEM-90 DRS5 KH KEM-140 DRS5 KH KEM-180 DRS5 KH

Pipe connection methods Hoop connection Hoop connection Hoop connection Hoop connection

Specifications of water pipe DN50 DN50 DN65 DN80

Specifications of screw thread / / / /

Fig.8-29
853 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 In certain occasion (especially in manufacture cooling process), for conforming the system water content requirement, it’s necessary to mount a tank equipping with a cut-off baffle at the system to avoid water short-circuit, Please see the following schemes:
31

Error

Recommendation

Error

Fig.8-26 Design of the store tank

Recommendation

8.5.4 Minimum chilled water flow
The minimum chilled water flow is shown in the table 8-8 If the system flow is less than the minimum unit flow rate, the evaporator flow can be recirculated, as shown in the diagram. For minimum chilled water flow rate

UNIT

Recirculation

Fig. 8-30-1
8.5.5 Maximum chilled water flow
The maximum chilled water flow is limited by the permitted pressure drop in the evaporator. It is provided in the table 8-8 If the system flow is more than the maximum unit flow rate, bypass the evaporator as shown in the diagram to obtain a lower evaporator flow rate.

UNIT

Recirculation

Fig. 8-30-2

8.5.6 Minimum and Maximum water flow

Table 8-6

Item Model KEM-75 DRS5 KH KEM-90 DRS5 KH KEM-140 DRS5 KH KEM-180 DRS5 KH

Waterflow rate(m3/h)

Minimum

Maximum

8

15.5

10.2

18

15.6

28.5

20.4

36.0

857 Selection and installation of the pump

1. Select the pump a) Select the water-flow of the pump The rated water-flow must no less than the unit rated waterflow; in terms of multi-connect the units, that water-flow must no less than total units’ rated water-flow. b) Select the left of the pump. H=h1+h2+h3+h4 H: The lift of the pump. h1: Main unit water resistance. h2: Pump water resistance. h3: Water resistance of the longest water-loop distance, includes: pipe resistance, different valve’s resistance, flexible pipe resistance, pipe elbow and three-way resistance, two-way resistance or three-way resistance, as well as filter resistance. H4: the longest terminal resistance.
2. Installation the pump a) The pump should be installed at the water inlet pipe, both of which sides must mount the soft connectors for vibration-proof. b) The backup pump for the system (recommended). c) Units must with a main unit controls (Please see Fig. 8-18 for the controls wiring diagram).
   858 Water quality
3. Water quality control When industrial water is used as chilled water, little furring may occur; however, well water or river water, used as chilled water, may cause much sediment, such as furring, sand, and so on. Therefore, well water or river water must be filtered and softened in softening water equipment before flowing into chilled water system. If sand and clay settle in the evaporator, circulation of chilled water may be blocked, and thus leading to freezing accidents; if hardness of chilled water is too high, furring may occur easily, and the devices may be corroded. Therefore, the quality of chilled water should be analyzed before being used, such as PH value, conductivity, concentration of chloride ion, concentration of sulfide ion, and so on.

32

2. Applicable standard of water quality for the unit Table 8-7

PH value Total hardness
Conductivity Sulfide ion Chloride ion Ammonia ion

6.8~8.0 <70ppm <200V/cm(25°C)
No <50ppm
No

Sulfate Silicon Iron content Sodium ion Calcium ion
/

<50ppm <30ppm <0.3ppm No requirement <50ppm
/

859 Installation of multi-module water system pipeline

Multi-module combination installation involves special design of the unit, so relevant explanation is given as follows. 1) Installation mode of multi-module combination water system pipeline

No.n module No. (n-1)address

No.(n-1) module No.(n-2) address

No.1 module No.0 address

….

Drill dead hole at the position, and move the total euent temperature sensor at No.0 address to the position

Fig.8-31 Installation of multi-module (no more than 16 modules)

No.n module No. (n-1)address

No.(n-1) module No.(n-2) address

No.1 module No.0 address

Drill dead hole at the position, and move the total euent temperature sensor at No.0 address to the position

Fig.8-32 Installation of multi-module (no more than 8 modules) KEM-180 DRS5 KH

2. Table of diameter parameters of main inlet and outlet pipes Table 8-8

Cooling capacity 15Q30 30<Q90 90<Q140
140<Q210 210<Q325 325<Q510 510<Q740 740<Q1300 1300<Q2080

Total inlet and outlet water pipe inside nominal diameter DN40 DN50 DN65 DN80 DN100 DN125 DN150 DN200 DN250

33

CAUTION
· Please pay attention to the following items when installing multiple modules: – Each module corresponds to an address code which cannot be repeated. – Main water outlet temperature sensing bulb, target flow controller and auxiliary electric heater are under control of the main module. – One wired controller and one target flow controller are required and connected on the main module. – The unit can be started up through the wired controller only after all addresses are set and the aforementioned items are determined. The wire length betweent the wired controller and outdoor unit should be <500m.

8510 Installation of single or multiple water pumps

1. DIP switch
   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 KEM-180 DRS5 KH.
   Pay attention to the following problems: a. If the DIP switch is inconsistent, and the error code is FP, the unit is not allowed to operate. b. Only the main unit has the water pump output signal when single water pump installed, auxiliary units has no water pump output signal. c. The water pump control signal is available for both the main unit and auxiliary units when multiple pumps installed.
2. Installation of water pipe system
   a. Single water pump
   Piping does not require a one-way valve when single water pump is installed, refer to figure as follow.

b. Multiple water pumps
Each unit is required to install a one-way valve when multiple pumps are installed, refer to figure as follow.

unit (n-1#)

unit (1#)

unit (0#)

water pump
inlet water

one-way valve

outlet water

Tw terminal

Fig.8-34 Installation of multiple water pump

unit (n-1#)
inlet water

unit (1#) unit (0#)

water pump

outlet water

Tw

terminal

3. Electric wiring
   Only the main unit requires wiring when single water pump installed, auxiliary units do not require wiring. All of the main unit and auxiliary units require wiring when multiple water pumps installed.For specific wiring, see figure 8-18.

Fig.8-33 Installation of single water pump

9 STRAT-UP AND CONFIGRUATION
91 Initial start-up at low outdoor ambient temperatures
During initial start-up and when water temperature is low, it is important that the water is heated gradually. Failure to do so may result in concrete floors cracking due to rapid temperature change. Please contact the responsible cast concrete building contractor for further details.
92 Points for attention prior to trial run

1. After the water system pipeline is flushed several times, please make sure that the purity of water meets the requirements; the system is re-filled with water and drained, and the pump is started up, then make sure that water flow and the pressure at the outlet meet the requirements.
2. The unit is connected to the main power 12 hours before being started up, to supply power to the heating belt and pre-heat the compressor. Inadequate pre-heating may cause damages to the compressor.
3. Setting of the wired controller. See details of the manual concerning setting contents of the controller, including such basic Zsettings as refrigerating and heating mode, manual adjustment and automatic adjustment mode and pump mode. Under normal circumstances, the parameters are set around standard operating conditions for trial run, and extreme working conditions should be prevented as much as possible.
4. Carefully adjust the target flow controller on the water system or the inlet stop valve of the unit, to make the water flow of the system be 90% of the water flow specified in troubleshooting table. .
   34

TEST RUN AND FINAL CHECK

101 Check item table after installation

Table 10-1

Checking item Whether installing site is meet for requirements
Whether water system is meeting for requirements
Whether electric wiring system is meeting for requirements

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. Noise and vibration is meeting for requirement. Sun radiation and rain or snow proof measures are meeting for requirements. External physical is meeting for requirement. Pipe diameter is meeting for requirement The length of system is meeting for requirement Water discharge is meeting for requirement Water quality control is meeting for requirement Flexible tube’s interface is meeting for requirement Pressure control is meeting for requirement Thermal insulation is meeting for requirement Wire capacity is meeting for requirement Switch capacity is meeting for requirement Fuse capacity is meeting for requirement Voltage and frequency are meeting for requirement Connecting tightly between wires Operation control device is meeting for requirement Safety device is meeting for requirement Chained control is meeting for requirement Phase sequence of power supply is meeting for requirement

Yes No

102 Trial run

1. Start up the controller and check whether the unit displays a fault code. If a fault occurs, remove the fault first, and start the unit according to the operating method in the “unit control instruction”, after determining that there is no fault existing in the unit.
2. Conduct trial run for 30 min. When the influent and effluent temperature becomes stabilized, adjust the water flow to nominal value, to ensure normal operation of the unit.
3. After the unit is shut down, it should be put into operation 10 minutes later, to avoid frequent start-up of the unit. In the end, check whether the unit meets the requirements according to the contents in Table 11-1.

CAUTION
· The unit can control start-up and shut-down of the unit, so when the water system is flushed, the operation of the pump should not be controlled by the unit.
· Do not start up the unit before draining the water system completely. · The target flow controller must be installed correctly. The wires of the target flow controller must be connected according
to electric control schematic diagram, or the faults caused by water breaking while the unit is in operation should be the user’s responsibility. · Do not re-start the unit within 10 min after the unit is shut down during trial run. · When the unit is used frequently, do not cut off the power supply after the unit is shut down; otherwise the compressor cannot be heated, thus leading to its damages. · If the unit is not in service for a long time, and the power supply needs to be cut off, the unit should be connected to the power supply 12 hours prior to re-starting of the unit, to pre-heat the compressor, the pump, the plate heat exchanger and the differential pressure value.

35

11 MAINTENANCE AND UPKEEP

111 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-75 DRS5 KH and KEM-90 DRS5 KH and KEM-140 DRS5 KH and KEM-180 DRS5 KH

No. Code Content

Note

1

E0

75&140 Model Main control Model setting error (Other Model Main control EPROM error)

The capability selection is inconsistent with the actual model. Power on again after setting correctly

2

E1

Phase sequence error of main control board check(for 90&180 model)

Recovered upon failure recovery

Communication failure between master and the HMI

Recovered upon failure recovery

3

E2

Communication failure between master and slave 2E2 Communication failure between main board and slave

board

Recovered upon failure recovery Recovered upon failure recovery

4 E3 Total water outlet temperature sensor failure (main unit valid) Recovered upon failure recovery

5 E4 Unit water outlet temperature sensor failure

Recovered upon failure recovery

6

E5

1E5 condenser tube temperature sensor T3A failure 2E5 condenser tube temperature sensor T3B failure

Recovered upon failure recovery Recovered upon failure recovery

7 E6 Water tank temperature sensor T5 failure

Recovered upon failure recovery

8 E7 Ambient temperature sensor failure

Recovered upon failure recovery

9 E8 Power supply phase sequence protector output error

Recovered upon failure recovery

10 E9 Water flow detection failure

Failure locking for 3 times in 60 minutes(Recovered by power off or Wired controller clear fault)

1Eb–>Taf1 the pipe of the tank antifreeze protection sensor

11

Eb

failure 2Eb–>Taf2 cooling evaporator low-temperature antifreeze

protection sensor failure

Recovered upon failure recovery Recovered upon failure recovery

12 EC Slave unit module reduction

Recovered upon failure recovery

13 Ed system discharge temperature sensor failure

Recovered upon failure recovery

1EE EVI plate heat exchanger refrigerant temperature T6A

14

EE

sensor failure 2EE EVI plate heat exchanger refrigerant temperature T6B

sensor failure

Recovered upon failure recovery Recovered upon failure recovery

15 EF Unit water return temperature sensor failure

Recovered upon failure recovery

16 EP Discharge sensor failure alarm

Recovered upon failure recovery

17 EU Tz sensor failure

Recovered upon failure recovery

18

P0 System high-pressure protection or discharge temperature

P0

protection 1P0 Compressor module 1 high pressure protection

for 3 times in 60 minutes (Recovered by power off) Recovered upon failure recovery

2P0 Compressor module 2 high pressure protection

Recovered upon failure recovery

19

P1

System low pressure protection (or Severe refrigerant leakage protection only for 75&140 model)

for 3 times in 60 minutes (Recovered by power off)

20 P2 Tz total cold outlet temperature too high(for 90&180 model)

Recovered upon failure recovery

21 P3 T4 ambient temperature too high in cooling mode

Recovered upon failure recovery

22

P4

1P4 System A current protection 2P4 System A DC bus current protection

for 3 times in 60 minutes (Recovered by power off)

23

P5

1P5 System B current protection 2P5 System B DC bus current protection

for 3 times in 60 minutes (Recovered by power off)

24 P6 Inverter module failure

Recovered upon error recovery

25 P7 High temperature protection of system condenser

for 3 times in 60 minutes (Recovered by power off)

26 P9 Water inlet and outlet temperature difference protection

Recovered upon failure recovery

27

PA

Abnormal water inlet and outlet temperature difference protection

Recovered upon failure recovery

28 Pb Winter antifreeze protection

Reminder code, non fault or protection

29 PC Cooling evaporator pressure too low

Recovered upon error recovery for 3 times in 60 minutes(Recovered by power off)

30 PE Cooling evaporator low temperature antifreeze protection

Recovered upon error recovery for 3 times in 60 minutes(Recovered by power off)

31 PH Heating T4 too high temperature protection

Recovered upon error recovery

32 PL Tfin module temperature too high protection

for 3 times in 100 minutes(Recovered by power off)

33

PU

1PU DC fan A module protection 2PU DC fan B module protection

Recovered upon failure recovery Recovered upon failure recovery

34

bH

1bH: Module 1 relay blocking or 908 chip self-check failed 1bH: Module 2 relay blocking or 908 chip self-check failed

Recovered upon error recovery Recovered upon error recovery

35 H5 Voltage too high or too low

Recovered upon error recovery

36

xH9

1H9 Compressor A inverter module is not matched 2H9 Compressor B inverter module is not matched

Recovered upon error recovery Recovered upon error recovery

37 HC High pressure sensor failure(for 75&140 model)

Recovered upon error recovery

1HE No inset A valve error

Recovered upon error recovery

38 HE 2HE No inset B valve error

Recovered upon error recovery

3HE No inset C valve error

Recovered upon error recovery

36

No. Code Content

Note

39

F0

1F0 IPM module A transmission error 2F0 IPM module B transmission error

Recovered upon error recovery Recovered upon error recovery

40 F2 Superheat insufficient

Wait at least 20min before recovering

1F4 module A L0 or L1 protection occurs for 3 times in 60

41

F4

minutes 2F4 module B L0 or L1 protection occurs for 3 times in 60

minutes

Recovered by power off Recovered by power off

42

F6

1F6 A system bus voltage error (PTC) 2F6 B system bus voltage error (PTC)

Recovered upon error recovery Recovered upon error recovery

43

Fb

Low pressure sensor error(pressure sensor error for 90&180 model)

Recovered upon error recovery

44 Fd Suction temperatrue sensor error

Recovered upon error recovery

45

FF

1FF DC fan A error 2FF DC fan B error

Recovered by power off Recovered by power off

46 FP DIP switch inconsistency of multiple water pumps

Recovered by power off

47

C7

If PL occurs 3 times in 100 minutes, the system reports the C7 failure

Recovered by power off or Wired controller clear fault

48

xL0

Compressor inverter module protection(x=1or 2, 1 for Compressor A, 2 for Compressor B)

Recovered upon error recovery

49

xL1

low-voltage protection(x=1or 2, 1 for Compressor A, 2 for Compressor B)

Recovered upon error recovery

50

xL2

high-voltage protection(x=1or 2, 1 for Compressor A, 2 for Compressor B)

Recovered upon error recovery

51 xL4 MCE error(x=1or 2, 1 for Compressor A, 2 for Compressor B) Recovered upon error recovery

52

xL5

zero-speed protection(x=1or 2, 1 for Compressor A, 2 for Compressor B)

Recovered upon error recovery

53 xL7 phase loss(x=1or 2, 1 for Compressor A, 2 for Compressor B) Recovered upon error recovery

54

xL8

frequency change over 15Hz(x=1or 2, 1 for Compressor A, 2 for Compressor B)

55

xL9

frequency phase difference 15Hz(x=1or 2, 1 for Compressor A, 2 for Compressor B)

Recovered upon error recovery

56 dF Defrosting prompt

Flash when entering the defrosting

L10 Overcurrent protection

57 L11 Transient phase current overcurrent protection

Overcurrent fault(Only for 75&140 Model )

L12 Phase current overcurrent lasts 30s protection

58 L20 Module over temperature protection

Over temperature fault(Only for 75&140 Model )

L30 Low bus voltage error

59

L31 High bus voltage error L32 Excessively high bus voltage error

Power fault(Only for 75&140 Model )

L34 Phase loss error

L43 Phase current sampling bias abnormal

60

L45 Motor code not match L46 IPM protection

hardware fault(Only for 75&140 Model )

L47 Module type not match

L50 Startup failure

61 L51 Out of step error

Control fault(Only for 75&140 Model )

L52 Zero speed error

L60 Fan motor phase loss protection

L65 IPM short circuit error

L66 FCT detection error

L6A Open circuit of U-phase upper tube

62 L6B Open circuit of U-phase lower tube

Diagnostic fault(Only for 75&140 Model )

L6C Open circuit of V-phase upper tube

L6D Open circuit of V-phase lower tube

L6E Open circuit of W-phase upper tube

L6F Open circuit of W-phase lower tube

37

112 Digital display of main board
The data display area is divided into Up area and Down area, with two groups of two-digit half 7-segment digital display, respectively.
a. Temperature display Temperature display is used for displaying the total outlet water temperature of unit system, outlet water temperature, condenser pipe temperature T3A of system A, condenser pipe temperature T3B of system B, outdoor environmental temperature T4, antifreezing temperature T6 and setting temperature Ts, with allowable data display scope -15°C~70°C. If the temperature is higher than 70°C, it is displayed as 70°C. If there is no effective date, it displays “– –” and indication point °C is on.

2. Maintenance of main parts
   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 found.
   Control and protect the equipment. See to it that no random adjustment be made on the set points on site.
   Regularly check whether the electric connection is loose, and whether there is bad contact at the contact point caused by oxidation and debris etc., and take timely measures if necessary.
   Frequently check the work voltage, current and phase balance.
   Check the reliability of the electric elements in time. Ineffective and unreliable elements should be replaced in time.

b. Current display Current display is used for displaying Modular unit system A compressor current IA or system B compressor current IB, with allowable display scope 0A~99A. If it is higher than 99A, it is displayed as 99A. If there is no effective date, it displays “– –” and indication point A is on.
c. Failure display It is used for displaying the total failure warning date of unit or that of Modular unit, with failure display scope E0~EF, E indicating failure, 0~F indicating failure code. “E-” is displayed when there is no failure and indication point # is on at the same time.
d. Protection display It is used for displaying the total system protection data of unit or the system protection data of Modular unit, with protection display scope P0~PF, P indicating system protection, 0~F indicating protection code. “P-” is displayed when there is no failure .
e. Unit number display It is used for displaying the address number of the currently selected Modular unit, with display scope 0~15 and indication point

is on at the same time.

f. Display of online unit number and startup unit number They are used for displaying the total online Modular units of the whole unit system and the number of the Modular unit under running state, respectively, with display scope 0~16. Any time when the spot check page is entered to display or change Modular unit, it is needed to wait for the up-to-date data of the Modular unit received and selected by wired controller. Before receiving the data, the wired controller only displays “—-” on the data display Down area, and the Up area displays the address number of the Modular unit. No page can be turned, which continues until the wired controller receives the communication data of this Modular unit.
113 Care and maintenance

1. Maintenance period
   It’s recommended that before cooling in summer and heating in winter every year, consult local air conditioner customer service center to check and maintain the unit, to prevent air conditioner errors which bring inconvenience to your life and work.

114 Removing scale
After long-time operation, calcium oxide or other minerals will be settled in the heat transfer surface of the water-side heat exchanger. These substances will affect the heat transfer performance when there is too much scale in the heat transfer surface.
and sequentially cause that electricity consumption increases and the discharge pressure is too high (or suction pressure too low). Organic acids such as formic acid, citric acid and acetic acid may be used to clean the scale. But in no way should cleaning agent containing fluoroacetic acid or fluoride should be used as the water-side heat exchange is made from stainless steel and is easy to be eroded to cause refrigerant leakage. Pay attention to the following aspects during the cleaning and scaleremoving process:

1. Water-side heat exchanger should be done be professionals. Please contact the local air-conditioner customer service center.
2. Clean the pipe and heat exchanger with clean water after cleaning agent is used. Conduct water treatment to prevent water system from being eroded or re- absorption of scale.
3. In case of using cleaning agent, adjust the density of the agent, cleaning time and temperature according to the scale settlement condition.
4. After pickling is completed, neutralization treatment needs to be done on the waste liquid. Contact relevant company for treating the treated waste liquid.
5. Protection equipments (such as goggles, gloves, mask and shoes) must be used during the cleaning process to avoid breathing in or contacting the agent as the cleaning agent and neutralization agent is corrosive to eyes, skins and nasal mucosa.
   115 Winter shutdown
   For shutdown in winter, the surface of the unit outside and inside should be cleaned and dried. Cover the unit to prevent dust. Open discharge water valve to discharge the stored water in the clean water system to prevent freezing accident (it is preferable to inject antifreezer in the pipe).
   116 Replacing parts
   Parts to be replaced should be the ones provided by our company.
   Never replace any part with different part.

38

117 First startup after shutdown

119 Disassembling compressor

The folowing preparations should be made for re-startup of unit after long- time shutdown:

1. Thoroughly check and clean unit.
2. Clean water pipe system.
3. Check pump, control valve and other equipments of water pipe system.
4. Fix connections of all wires.
5. It is a must to electrify the machine 12 hours before starup.
   118 Refrigeration system
   Determine whether refrigerant is needed by checking the value of suction and discharge pressure and check whether there is a leakage. Air tight test must be made if there is a leakage or parts of refrigerating system is to be replaced. Take different measures in the following two different conditions from refrigerant injection.
6. Total leakage of refrigerant. In case of such situation, leakage detection must be made on the pressurized nitrogen used for the system. If repair welding is needed, welding cannot be made until all the gas in the system is discharged. Before injecting refrigerant, the whole refrigeration system must be completely dry and of vacuum pumping.
   Connect vacuum pumping pipe at the fluoride nozzle at lowpressure side.
   Remove air from the system pipe with vacuum pump. The vacuum pumping lasts for above 3 hours. Confirm that the indication pressure in dial gauge is within the specified scope.
   When the degree of vacuum is reached, inject refrigerant into the refrigeration system with refrigerant bottle. Appropriate amount of refrigerant for injection has been indicated on the nameplate and the table of main technical parameters. Refrigerant must be injected from the low pressure side of system.
   The injection amount of refrigerant will be affected by the ambient temperature. If the required amount has not been reached but no more injection can be done, make the chilled water circulate and start up the unit for injection. Make the low pressure switch temporarily short circuit if necessary.
7. Refrigerant supplement. Connect refrigerant injection bottle on the fluoride nozzle at low-pressure side and connect pressure gauge at low pressure side.
   Make chilled water circulate and start up unit, and make the low pressure control switch short circuit if necessary.
   Slowly inject refrigerant into the system and check suction and discharge pressure.
   CAUTION
   · Connection must be renewed after injection is completed.
   · Never inject oxygen, acetylene or other flammable or poisonous gas to the refrigeration system at leakage detection and air tight test. Only pressurized nitrogen or refrigerant can be used.

Follow the following procedures if compressor needs to be disassembled:

1. Cut off the power supply of unit.
2. Remove power source connection wire of compressor.
3. Remove suction and discharge pipes of compressor.
4. Remove fastening screw of compressor.
5. Move the compressor.
   1110 Auxiliary electric heater
   When the ambient temperature is lower than 2°C, the heating efficiency decreases with the decline of the outdoor temperature. In order to make the air-cooled heat pump stably run in a relatively cold region and supplement some heat lost due to de-frosting. When the lowest ambient temperature in the user’s region in winter is within 0°C~10°C, the user may consider to use auxiliary electric heater.
   Please refer to relevant professionals for the power of auxiliary electric heater.
   1111 System antifreezing
   In case of freezing at the water-side heat exchanger interval channel, severe damage may be caused, i.e. heat exchange may be broken and appears leakage. This damage of frost crack is not within the warranty scope, so attention must be paid to antifreezing.
6. If the unit that is shutdown for standby is placed in an environment where the outdoor temperature is lower than 0°C, the water in the water system should be drained.
7. Water pipe may be frozen when the chilled water target flow controller and anti-freezing temperature senor become ineffective at running, therefore, the target flow controller must be connected in accordance with the connection diagram.
8. Frost crack may happen to water-side heat exchanger at maintenance when refrigerant is injected to the unit or is discharged for repair. Pipe freezing is likely to happen any time when the pressure of refrigerant is below 0.4Mpa. Therefore, the water in the heat exchanger must be kept flowing or be thoroughly discharged.

39

1112 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; 3) Heat the sealant to screw off the safety valve. Note to protect the area where the screwing tool meets the tank body and avoid damaging to the tank coating; 4) If tank coating is damaged, repaint the damaged area.
outlet of safty valve 7/8° UNF
safety valve
liquid-vapor separator
Fig.11-1 Replacement of safety valve
WARNING
· The air outlet of safty valve must be connected to the appropriate pipe, which can direct the leaking refrigerant to the appropriate place for discharge.
· Safety valve warranty period is 24 months. Under the specified conditions, if flexible sealing parts is used, the safety valve life expectancy is 24 to 36 months, If metal or PIFE sealing components is used, the average life expectancy is 36 to 48 months. Visual inspection is needed after that period, Serviceman should check the appearance of the valve body and the operating environment. If the valve body is not obvious corrosion, cracks, dirt, damage, then the valve can be used continually. Otherwise, please contact your supplier for spare part.
40

1113 I

NFORMATION SERVICING

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.
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. Work in confined sapces shall be avoided. The area around the work space shall be sectioned off. Ensure that the conditions within the area have been made safe by controlling of flammable material.
4. Checking for presence of refrigerant The area shall be checked with an appropriate refrigerant detector prior to and during work to ensure the technician is aware of potentially flammable atmospheres. Ensure that the leak detection equipment being used is suitable for use with flammable refrigerants, i.e. no sparking, adequately sealed or intrinsically safe.
5. Presence of fire extinguisher If any hot work is to be conducted on the refrigeration equipment or any associated parts, appropriate fire extinguishing equipment shall be available to hand. Have a dry power or CO2 fire extinguisher adjacent to the charging area.
6. No ignition sources No person carrying out work in relation to a refrigeration system which involves exposing any pipe work that contains or has contained flammable refrigerant shall use any sources of ignition in such a manner that it may lead to the risk of fire or explosion. All possible ignition sources, including cigarette smoking, should be kept sufficiently far away from the site of installation. Repair, ing repairing, removing and disposal, during which flammable refrigerant can possibly be released to the surrounding space. Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no flammable hazards or ignition risks. NO SMOKING signs shall be displayed.
7. Ventilated area Ensure that the area is in the open or that it it adequately ventilated before breaking into the system or conducting any hot work. A degree of ventilation shall continue during the period that the work is carried out. The ventilation should safely disperse any released refrigerant and preferably expel it externally into the atmosphere.
8. Checks to the refrigeration equipment Where electrical components are being changed, they shall be fit for the purpose and to the correct specification. At all times the manufacturer s maintenance and service guidelines shall be followed. If in doubt , please consult the manufacturer’s technical department for assistance. The following checks shall be applied to installations using flammable refrigerants:
   · The charge size is in accordance with the room size within which the refrigerant containing parts are installed; · The ventilation machinery and outlets are operating adequately and are not obstructed; · If an indirect refrigerating circuit is being used, the secondary circuits shall be checked for the presence of refrigerant;
   marking to the equipment continues to be visible and legible. · Marking and signs that are illegible shall be corrected; · Refrigeration pipe or components are installed in a position where they are unlikely to be exposed to any substance which
   may corrode refrigerant containing components, unless the components are constructed of materials which are inherently resistant to being corroded or are suitably protected against being so corroded.
9. Checks to electrical devices Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures. If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, and adequate temporary solution shall be used. This shall be reported to the owner of the equipment so all parties are advised.
   Initial safety checks shall include:
   · That capacitors are discharged: this shall be done in a safe manner to avoid possibility of sparking; · That there no live electrical components and wiring are exposed while charging, recovering or purging the system; · That there is continuity of earth bonding.
10. Repairs to sealed components
    41

a) During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being worked upon prior to any removal of sealed covers, etc. If it is absolutely necessary to have an electrical supply to equipment during servicing, then a permanently operating form of leak detection shall be located at the most critical point to warn of a potentially hazardous situation. 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.
· Ensure that apparatus is mounted securely. · Ensure that seals or sealing materials have not degraded such that they no longer serve the purpose of preventing the
ingress of flammable atmospheres. Replacement parts shall be in accordance with the manufacturer’s specifications.
NOTE
The use of silicon sealant may inhibit the effectiveness of some types of leak detection equipment. Instrinsically safe components do not have to be isolated prior to working on them.
11) Repair to intrinsically safe components Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use. Intrinscially safe components are the only types that can be worked on while live in the presence of a flammable atmosphere. The test apparatus shall be at the correct rating. Replace components only with parts specified by the manufacturer. Other parts may result in the ignition of refrigerant in the atmosphere from a leak.
12) Cabling Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.
13) Detection of flammable refrigerants Under no circumstances shall potential sources of ignition be used in the searching for or detection of refrigerant leaks.
14) Leak detection methods The following leak detection methods are deemed acceptable for systems containing flammable refrigerants. Electronic leak detectors shall be used to detect flammable refrigerants, but the sensitivity may not be adequate, or may need re-calibration. (Detection equipment shall be calibrated in a refrigerant-free area.) Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant. Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed and the appropriate percentage of gas (25% maximum) is confirmed. Leak detection fluids are suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work. If a leak is suspected, all naked flames shall be removed or extinguished. If a leakage of refrigernat is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated(by means of shut off valves) in a part of the system remote from the leak . Oxygen free nitrogen(OFN) shall then be purged through the system both before and during the brazing process.
15) Removal and evacuation When breaking into the refrigerant circuit to make repairs of for any other purpose, conventional procedures shall be used, However, it is important that best practice is followed since flammability is a consideration. The following procedure shall be as below: · Remove refrigerant; · Purge the circuit with inert gas; · Evacuate; · Purge again with inert gas; · Open the circuit by cutting or brazing. The refrigerant charge shall be recovered into the correct recovery cylinders. The system shall be flushed with OFN to render the unit safe. This process may need to be repeated several times.
Compressed air or oxygen shall not be used for this task. Flushing shall be achieved by breaking the vacuum in the system with OFN and continuing to fill until the working pressure is achieved, then venting to atmosphere, and finally pulling down to a vacuum. This process shall be repeated until no refrigerant is within the system.
When the final OFN charge is used, the system shall be vented down to atmospheric pressure to enable work to take place. This operation is absolutely vital if brazing operations on the pipe-work are to take place. Ensure that the outlet for the vacuum pump is not closed to any ignition sources and there is ventilation available.
16) Charging procedures In addition to conventional charging procedures, the following requirements shall be followed: · Ensure that contamination of different refrigerants does not occur when using charging equipment. Hoses or lines shall be
as short as possible to minimize the amount of refrigerant contained in them. · Cylinders shall be kept upright.
42

· 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. · 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. A follow up leak test shall be carried out prior to leaving the site.
17) Decommissioning Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail. It is recommended good practice that all refrigerants are recovered safely. Before the task being carried out, an oil and refrigerant sample shall be taken.
In case analysis is required prior to re-use of reclaimed refrigerant. It is essential that electrical power is available before the task is commenced. a) Become familiar with the equipment and its operation. b) Isolate system electrically c) Before attempting the procedure ensure that: · Mechanical handling equipment is available, if required, for handling refrigerant cylinders; · All personal protetive equipment is available and being used correctly; · The recovery process is supervised at all times by a competent person; · Recovery equipment and cylinders conform to the appropriate standards. d) Pump down refrigerant system, if possible. e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system. f) Make sure that cylinder is situated on the scales before recovery takes place. g) Start the recovery machine and operate in accordance with manufacturer s instructions. h) Do not overfill cylinders. (No more than 80% volume liquid charge). i) Do not exceed the maximum working pressure of the cylinder, even temporarily. j) When the cylinders have been filled correctly and the process completed, make sure that the cylinders and the equipment are removed from site promptly and all isolation valves on the equipment are closed off. k) Recovered refrigerant shall not be charged into another refrigeration system unless it has been cleaned and checked.
18) Labelling Equipment shall be labelled stating that it has been de- commissioned and emptied of refrigerant. The label shall be dated and signed. Ensure that there are labels on the equipment stating the equipment contains flammable refrigerant.
19) Recovery When removing refrigerant from a system, either for service or decommissioning, it is recommended good practice that all refrigerants are removed safely. When tranferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct numbers of cylinders for holding the total system charge are available. All cylinders to be used are designated for the recovered refrigerant and labelled for that refrigerant(i.e special cylinders for the recovery of refrigerant). Cylinders shall be complete with pressure relief valve and associated shut-off valves in good working order. Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs. The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the recovery of flammable refrigerants. In addition, a set of calibrated weighing scales shall be available and in good working order. Hoses shall be complete with leak-free disconnect couplings and in good condition. Before using the recovery machine, check that it is in satisfactory working order, has been properly maintained and that any associated electrical components are sealed to prevent ignition in the event of a refrigerant release. Consult manufacturer if in doubt. The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and the relevant Waste Transfer Note arranged. Do not mix refrigerants in recovery units and especially not in cylinders. If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that flammable refrigerant does not remain within the lubricant. The evacuation process shall be carried out prior to retruning the compressor to the suppliers. Only electric heating to the compressor body shall be employed to accelerate this process. When oil is drained from a system, it shall be carried out safely.
20) Transportation, marking and storage for units Transport of equipment containing flammable refrigerants compliance with the transport regulations Marking of equipment using signs compliance with local regulations Disposal of equipment using flammable refrigerants compliance with national regulations Storage of equipment/appliances The storage of equipment should be in accordance with the manufacturer’s instructions. Storage of packed (unsold) equipment Storage package protection should be constructed such that mechanical damage to the equipment inside the package will not cause a leak of the refrigerant charge. The maximum number of pieces of equipment permitted to be stored together will be determined by local regulations.
43

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. Check refrigerant suction temperature and superheating temperature:

Refrigerant suction temperature: ( ) ( ) ( ) ( ) ( )

Superheating temperature:

( )( )( )( )( )

4. Check pressure:

Discharge pressure:

( )( )( )( )( )

Suction pressure:

( )( )( )( )( )

5. Check running current: ( ) ( ) ( ) ( ) ( )

6. Whether unit has been through refrigerant leakage test?

( )

7. Whether there is noise on all the panels of unit?

( )

8. Check whether the main power source connection is correct. ( )

RECORD TABLE OF ROUTINE RUNNING

Table 11-3

Model:

Weather:

Outdoor

Dry bulb

temperature

Wet bulb

Indoor temperature

High pressure

Compressor

Low pressure Voltage

Current

Air temperature

Inlet (dry bulb)

of air-side heat

Outlet (dry

exchanger

bulb)

Temperature of

Inlet

chilled water or hot Outlet
water

Current of cooling water pump or hot

water pump

Note:

°C °C °C MPa MPa V A °C
°C
°C
°C
A

Date: Operation time: Startup ( ) Shutdown ( )

44

12 APPLICABLE MODELS AND MAIN PARAMETERS

Table 12-1

Model

KEM-75 DRS5 KEM-90 DRS5 KEM-140 DRS5 KEM-180 DRS5

KH

KH

KH

KH

Cooling capacity

kW

69.7

82.0

129.5

163.0

Heating capacity

kW

75.4

90.0

138.6

181.2

Standard cooling input

kW

27.3

28.3

51.4

57.7

Cooling rated current

A

42.0

47.0

79.0

89.0

Standard heating input

kW

24.3

29.0

45.6

59.1

Heating rated current

A

37.3

48.0

70.0

91.0

Power supply

380-415V 3N~ 50Hz

Operation control

Control of wired controller, auto startup, running state display, failure alert etc.

Safety device

High or low pressure switch, freeze-proof device, water flow volume controller, Overcurrent device, power phase sequence device etc.

Refrigerant

Type

Chargeing volume kg

9.0

Waterflow volume m3/h(cooling)

12.0

Waterflow volume m3/h(heating)

12.9

R32

16.0

15.5

14.1

22.4

15.5

23.7

16.0*2 28.2 31.0

Hydraulic resistance lose kPa

156

220

94

205

Water pipe system

Water side heat exchanger

Plate heat exchanger

Max. pressure MPa

1.0

Min. pressure MPa

0.15

Inlet and outlet pipe dia.

DN50

DN50

DN65

DN80

Air side heat exchanger

Type Air flow volume m3/h

28500

Fin coil model

35000

50000

70000

Outline dimension N.W. of the unit

L mm W mm H mm

2000 960 1770

2220 1135 2315

2220 1135 2300

2220 2752 2413

Net Weight

kg

475

686

746

1500

Operation Weight

kg

485

700

776

1520

Packing dimension

L × W × H mm

2085×1030×1890 2250×1180×2445 2250×1180×2445 224528102446

45

13 INFORMATION REQUIREMENTS

Table 13-1

Model(s): Outdoor side heat exchanger of chiller: Indoor side heat exchanger chiller: Type: Driver of compressor:

Information requirements for comfort chillers KEM-75 DRS5 KH Air Water
Compressor driven vapour compression Electric motor

Item

Symbol Value

Unit

Item

Symbol Value

Unit

Rated cooling capacity

Prated, c 70.00

kW

Seasonal space cooling energy efficiency

s, c

166

%

Declared cooling capacity for part load at given outdoor temperature Tj

Declared energy efficiency ratio for part load at given outdoor temperature Tj

Tj = + 35°C

Pdc 68.74

kW

Tj = + 35°C

EERd

2.55

—

Tj = + 30°C

Pdc 51.77

kW

Tj = + 30°C

EERd

3.53

—

Tj = + 25°C

Pdc 32.76

kW

Tj = + 25°C

EERd

4.84

—

Tj = + 20°C

Pdc 17.49

kW

Tj = + 20°C

EERd

6.32

—

Degradation co-efficient for chillers (*) Cdc

—

Power consumption in modes other than ‘active mode’

Off mode Thermostat-off mode

POFF

0.08

kW

Crankcase heater mode PCK

0

kW

PTO 0.556

kW

Standby mode

PSB

0.35

kW

Other items

Capacity control

Variable

For air-to-water comfort chillers: air flow rate, outdoor measured

—

28500 m3 /h

Sound power level, indoors/outdoors L WA –/86

dB

For water / brine-to-water

Emissions of nitrogen oxides (if applicable)

chillers: Rated brine or

NOX (**)

—

mg/ kWh water flow rate, outdoor input GCV side heat exchanger

—

—

m3 /h

GWP of the refrigerant

—

675

kg CO2 eq (100 years)

Standard rating conditions used:

Low temperature application

Contact details

GD Midea Heating & Ventilating Equipment Co. , Ltd. Penglai industry Road, Beijiao, Shunde, Foshan, Guangdong, 528311 P.R. China.

(*) If Cdc is not determined by measurement then the default degradation coefficient of chillers shall be 0, 9. (**) From 26 September 2018.

46

Table 13-2

Model(s): Outdoor side heat exchanger of chiller: Indoor side heat exchanger chiller: Type: Driver of compressor:

Information requirements for comfort chillers KEM-90 DRS5 KH Air to water Water
Compressor driven vapour compression Electric motor

Item

Symbol Value Unit

Item

Symbol Value

Unit

Rated cooling capacity

Prated, c 82.13

kW

Seasonal space cooling energy efficiency

s, c

174.55

%

Declared cooling capacity for part load at given outdoor temperature Tj

Declared energy efficiency ratio for part load at given outdoor temperature Tj

Tj = + 35°C

Pdc 82.13

kW

Tj = + 35°C

EERd

2.89

—

Tj = + 30°C

Pdc 59.15

kW

Tj = + 30°C

EERd

4.09

—

Tj = + 25°C

Pdc 37.36

kW

Tj = + 25°C

EERd

5.10

—

Tj = + 20°C

Pdc 26.05

kW

Tj = + 20°C

EERd

5.91

—

Degradation co-efficient for chillers (*) Cdc

0.9

—

Power consumption in modes other than ‘active mode’

Off mode Thermostat-off mode

POFF 0.090

kW

Crankcase heater mode

PCK

0

kW

PTO 0.700

kW

Standby mode

PSB

0.090

kW

Other items

Capacity control

Variable

For air-to-water comfort chillers: air flow rate, outdoor measured

—

35000 m3 /h

Sound power level, indoors/outdoors

L WA

83

dB

For water / brine-to-water

Emissions of nitrogen oxides (if applicable)

chillers: Rated brine or

NOX (**)

—

mg/ kWh water flow rate, outdoor input GCV side heat exchanger

—

—

m3 /h

GWP of the refrigerant

—

675

kg CO2 eq (100 years)

Standard rating conditions used:

Low temperature application

Contact details

GD Midea Heating & Ventilating Equipment Co. , Ltd. Penglai industry Road, Beijiao, Shunde, Foshan, Guangdong, 528311 P.R. China.

(*) If Cdc is not determined by measurement then the default degradation coefficient of chillers shall be 0, 9. (**) From 26 September 2018.

47

Table 13-3

Model(s): Outdoor side heat exchanger of chiller: Indoor side heat exchanger chiller: Type: Driver of compressor:

Information requirements for comfort chillers KEM-140 DRS5 KH Air Water
Compressor driven vapour compression Electric motor

Item

Symbol Value

Unit

Item

Symbol Value

Unit

Rated cooling capacity

Prated, c

130

kW

Seasonal space cooling energy efficiency

s, c

170

%

Declared cooling capacity for part load at given outdoor temperature Tj

Declared energy efficiency ratio for part load at given outdoor temperature Tj

Tj = + 35°C

Pdc 129.63

kW

Tj = + 35°C

EERd

2.52

—

Tj = + 30°C

Pdc

96.05

kW

Tj = + 30°C

EERd

3.52

—

Tj = + 25°C

Pdc

60.69

kW

Tj = + 25°C

EERd

4.87

—

Tj = + 20°C

Pdc

31.50

kW

Tj = + 20°C

EERd

6.62

—

Degradation co-efficient for chillers (*) Cdc

0.9

—

Power consumption in modes other than ‘active mode’

Off mode Thermostat-off mode

POFF

0.14

kW

Crankcase heater mode PCK

0

kW

PTO

0.70

kW

Standby mode

PSB

0.14

kW

Other items

Capacity control

Variable

For air-to-water comfort chillers: air flow rate, outdoor measured

—

50000 m3 /h

Sound power level, indoors/outdoors L WA –/93

dB

For water / brine-to-water

Emissions of nitrogen oxides (if applicable)

chillers: Rated brine or

NOX (**)

—

mg/ kWh water flow rate, outdoor input GCV side heat exchanger

—

—

m3 /h

GWP of the refrigerant

—

675

kg CO2 eq (100 years)

Standard rating conditions used:

Low temperature application

Contact details

GD Midea Heating & Ventilating Equipment Co. , Ltd. Penglai industry Road, Beijiao, Shunde, Foshan, Guangdong, 528311 P.R. China.

(*) If Cdc is not determined by measurement then the default degradation coefficient of chillers shall be 0, 9. (**) From 26 September 2018.

48

Table 13-4

Model(s): Outdoor side heat exchanger of chiller: Indoor side heat exchanger chiller: Type: Driver of compressor:

Information requirements for comfort chillers KEM-180 DRS5 KH Air to water Water
Compressor driven vapour compression Electric motor

Item

Symbol Value

Unit

Item

Symbol Value

Unit

Rated cooling capacity

Prated, c 164.0

kW

Seasonal space cooling energy efficiency

s, c

171

%

Declared cooling capacity for part load at given outdoor temperature Tj

Declared energy efficiency ratio for part load at given outdoor temperature Tj

Tj = + 35°C

Pdc 163.1

kW

Tj = + 35°C

EERd

2.83

—

Tj = + 30°C

Pdc 117.9

kW

Tj = + 30°C

EERd

4.01

—

Tj = + 25°C

Pdc

76.8

kW

Tj = + 25°C

EERd

4.98

—

Tj = + 20°C

Pdc

52.3

kW

Tj = + 20°C

EERd

5.87

—

Degradation co-efficient for chillers (*) Cdc

0.9

—

Power consumption in modes other than ‘active mode’

Off mode Thermostat-off mode

POFF 0.180

kW

Crankcase heater mode PCK

0

kW

PTO 1.400

kW

Standby mode

PSB

0.180

kW

Other items

Capacity control

Variable

For air-to-water comfort

chillers: air flow rate, outdoor measured

—

70000 m3 /h

Sound power level, indoors/outdoors L WA

92

dB

For water / brine-to-water

Emissions of nitrogen oxides (if applicable)

NOX (**) —

mg/ kWh input GCV

chillers: Rated brine or water flow rate, outdoor side heat exchanger

—

—

m3 /h

GWP of the refrigerant

—

675

kg CO2 eq (100 years)

Standard rating conditions used:

Low temperature application

Contact details

GD Midea Heating & Ventilating Equipment Co. , Ltd. Penglai industry Road, Beijiao, Shunde, Foshan, Guangdong, 528311 P.R. China.

(*) If Cdc is not determined by measurement then the default degradation coefficient of chillers shall be 0, 9. (**) From 26 September 2018.

49

Table 13-5

Information requirements for heat pump space heaters and heat pump combination heaters

Model(s):

KEM-75 DRS5 KH

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. Otherwise, parameters shall be declared for medium- temperature application. Parameters shall be declared for average climate conditions.

Item
Rated heat output(3)at Tdesignh = -10 (-11) °C

Symbol Value Unit

Prated = Pdesignh

47.4

kW

Item

Symbol Value Unit

Seasonal space heating energy efficiency

s

155 %

Seasonal coefficient of performance

SCOP 3.95 — Active mode coef. of performance SCOPon —

—

Net seasonal coef. of performance SCOPnet —

—

Tj = -7°C

Pdh 43.20 kW

Tj = +2°C

Pdh 26.64 kW

Tj = +7°C

Pdh 24.71 kW

Tj = +12°C

Pdh 21.62 kW

Tj = bivalent temperature

Pdh 43.20 kW

Tj = operation limit temperature

Pdh 45.75 kW

For air-to-water heat pumps: Tj = ­ 15 °C (if TOL < ­ 20 °C)

Pdh

— kW

Bivalent temperature (maximum +2°C) Tbiv

-7 °C

Cycling interval capacity for heating at Tj = -7°C Degradation coefficient(4) at T= -7°C

Pcych Cdh

— kW 0.9 —

Cycling interval capacity for heating at Tj = +2°C Degradation coefficient(4) at T= +2°C

Pcych Cdh

— kW

—

—

Cycling interval capacity for heating at Tj = +7°C Degradation coefficient(4) at Tj = +7°C
Cycling interval capacity for heating at Tj = +12°C Degradation coefficient(4) at Tj = +12°C

Pcych Cdh Pcych Cdh

— kW

—

—

— kW

—

—

Power consumption in modes other than active mode

Tj = -7°C Tj = +2°C Tj = +7°C Tj = +12°C Tj = bivalent temperature Tj =operation limit temperature For air-to-water heat pumps: Tj =­15°C (if TOL<­20°C)

COPd 2.70 -COPd 3.75 -COPd 5.42 -COPd 7.14 -COPd 2.70 -COPd 2.21 —

COPd

—

—

For air-to-water HP : Operation limit temperature(maximum-7°C)

TOL -10 °C

Heating water operating limit temperature

WTOL —

°C

Cycling interval efficiency at Tj = +7°C

COPcyc

—

—

Cycling interval capacity for heating at Tj = +12°C

COPcyc —

—

Cycling interval efficiency at Tj = +7°C

COPcyc

—

—

Cycling interval capacity for heating at Tj = +12°C

COPcyc —

—

Supplementary heater (to be declared even if not provided in

the unit)

Off mode

POFF

Thermostat-off mode

PTO

Standby mode

PSB

Crankcase heater mode

PCK

Other items

0.08 kW Rated heat output(3) 0.35 kW Type of energy input

Psup = sup(Tj)

—

kW

0.08 kW

Outdoor heat exchanger

0

kW

For air-to-water HP: Rated air flow rate

Qairsource

28500 m3/h

Capacity control

Fixed/ Variable

Variable

For water-to-water: Rated water flow rate

Qwatersource

—

m3/h

Sound power level, indoors Sound power level, outdoors Contact details

L WA L WA

— dB(A) For brine-to-water: Rated brine 86 dB(A) flow rate

Qbrinesource

—

m3/h

Name and address of the manufacturer or its authorised representative.

(1) For heat pump space heaters and heat pump combination heaters, the rated heat output Prated is equal to the design load for heating Pdesignh, and the rated heat output of a supplementary heater Psup is equal to the supplementary capacity for heating sup(Tj). (2) If Cdh is not determined by measurement then the default degradation coefficient is Cdh = 0, 9.

50

Table 13-6

Information requirements for heat pump space heaters and heat pump combination heaters

Model(s):

KEM-90 DRS5 KH

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. Otherwise, parameters shall be declared for medium- temperature application. Parameters shall be declared for average climate conditions.

Item
Rated heat output(3)at Tdesignh = -10 (-11) °C

Symbol Value Unit

Prated = Pdesignh

74.3

kW

Item
Seasonal space heating energy efficiency

Symbol Value Unit s 147.70 %

Seasonal coefficient of performance

SCOP 3.77 — Active mode coef. of performance SCOPon —

—

Net seasonal coef. of performance SCOPnet —

—

Tj = -7°C

Pdh 65.41 kW

Tj = +2°C

Pdh 43.01 kW

Tj = +7°C

Pdh 26.42 kW

Tj = +12°C

Pdh 28.54 kW

Tj = bivalent temperature

Pdh 65.41 kW

Tj = operation limit temperature

Pdh 71.03 kW

For air-to-water heat pumps: Tj = ­ 15 °C (if TOL < ­ 20 °C)

Pdh

— kW

Bivalent temperature (maximum +2°C) Tbiv

-7 °C

Cycling interval capacity for heating at Tj = -7°C Degradation coefficient(4) at T= -7°C

Pcych Cdh

— kW

—

—

Cycling interval capacity for heating at Tj = +2°C Degradation coefficient(4) at T= +2°C

Pcych Cdh

— kW

—

—

Cycling interval capacity for heating at Tj = +7°C Degradation coefficient(4) at Tj = +7°C
Cycling interval capacity for heating at Tj = +12°C Degradation coefficient(4) at Tj = +12°C

Pcych Cdh Pcych Cdh

— kW

—

—

— kW

—

—

Power consumption in modes other than active mode

Tj = -7°C Tj = +2°C Tj = +7°C Tj = +12°C Tj = bivalent temperature Tj =operation limit temperature For air—to-water heat pumps: Tj =­15°C (if TOL<­20°C)

COPd 2.45 -COPd 3.63 -COPd 5.08 -COPd 5.94 -COPd 2.45 -COPd 2.32 —

COPd —

—

For air-to-water HP : Operation limit temperature(maximum-7°C)

TOL -10 °C

Heating water operating limit temperature

WTOL —

°C

Cycling interval efficiency at Tj = +7°C

COPcyc

—

—

Cycling interval capacity for heating at Tj = +12°C

COPcyc —

—

Cycling interval efficiency at Tj = +7°C

COPcyc

—

—

Cycling interval capacity for heating at Tj = +12°C

COPcyc —

—

Supplementary heater (to be declared even if not provided in

the unit)

Off mode Thermostat-off mode

POFF 0.090 kW Rated heat output(3) PTO 0.700 kW Type of energy input

Psup = sup(Tj)

—

kW

Standby mode

PSB

0.090 kW

Outdoor heat exchanger

Crankcase heater mode

PCK

Other items

0

kW

For air-to-water HP: Rated air flow rate

Qairsource

35000 m3/h

Capacity control

Fixed/ Variable

Variable

For wate

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