Kaysun KEM-30 DNH3 User manual

TECHNICAL MANUAL
Modular Chiller
KEM-30 DNH3 KEM-65 DHN3
KEM-130 HN3 KEM-200 HN3 KEM-250 HN3
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.

Content
1 General information ---------------------------------------------------------------------------------------------------------- 1
1.1 Product lineup ---------------------------------------------------------------------------------------------------------------------- 1
1.2 External appearance -------------------------------------------------------------------------------------------------------------- 2
2 Features -------------------------------------------------------------------------------------------------------------------------- 3
3 Specifications ------------------------------------------------------------------------------------------------------------------- 7
4 Dimensions -------------------------------------------------------------------------------------------------------------------- 15
5 Refrigeration System Drawings ----------------------------------------------------------------------------------------- 20
6 Piping Diagrams ------------------------------------------------------------------------------------------------------------- 23
7 Wire Diagrams --------------------------------------------------------------------------------------------------------------- 28
8 Electric Characteristics ----------------------------------------------------------------------------------------------------- 39
9 Capacity Tables -------------------------------------------------------------------------------------------------------------- 40
10 Troubleshooting------------------------------------------------------------------------------------------------------------ 50
10.1 Failure & Protection Codes --------------------------------------------------------------------------------------------------- 50
10.2 Troubles and Solutions -------------------------------------------------------------------------------------------------------- 55
10.3 Typical malfunction solutions ----------------------------------------------------------------------------------------------- 57
11 Installation ------------------------------------------------------------------------------------------------------------------ 66
12 Commissioning ------------------------------------------------------------------------------------------------------------- 93
13 Maintenance ---------------------------------------------------------------------------------------------------------------- 94
14 Control System ------------------------------------------------------------------------------------------------------------- 98
14.1 PCB Outline and Description------------------------------------------------------------------------------------------------- 98
14.2 Wired controller KCCH-02 PS(Optional) -------------------------------------------------------------------------------- 103
14.3 Wired controller KCCHT-02(Standard) ----------------------------------------------------------------------------------- 112
14.4 Control software -------------------------------------------------------------------------------------------------------------- 120
15 Optional Accessories ---------------------------------------------------------------------------------------------------- 151
Appendix ----------------------------------------------------------------------------------------------------------------------- 152
Manufacture reserves the right to discontinue, or change at any time, specifications or designs without notices and without
incurring obligations.

MCAC-ATSM-2017-08 Aqua Tempo Power Series (with LAK) air cooled scroll chiller unit (50Hz)
1
1 General information
1.1 Product lineup
No
Model
Power supply
Heat exchanger
type
Maximum
combination
s
Maximum
capacity(kW)
Wired controller
1
KEM-30 DHN3
380~415V/3ph/50Hz
Double-pipe
16
480
KCCHT-02
2
KEM-65 DHN3
380~415V/3ph/50Hz
Shell and tube
16
1040
KCCHT-02
3
KEM-130 HN3
380~400V/3ph/50Hz
Shell and tube
8
1040
KCCHT-02
4
KEM-200 HN3
380~400V/3ph/50Hz
Shell and tube
5
1000
KCCHT-02
5
KEM-250 HN3
380~400V/3ph/50Hz
Shell and tube
8
2000
KCCHT-02

2
1.2 External appearance
KEM-130 HN3
KEM-200 HN3
KEM-250 HN3
KEM-30 DHN3
KEM-65 DHN3

MCAC-ATSM-2017-08 Aqua Tempo Power Series (with LAK) air cooled scroll chiller unit (50Hz)
3
2 Features
1). Low ambient temperature cooling function
the ambient temperature is down to -10  in cooling mode with low ambient kitthis function should be
activated by S8 switch on the PCB board.
Mode
Ambient temp.
Cooling
NormallyS8 address OFF
10~46
Low temp. (S8 address ON)
-10~46
2). Wide range of outlet water temperature
Cooling: 5~17˚C (Set in factory), 0~17˚C can be available by switch the S5 on PCB, the antifreeze must be
put into water system.
Heating: 40~50˚C (Set in factory), 22~50˚C can be available by switch the address.
Mode
Outlet water temp.
Cooling(S5 address)
Default(OFF)
5~17
Low water temp.(ON)
0~17
Heating(S4 address)
Default (OFF)
40~50
Low water temp. (ON)
22~50
3).Digital scroll technique
When the system operates at the part-load, the system can accurately adjust cooling and heating capacity
output basing on actual requirement of the indoor room. Digital scroll technique, provide maximum reliability,
high efficiency and quiet operation.
4).Modular design, flexible combination
The unit adopts modular design, which can make more units to connect together. The unit can be combined
max16 modules (30&65kW module),5 modules (200kW module) or 8 modules (130&250kW
module),meanwhile every separate module can be operated as main unit, also each module can be a slave
unit with modules combination(The digital unit must be operated as main unit if the system has digital unit.),
more convenient for design and installation.
5).Easy connection between main unit and slave units.
All the units can be connected together with a wired controller in series type. Using three-core shielded
twisted wire as communication wire.
Max 8 modules
2000kW
250kW
250kW
0
25
50
75
100
1.2
60
120
180
240
Capacity output
(%)
Capacity output of digital scroll air-cooled chiller system
(100%)ON
(0%)OFF
Capacity output of traditional air-cooled scroll chiller system

4
6). Backup functions
When unit is failed.
n If master unit fails, all the units will stop.
n If one slave unit fails, this unit will stop but the others will keep running.
n When the master unit fails, any of the slave one can be set as the master unit by manual setting.
When unit is under protection.
n If master unit’s protection happens, this unit will stop but the others will keep running.
n If slave unit’s protection happens, this unit will stop but the others will keep running.
n ( Except PE, P9 protection happens)
PELow temperature protection of evaporator.
P9Outlet and inlet water temperature difference protection.
7).Built-in hydraulic module (Available for MGCSL-F(D)30W/RN1)
The unit built-in hydraulic module to simplified installation, save space and
outstanding appearance, simultaneous effectively reduce installation costs and
covering area.
8) Economical operation
New design adopts electronic expansion valve precise refrigerant control in wider range. Electronic
expansion valve allows operation at lower condensing pressure, adjustment can be made fast linear
response, making the system more stable output, the indoor temperature more uniform, and enhance
human comfortable.
Wired controller
Three-core shielding
twisted pair
Three-core shielding
twisted pair
Water outlet temp. Water outlet temp. Water outlet temp.
Total water outlet temp.
(Just for master unit)
Total water outlet temp.
(Just for master unit)
Total water outlet temp.
(Just for master unit)
Master Slave
Master Slave

MCAC-ATSM-2017-08 Aqua Tempo Power Series (with LAK) air cooled scroll chiller unit (50Hz)
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9).Humanized remote control
S7 address on PCB should be switched to ON to realize remote control, which including remote ON/OFF,
remote heating and cooling mode selection, remote alarm. The customer can simply and conveniently control
the chiller and acquire the running information on real time.
Note: When use the remote control function, the wired controller will be invalid.
10). Easy transportation and installation
Air cooled scroll chiller structure is compact, light weight, easy transportation and installation, no need
cooling water tower, significant cost-savings.
Easy to transport No need cooling water tower
11). Reliable protections
Many kinds of protection are adopted to make sure the safe running for chiller.
12). Super reliability
System will be more reliable with new type efficient heat exchanger.
Evaporator of 30kW module adopt double-pipe heat exchangerevaporator of 65kW ,130kW,200kW and
250kW modules adopt shell and tube heat exchanger.
Double-pipe heat exchanger Shell and tube heat exchanger
Power phases
sequence protection
Frequently ON/OFF
protection of compressor
System anti-freezing
protection in winter
Evaporator low temperature
protection in cooling
Over-current protection
of compresor
Air discharge temperature
protection of compressorSensor malfunction protection
Water flow protection
System high temperature
protection
High/lowpressure
protection of compressor

6
13). Applicable temperature range
Mode
Ambient temperature range
Water outlet temperature range
Cooling
10˚C ~46˚C
0~17˚C(7˚C is default, less than 5˚C must add antifreeze)
-10˚C ~46˚C
5˚C ~17˚C(7˚C is default)
Heating
-10˚C ~21˚C
22˚C ~50˚C(45˚C is default)
Chilled outlet water temperature can be adjusted by wired controller according to customer’s demand.
-15 ˚C
Ambient temp. range
-10 ˚C
-5 ˚C
0 ˚C
5 ˚C
10 ˚C
15 ˚C
20 ˚C
25 ˚C
30˚C
35 ˚C
40 ˚C
45 ˚C
Heating range
-10 ˚C
21 ˚C
Water outlet temp. range
5 ˚C
50 ˚C
17 ˚C
45 ˚C
22 ˚C
0 ˚C
Cooling range
0 ˚C
17 ˚C
Heating range
22 ˚C
50 ˚C
Cooling range
-10 ˚C
46 ˚C
50 ˚C

MCAC-ATSM-2017-08 Aqua Tempo Power Series (with LAK) air cooled scroll chiller unit (50Hz)
7
3 Specifications
Model
KEM-30 DHN3
Cooling Capacity
kW
30
Btu/h
102,300
Heating Capacity
kW
32
Power supply
V/Ph/Hz
380-415/3/50
Power supply
Manual switch
A
50
Fuse
A
36
Compressor
Type
Fixed scroll + digital scroll
Quantity
Pieces
1+1
Model
ZPD67KCE-TFD-532/ZP67KCE-TFD-522
Brand
Copeland
Capacity
kW
16.2/16.2
Input
kW
5.26/5.2
Rate current(RLA)
A
10.6/11.8
Locked rotor Amp(LRA)
A
74/74
Power input
Cooling
kW
10.0
Cooling rated current
A
16.3
Heating
kW
9.8
Heating rated current
A
16
Max. input consumption
kW
12.6
Max. running current
A
21.1
Max. starting current
A
85
Refrigerant
Type
R410A
Weight
kg
3.5×2
Refrigerant control
EXV
Condenser
(Air side)
Type
Fin-coil
Quantity of fan motor
Pieces
1
Air flow
×103m3/h
12
Fan motor input
kW
0.67
Evaporator
(Water side)
Type
Double-pipe
Water resistance loss
kPa
60
Volume
L
10
Water inlet/outlet pipeline inside
diameter
mm
DN40
inch
1-1/2”
Water flow
m3/h
5.2
Max. design pressure
MPa
1
Water pipe connection type
Flexible joint

8
Note:
Please refer to the water flow in the above table strictly to design and install.
All the above data is measured base on the following working condition:
1. Cooling mode: water side fouling factor: 0.086m2/kW, chilled water inlet/outlet: 12 / 7, and outdoor ambient temp.
35 DB.
2. Heating mode: water side fouling factor: 0.086m2 /kW, warm water inlet/outlet: 40 / 45, and outdoor ambient temp. 7
DB/6 WB.
Dimension
Net(D×H×W)
mm
1514×1865×841
inch
59.6×73.4×33.1
Packing(D×H×W)
mm
1590×2065×995
inch
62.6×81.3×39.2
Weight
Net weight
kg
375
Operation weight
kg
400
Connection wire
Power wire
mm2×No.
10×4+6×1
Signal wire
mm2×No.
0.75×3-core with shielding
Control type
Wired controller
Safety protection device
1) Protection for over-high discharge pressure.
2) Protection for over-low suction pressure.
3) Power supply phase sequence protection.
4) Anti-freezing protection in cooling mode.
5) Anti-freezing protection in Winter.
6) Protection for compressor over current.
7) Protection for compressor overload.
8) Outlet and inlet water temperature difference
protection.
9) Compressor discharge temperature protection.
10) Water flow cut-off protection.
11) Sensor malfunction protection.
12) Low-temperature protection of shell and tube heat
exchanger.
Noise level(semi-anechoic )
dB(A)
65
Operation water temp

Cooling017(Less than 5 must add antifreeze)
Heating2250
Ambient temp

Cooling-1046
Heating-1021

MCAC-ATSM-2017-08 Aqua Tempo Power Series (with LAK) air cooled scroll chiller unit (50Hz)
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Model
KEM-65 DHN3
Cooling Capacity
kW
65
Heating Capacity
kW
69
Power input
Cooling
kW
20.4
Cooling rated current
A
36.5
Heating
kW
21.5
Heating rated current
A
37.2
Power supply
V/Ph/Hz
380-415/3/50
Power supply
Manual switch
A
100
Fuse
A
70
Max. input consumption
kW
27.1
Max. running current
A
54.5
Max. starting current
A
168
Compressor
Type
Fixed scroll + digital scroll
Brand
Copeland
Model
ZP144KCE-TFD-522 / ZPD72KCE-TFD-433 /
ZP67KCE-TFD-420
Quantity
Pieces
3
Capacity
kW
35.4
16.848
16.2
Input
kW
10.8
5.75
5.2
Rate current(RLA)
A
21.1
12.7
11.8
Locked rotor Amp(LRA)
A
144
82.4
74
Refrigerant
Type
R410A
Refrigerant control
EXV+ capillary
Weight
kg
7.0×2
Condenser
(Air side)
Type
Fin-coil
Quantity of fan motor
Pieces
2
Air flow
×103m3/h
24
Fan motor input
kW
0.865×2
Evaporator
(Water side)
Type
Shell and tube
Water resistance loss
kPa
15
Volume
L
42
Water inlet/outlet pipeline
inside diameter
mm
DN100
Water flow
m3/h
11.2
Max. design pressure
MPa
1
Water pipe connection type
Flexible joint
Dimension
Net(D×H×W)
mm
2000×1880×900
Packing size(D×H×W)
mm
2106×2090×998
Weight
Net weight
kg
610
Operation weight
kg
680

10
Connection wire
Power wire
mm2
25×4+16×1
Signal wire
mm2
0.75×3-core with shielding
Control type
Wired controller
Safety protection device
1) Protection for over-high discharge pressure.
2) Protection for over-low suction pressure.
3) Power supply phase sequence protection.
4) Anti-freezing protection in cooling mode.
5) Anti-freezing protection in Winter.
6) Protection for compressor over current.
7) Protection for compressor overload.
8) Outlet and inlet water temperature difference protection.
9) Compressor discharge temperature protection.
10) Water flow cut-off protection.
11) Sensor malfunction protection.
12) Low ambient temperature drive-up protection
13) Low-temperature protection of shell and tube heat
exchanger.
Noise level
dB(A)
67
Operation water temp

Cooling017 Less than 5 must add antifreeze
Heating2250
Ambient temp

Cooling-1046 Heating-1021
Note:
Please refer to the water flow in the above table strictly to design and install.
All the above data is measured base on the following working condition:
1. Cooling mode: water side fouling factor: 0.086m2/kW, chilled water inlet/outlet: 12 / 7, and outdoor ambient temp.
35 DB.
2. Heating mode: water side fouling factor: 0.086m2 /kW, warm water inlet/outlet: 40 / 45, and outdoor ambient temp. 7
DB/6 WB.

MCAC-ATSM-2017-08 Aqua Tempo Power Series (with LAK) air cooled scroll chiller unit (50Hz)
11
Model
KEM-130 HN3
KEM-200 HN3
Cooling Capacity
kW
130
185
Btu/h
443,560
631,220
Heating Capacity
kW
138
200
Power supply
V/Ph/Hz
380-400/3/50
380-400/3/50
Power supply
Manual switch
A
200
300
Fuse
A
150
200
Compressor
Type
Fixed scroll
Fixed scroll
Quantity
Pieces
4
6
Model
SH140A4ALC
SH140A4ALC
Brand
Danfoss
Danfoss
Capacity
kW
34.7
34.7
Input
kW
10.86
10.86
Rate current(RLA)
A
21.4
21.4
Locked rotor Amp(LRA)
A
147
147
Power input
Cooling
kW
40.8
63
Cooling rated current
A
73
110
Heating
kW
43
61
Heating rated current
A
74.4
107
Max. input consumption
kW
55.5
78.3
Max. running current
A
109
150
Max. starting current
A
252
312
Refrigerant
Type
R410A
R410A
Weight
kg
7×4
7×6
Refrigerant control
EXV+ capillary
EXV+ capillary
Condenser
(Air side)
Type
Fin-coil
Fin-coil
Quantity of fan motor
Pieces
4
6
Air flow
×103m3/h
48
72
Fan motor input
kW
0.865×4
0.865×6
Evaporator
(Water side)
Type
Shell and tube
Shell and tube
Water resistance loss
kPa
25
30
Volume
L
64
90
Water inlet/outlet pipeline
inside diameter
mm
DN65
DN80
inch
2-1/2”
3”
Water flow
m3/h
22.4
31.8
Max. design pressure
MPa
1
1
Water pipe connection type
Flexible joint
Flexible joint

12
Dimension
Net(D×H×W)
mm
2000×2080×1685
2850×2110×2000
inch
78.7×82.3×66.3
112.2×83.1×78.7
Packing(D×H×W)
mm
2090×2240×1755
2980×2260×2135
inch
82.3×88.2×69
117.3×89×84.1
Weight
Net weight
kg
1150
1730
Operation weight
kg
1270
2000
Connection
wire
Power wire
mm2×No.
35×3+16×2
75×3+35×2
Signal wire
mm2×No.
0.75×3-core with shielding
0.75×3-core with shielding
Control type
Wired controller
Wired controller
Safety protection device
1) Protection for over-high discharge pressure.
2) Protection for over-low suction pressure.
3) Power supply phase sequence protection.
4) Anti-freezing protection in cooling mode.
5) Anti-freezing protection in Winter.
6) Protection for compressor over current.
7) Protection for compressor overload.
8) Outlet and inlet water temperature difference protection.
9) Compressor discharge temperature protection.
10) Water flow cut-off protection.
11) Sensor malfunction protection.
12) Low ambient temperature drive-up protection
13) Low-temperature protection of shell and tube heat
exchanger.
Noise level(semi-anechoic)
dB(A)
70
74
Operation water temp

Cooling017 Less than 5 must add antifreeze
Heating2250
Ambient temp

Cooling-1046 Heating-1021
Note:
Please refer to the water flow in the above table strictly to design and install.
All the above data is measured base on the following working condition:
1. Cooling mode: water side fouling factor: 0.086m2/kW, chilled water inlet/outlet: 12 / 7, and outdoor ambient temp.
35 DB.
2. Heating mode: water side fouling factor: 0.086m2 /kW, warm water inlet/outlet: 40 / 45, and outdoor ambient temp. 7
DB/6 WB.

MCAC-ATSM-2017-08 Aqua Tempo Power Series (with LAK) air cooled scroll chiller unit (50Hz)
13
Model
KEM-250 HN3
Cooling Capacity
kW
250
Heating Capacity
kW
270
Power input
Cooling
kW
78.3
Cooling rated current
A
141.9
Heating
kW
80
Heating rated current
A
146
Power supply
V/Ph/Hz
380-400/3/50
Power supply
Manual switch
A
450
Fuse
A
300
Max. input consumption
kW
104.9
Max. running current
A
200
Max. starting current
A
344
Compressor
Type
Scroll (fixed speed)
Brand
Danfoss
Model
SH120A4ALC
Quantity
Pieces
8
Capacity
kW
32.6
Input
kW
10.3
Rate current(RLA)
A
20.7
Locked rotor Amp(LRA)
A
142
Refrigerant oil
ml
3300
Refrigerant
Type
R410A
Refrigerant control
EXV+ capillary
Weight
kg
15×4
Condenser (Air side)
Type
Fin-coil
Number of rows
3
Fan motor model
YDK550-6E
Quantity of fan motor
Pieces
8
Air flow
×103m3/h
96
Fan motor rated current
A
1.8×8
Fan motor input
kW
0.7×8
Evaporator (Water side)
Type
Shell-tube
Water pressure drop
kPa
40
Volume
L
131
Water inlet/outlet
pipeline inside normal
diameter
mm
DN100
Water flow volume
m3/h
43
Max. Pressure
MPa
1
Water pipe connection type
Flexible joint
Dimension
Net(D×H×W)
mm
3800×2130×2000
Packing size(D×H×W)
mm
3900×2200×2100
Weight
Net weight
kg
2450
Operation weight
kg
2600
Connection wire
Power wire
mm2
150×4+70×1
Signal wire
mm2
0.75×3-core with shielding

14
Control type
Wired controller
Safety protection device
1) Protection for over-high discharge pressure.
2) Protection for over-low suction pressure.
3) Power supply phase sequence protection.
4) Anti-freezing protection in cooling mode.
5) Anti-freezing protection in Winter.
6) Protection for compressor over current.
7) Protection for compressor overload.
8) Outlet and inlet water temperature difference
protection.
9) Compressor discharge temperature protection.
10) Water flow cut-off protection.
11) Sensor malfunction protection.
12) Low ambient temperature drive-up protection
13) Low-temperature protection of shell and tube heat
exchanger.
Noise level
dB(A)
74
Operation water temp

Cooling017 Less than 5 must add antifreeze
Heating2250
Ambient temp

Cooling-1046
Heating-1021
Note:
Please refer to the water flow in the above table strictly to design and install.
All the above data is measured base on the following working condition:
1. Cooling mode: water side fouling factor: 0.086m2/kW, chilled water inlet/outlet: 12 / 7, and outdoor ambient temp.
35 DB.
2. Heating mode: water side fouling factor: 0.086m2 /kW, warm water inlet/outlet: 40 / 45, and outdoor ambient temp. 7
DB/6 WB.

MCAC-ATSM-2017-08 Aqua Tempo Power Series (with LAK) air cooled scroll chiller unit (50Hz)
15
4 Dimensions
30kW module
Front view
Top view
Model
Unit
A
B
C
D
E
F
KEM-30 DHN3
mm
1514
841
1865
115
315
172
inch
59.6
33.11
73.43
4.53
12.4
6.77
No.
Name
1
Top cover
2
Air outlet
3
Air inlet
4
Water outlet
5
Water inlet
6
Electric control box

16
65kW module
Front view
Top view
Model
Unit
A
B
C
D
E
F
G
H
I
J
K
KEM-65 DHN3
mm
2000
900
1880
350
1420
225
1500
506
530
930
450
inch
78.74
35.4
74
13.78
55.91
8.86
59.06
19.92
20.87
36.61
17.72
130kW module
Front view Side view
No.
Name
1
Top cover
2
Air outlet
3
Air inlet
4
Water outlet
5
Compressor
6
Electric control box
7
Water inlet

MCAC-ATSM-2017-08 Aqua Tempo Power Series (with LAK) air cooled scroll chiller unit (50Hz)
17
Top view Anchor hole
Model
Unit
A
B
C
D
E
F
G
H
KEM-130 HN3
mm
2000
1685
2080
350
1420
506
1550
1586
inch
78.74
66.34
81.89
13.78
55.91
19.92
61.02
62.44
No.
Name
1
Top cover
2
Condenser
3
Compressor
4
Evaporator
5
Electric control box Air inlet
6
Water outlet
7
Water inlet
8
Compressor