Инструкция на Чиллеры KKT chillers Compact-Line cBoxX 30–200 бренда KKT chillers

Compact-Line

Translation of the original operating Instructions cBoxX 30 cBoxX 40 cBoxX 50 cBoxX 60 cBoxX 70 cBoxX 80 cBoxX 90 cBoxX 100 cBoxX 120 cBoxX 160 cBoxX 180 cBoxX 200

Table 1: Contact details

Manufacturer ait-deutschland GmbH Industriestraße 3 95359 Kasendorf Germany T +49 9228 9977 0 F +49 9228 9977 149 E info@kkt-chillers.com W www.kkt-chillers.com Service ait-deutschland GmbH Industriestraße 3 95359 Kasendorf Germany T +49 9228 9977 7190 * F +49 9228 9977 7474 E…

Introduction

These operating instructions have been drawn up by KKT chillers on the basis of the Machinery Directive 2006/42/EC. They contain all important information and instructions for the installation and safe operation of the refrigerating machine (chiller). It also contains advice on how to prevent or…

Product description Please read all the points in these operating instructions before starting up the machine. You should pay particular attention to the points on safety, commissioning/startup and operation. If you have further questions about your machine, please contact the KKT chillers Service…

Technical data

Table 3: Technical data Compact-Line - cBoxX 30 cBoxX 40 cBoxX 50 cBoxX 60 Refrigerating capacity @ tw2=20°C / tu=32°C kW Refrigeration circuit hermetically tight Refrigerant cBoxX 70 cBoxX 80 cBoxX 90 cBoxX no - R410A GWP 2088 Refrigerant capacity kg CO2 equivalent t CO2 12,5 12,5 12,5 14,6 16,7…

Refrigerant

- R410A GWP 2088 Refrigerant capacity kg 17 17 23,5 23,5 CO2 equivalent t CO2 35,5 35,5 49,1 49,1 Cooling medium (liquid/secondary refrigerant) - Water or water / glycol Ambient temperature range °C +5 to +45 (optionally -25 to +50°C) Liquid feed temperature °C +8 to +30 (optionally to -10) Target…

1.2. Elements

e a b c 6 d Metal cladding, top, operator side a Safety instructions 2 Metal cladding, bottom, operator side b Water connections 3 Metal cladding, top, service side c Rating plate 4 Metal cladding, bottom, service side d Display 5 Metal cladding, condenser protective grating e Main switch 6…

1.3. Explanation of terms

A few important terms which appear in this document are briefly explained here for improved understanding. Table 4: Explanation of terms Term Explanation Application The heat source connected hydraulically with the chiller. Process circuit Application and piping to the chiller. Cold water cycle The…

Function and main components The chiller consists of the main components: compressor, condenser, expansion valve and evaporator, which are arranged in a circuit (Figure 1). Refrigerant circulates in this circuit (cycle). It absorbs heat from the cold water in the evaporator and gives it up to the…

Contaminated cooling air can cause deposits to form on the surface of the condenser over time. This impairs heat transfer to the refrigerant which restricts the operating limit of the machine and reduces the machine's refrigerating capacity. Please refer to Chapter 9: Cleaning for a description of…

2.12. Control cabinet

The control cabinet conforms to the requirements of EN 60204 and contains the electrical and electronic components for controlling the chiller. After removing the operator control panel the control cabinet is accessible and can be opened using a standard two-way key. In order to avoid a damage of…

2.16. Materials used in the water circuit

The material composition of the standard equipment is shown in Table 5: Table 5: Materials used - standard version Component Material (cBoxX 30 – cBoxX 100) Unit connections V2A 1.4305 Hose Synthetic rubber Evaporator V2A 1.4301 and copper (99.9%) Tank Tank ports/connection sockets V2A 1.4301 V4A…

Filling and drain cock

V4A 1.4401 Fittings V4A 1.4408 Hose nozzles V4A 1.4408 Elbow threaded couplings (level indicator) PVC and polyoxymethylene (POM) Hose (level indicator) PE natural Temperature sensor PT1000 V2A 1.4301 Pressure sensor XSK AC10I-U188 V2A 1.4301 Overflow valve (optional) V2A 1.4301 Tank heater…

2.17. Water quality

The following limits must be maintained for safe operation of the equipment: Table 7: Water quality Property / components Unit Value range Standard version Value range Non-ferrous metal-free version pH value (20 °C) - 7-9 6-9 Saturation index - -0.2 < 0 < +0.2 -0.2 < 0 < +0.2 Conductivity µS/cm…

Table 8: AFN and AFL mix ratios (or equivalent)

Setting Frost-free at t-environment to AFN mix ratio AFL mix ratio -10°C 20-25 % 25-30 % Glycol 30 - 35 % -15°C 30-35 % 32-37 % Glycol 40 % -25 °C 40 % 42 % Glycol 20 - 25 % 3. Options and accessories The chiller can be equipped in the factory with the options described in the following. The items…

The project specific data as well as the adapted hydraulic scheme and the dimension sketch can be found in the additional short documentation. 3.4. Heater for compressor and control cabinet The oil sump heater prevents refrigerant from becoming deposited in the oil of the compressor at low ambient…

cBoxX

Application Figure 4: C6863 overflow valve for standby mode 3.8. Higher pressure pump The standard Compact-Line units have a 3 bar pump, which is designed for the nominal volumetric flow of the respective unit. Optionally the units can also be built with higher pressure pumps, within the limits of…

3.12. Automatic water feed

Any leaks and evaporation can cause the quantity of cold water available for the chiller function to reduce during the course of operation of the chiller. The Automatic water feed option provides the possibility of topping up the cold water circuit automatically. The tank contents are monitored…

the standard control by switching compressors on or off, a higher target constant is achieved by the continuous regulation of the valve. 3.18. High-temperature package In principle, the units must be operated within the given ambient temperature range (see Table 3). If the high-temperature package…

3.23. Filter assembly group coolant circuit (accessories)

The water filter protects the coolant circuit against dirt. The set, consisting of a filter, fitting and two shut off valves, is enclosed with the chiller in a separate pack and must be fitted onto the cold water inlet of the chiller from the outside when the chiller is installed. 3.24. Filter…

3.30. Wooden Crate (accessories)

Whereas the chillers of the Compact-Line are delivered on a wooden palette with Styrofoam corners stretched in the foil as a standard, the chillers can be also ordered in a wooden crate. There the chillers are protected additionally by a wooden crate with IPPC-Label according ISPM 15. 3.31.…

Safety Provided it is used as intended, the chiller is designed to operate safely, provided also that the instructions concerning transport, installation, commissioning/startup and maintenance given in these operating instructions are complied with. The machine conforms to the safety standards in…

Table 9: Definition of the safety symbols

Note and follow the instructions for use! Before opening the machine it must be disconnected from the power supply! After disconnecting the machine from the power supply, always wait for at least 5 minutes before opening it. Danger! High voltage! If the machine is only switched off at its main…

Table 10: Hazard warnings

ATTENTION! Work on the chiller must be carried out by properly qualified, competent personnel! The surfaces of pipes and components of the refrigerant and cold water circuit and electrical equipment can be very hot during operation and even for a while after. The surfaces of pipes and components of…

4.3. Residual energy

Even if all the hazard warnings in the chapter above are taken into account, the following residual energy situations can result in a hazard: ▪ ▪ ▪ ▪ Rotational energy of the decelerating fan o Despite the installed protective grille, hair or pieces of clothing can still be drawn in and caught. Hot…

4.4. Safety devices, guards and safeguards

4.4.1. High-pressure limiter The high-pressure limiter (PZH) is a pressure switch with manual reset. The PZH limits the condensing pressure and switches off all compressors via their load contactors when the maximum permitted system operating pressure is reached. It is part of the safety chain. The…

4.4.4. Flow monitoring

If the volumetric flow of the cold water which is pumped through the evaporator is too low, there is a risk of freezing. For this reason the flow through the evaporator is monitored continuously. If the volumetric flow rate is only around 50 % of the nominal volumetric flow rate, the message "Flow…

4.6. Airborne sound emissions

The airborne sound emissions data is given as the sound pressure level, measured at a distance of five metres without reflection. Its maximum value is shown in the technical data. This only occurs at the highest fan speed at the air intake side of the chiller (Figure 9, measuring point [1]). The…

4.8. Residual risks

4.8.1. Electrical ATTENTION! Based on the quality features of EN 50160 and the defined standard voltages of IEC 60038, the mains voltage deviation must not exceed +/- 10% of the nominal voltage. If all safety provisions are complied with there is no risk. 4.8.2. Mechanical If all safety provisions…

4.9. Dangerous substances

4.9.1. Refrigerant R410A First aid measures: ▪ After inhaling: remove victim to fresh air, ensuring your own safety, and keep the person at rest in a comfortable position. Get medical attention. If the person stops breathing, give artificial respiration. ▪ Following skin contact: leave clothing that…

Personal protective equipment

▪ Respiratory protection: not necessary if adequate ventilation available. Self-contained or air-line breathing apparatus within enclosed rooms, if insufficient oxygen supply available, in case of substantial or uncontrollable release. Only use breathing apparatus in accordance with the…

Measures in case of accidental release

▪ Environmental protection measures: do not allow the product to get into the sewers or bodies of water. Absorb with sand, soil or a similar absorbent material. Ensure proper disposal in containers. ▪ Cleaning procedure: Clean the contaminated area with water. Caution! Slipping hazard! ▪ Further…

factory, a quantity of refrigerant is filled in a certified refrigerant cylinder so that the 12kg limit is kept to in the unit. The refill cartridge is then delivered together with the unit. The refrigerant quantity drained for transport can be returned to the system as part of the commissioning…

5.2.1. Forklift truck

It is possible to transport the machine both in a packed and an unpacked condition by means of fork lift truck. In this case, please note the defined centre of gravity marking as shown in Figure 10 and Figure 11. Figure 10: C6845-0 centre of gravity cBoxX 30 - 60 Figure 11: C6846-0 centre of gravity…

Figure 14: C6841-0 crane transport cBoxX 30 - 100

Table 12: Description of figure C6841-0 A Transport sling or rope (do not use chains) B Locking bolt C Split rivet D Steel pipe diameter: 30 - 35 mm, wall thickness: min. 3 mm, length BG 1&2: approx. 1000mm E 1300 mm (cBoxX 30 – cBoxX 60) 1900 mm (cBoxX 70 – cBoxX 100) 5.3. Unpacking ATTENTION!…

The packaging can be recycled according to the local regulations. Refer to the following table for details of the packaging materials used: Table 13: Materials in the packaging Element Material Recycling code Polystyrene corner protectors Polystyrene Stretch film Polyethylene Edge protection /…

choosing the installation site, ensure that waste heat from other processes cannot be guided directly onto the air intake side of the chiller. ATTENTION! Do not install in rooms with naked flames or smoke. 6.2.2. Minimum room volume The refrigerant R410A contained in the system is classified in…

the gross weight of your machine is listed in the technical data (Table 3: Technical data). In the case of chillers equipped with a tank the net weight increases during operation by the quantity of liquid in the tank. This gives the gross weight. If it is not possible to lay a foundation, the…

Hydraulic installation The system designer is responsible for choosing the material and the cross-section of the hydraulic connections between the chiller and the application. Other dependent factors include the accepted pressure loss in the connection lines and the available pump pressure. When…

ATTENTION! Only use approved refrigerants, see Chapter 2.17

If there is a risk of frost, note Chapter 6.2.14! All operating liquids must be mixed before they are added to the system! and 2.18! Procedure for chillers with integrated tank: Remove the cladding panels 3 and 4 (see Chapter 1.2 Elements) and fill your system via the internal filling connection…

6.2.16. Venting

If your chiller contains a horizontal pump (standard for cBoxX 30 – cBoxX 100), the pump does not have to be vented. If your chiller contains a vertical pump (standard for cBoxX 120 – cBoxX 200) the pump has to be vented. To do this, before switching on the pump the vent plug must be opened and left…

Figure 17: Main supply

The dimensioning of the load cable and the fusing must be in accordance with the machine's technical data and the local regulations of the power supply company. The supply cable must be routed into the machine. Cut-outs are provided for this purpose in the baseplate and in the compressor mount…

▪ ▪ ▪ ▪ ▪ ▪ ▪ ▪ ▪ ▪ ▪ ▪ ▪ Unit installed horizontal and stable? Any vibration damping and floor anchors installed? Spaces / clearances around the unit are adequate according to the requirements? Air intake side free from packaging materials, etc. ? Hydraulic connection OK? Cold water circuit filled…

8.5. Control panel

The following Figure 18 shows the chiller's display elements and controls. Figure 18: C6842 Display elements and controls Table 15: Description of C6842 Number Function 1 "UP" button 2 "OK" button 3 "DOWN" button 4 Display with plain text 5 Main switch Use the "UP" and "DOWN" buttons to select the…

8.5.1. Start screen

Figure 19: Start screen with tank and without alarm Figure 20: Start screen with alarm The general operating state of the chiller is displayed on the Start screen: • Active alarm • Top left-hand side: Number of pumps running • Left-hand middle: Number of compressors running • Bottom left-hand side…

8.5.3. Information

In the Information menu you can move into various submenus to obtain an overview of the state of the chiller. Figure 22: Information In the Measured Value (Readings) menu you can call up the values of the analog inputs. Figure 23: Measured Value menu In the Status menu the states of the digital…

Figure 26: Digital inputs

The digital outputs show the state of the output relays. Figure 27: Digital outputs The analog inputs show the signal upstream of the analog digital converter. The value must be between 0 and 4095. 0 means that no sensor is connected. 4095 means that the input is short-circuited. Figure 28: Analog…

Figure 30: Setting

8.5.5. Alarm menu The alarm is acknowledged if the "OK" button is pressed for longer than eight seconds.(after five seconds, the display switches back to the main menu) • active: The alarm is still active. (e.g. DI MSS …) The motor protection switch has triggered. • OK: The alarm is no longer on and…

8.7. Controller description

8.7.1. Thermostatic pump start To save energy, the consumer pump is not operated permanently, but cyclically. An evaporator pump, if present, is also controlled. The tank heater or compressor is released after a short circulation of the cold water. The thermostatic pump start is intended for two…

• No motor protection switch faults are queued, • No fault is queued at the digital fault input (e.g. control unit group fault). From the standby state, the chiller can be switched on or off via a software switch in the display. In Automatic mode the floating contact for the remote control must be…

8.7.4. Cold water flow temperature control

In the normal case the sensor in the tank (system with tank, with pump) is used to control the cold water feed temperature. If this sensor fails, the control switches internally to the sensor in the cold water return and the target value (setpoint value) is increased by a defined value. A purely…

Low pressure is also monitored by pressure transmitters. If the value falls below the setpoint the compressors switch off. If the switch-off value is exceeded by the hysteresis, the compressors are released again. The triggering of the alarm is delayed by two timing elements. The first timing…

Cleaning 9.1. Air filter mat To maintain high performance the optional air filter mat (3.19 Air filter mat) must be checked for contamination at least once a month. The correct air filter mats can be ordered at any time as an original spare part – please contact our KKT chillers Service Team (Table…

10. Service

All service work may only be carried out by properly trained, competent personnel. 10.1. Maintenance Reliable operation and a long service life for the entire system can be guaranteed by proper maintenance. The purpose of the maintenance is: • to ensure that the machine operates reliably and without…

11. Taking out of service

ATTENTION! Decommissioning must only be carried out by professional and qualified technicians. They must also be familiar with the local regulations. For safety-relevant instructions regarding possible residual energy, please refer to Chapter 4.3 Residual energy. 11.1. Draining If the system is…

All parts (e.g. refrigerant, oil, glycol, metal, electronics, battery etc.) must be recycled, reused or disposed of. Please note and follow all local and national regulations and if necessary contact your local waste management agency. A specialised disposal company must be contracted to dispose of…

I

Main dimensions 62 / 99 83000102.l

II

Installation instructions 66 / 99 83000102.l

III

Menu navigation Main menu Information Settings Alarm menu Control Panel Information Measuring Status Digital inputs Digital outputs Analogue inputs Analogue outputs Alarm menu Measuring Pump 1 press outlet Y pump 1 Pump 2 press outlet Y pump 2 Press exp.tank Tank pressure Tank pressure Coldwater…

Settings

Alarm menu Control Panel Information Measuring Status Digital inputs Digital outputs Analogue inputs Analogue outputs Alarm menu Status DI resetswitch DI remotecontrol DI phase monitoring DI mpcb Pump 1 DI pump 1 flow-switch DI mpcb Pump 2 DI pump 2 flow-switch DI compressor 1 mpcb DI compressor 2…

Settings

Alarm menu Control Panel Information Digital inputs Measuring Status Digital inputs Digital outputs Analogue inputs Analogue outputs Alarm menu DI1 clip 1,2 DI1 clip 3,4 DI1 clip 5,6 DI1 clip 7,8 DI1 clip 9,10 DI2 clip 1,2 DI2 clip 3,4 DI2 clip 5,6 DI3 clip 1,2 DI3 clip 3,4 DI4 clip 1,2 DI4 clip 3,4…

Settings

Alarm menu Control Panel Information Digital outputs Measuring Status Digital inputs Digital outputs Analogue inputs Analogue outputs Alarm menu DO1 clip 1,2 DO1 clip 3,4 DO1 clip 5,6 DO1 clip 7,8 DO2 clip 1,2 DO3 clip 1,2 DO4 clip 1,2 DO4 clip 3,4 DO4 clip 5,6 DO4 clip 7,8 DO5 clip 1,2,3 cf ES1…

Settings

Alarm menu Control Panel Information Analogue inputs Measuring Status Digital inputs Digital outputs Analogue inputs Analogue outputs Alarm menu AI1 clip 1,2 AI2 clip 1,2 AI2 clip 3,4 AI2 clip 5,6 AI3 clip 1,2 AI3 clip 3,4 AI3 clip 5,6 AI4 clip 1,2 AIO1 clip 1,2 AIO2 clip 1,2 AIO2 clip 5,6 IFPAI1…

Settings

Alarm menu Control Panel Information Measuring Status Digital inputs Digital outputs Analogue inputs Analogue outputs Alarm menu DI mpcb freecool.fan DI fault freecool.fan Outlettemp. max STOP Outlettemp. max warning Outlettemp. min STOP Min tank level warning Min tank level STOP Coldwater press…

Settings

Alarm menu Control Panel Settings Limit monitoring Control Control pump Control compressor Chillerconfiguration Sensor configuration 76 / 99 Limit monitoring Limit outlettemperature Time delay Outlettemp. max STOP Outlettemp. max warning Outlettemp. min STOP Limit tank pressure Tank max level Min…

Settings

Information Settings Alarm menu Control Panel Control Limit monitoring Control Control pump Control compressor Chillerconfiguration Sensor configuration Controls tank heater Thermost. Pump start Interval Runtime Time delay Minimum Setpoint Hysteresis Maximum Setpoint Hysteresis Thermost. Pump start…

Settings

Alarm menu Control Panel Settings Limit monitoring Control Control pump Control compressor Chillerconfiguration Sensor configuration Control pump Time delay controlling Time delay Time delay pump Flow switch Time delay start Time delay running sec. sec. sec. 20 10 sec. sec. 300 5 sec. sec. 0.2 30…

Settings

Alarm menu Control Panel Settings Limit monitoring Control Control pump Control compressor Chillerconfiguration Sensor configuration 79 / 99 Chillerconfiguration Control number Compressor type Year of construction Thermost. Pump start Pump 1? Pump 1 VFD? Pump 1 flow-switch? Pump 2? Pump 2 VFD? Pump…

Settings

Alarm menu Control Panel Settings Limit monitoring Control Control pump Control compressor Chillerconfiguration Sensor configuration 80 / 99 Sensor configuration AI pump pressure 1 Measuring 4 mA Measuring 20 mA AI pump pressure 2 Measuring 4 mA Measuring 20 mA AI press. exp. vess. Measuring 4 mA…

Alarm menu

Information Settings Alarm menu Control Panel DI mpcb freecool.fan DI fault freecool.fan Outlettemp. max STOP Outlettemp. max warning Outlettemp. min STOP Min tank level warning Min tank level STOP Coldwater press warning Coldwater press STOP Coldwater press STOP Press pump 1 max STOP Press pump 1…

Settings

Alarm menu Control Panel Control Panel Settings Language Settings IP address Serial number Save parameters Load parameters Password Units Remote maintenance DHCP GLT data transfer Metric No Off Auto IP address IP Subnetmask Broadcast Gateway 172.017.010.070 255,255,254,000 172.017.011.255…

IV

Troubleshooting Error code Display view Type of message Message description Cause of the message Troubleshooting Reaction of the chiller 111 HP warning Group warning Condensation pressure has exceeded the warning limit Condensation pressure threatens to run against the design limit of the high…

LP STOP Group fault alarm Pressure has fallen below the minimum allowable pressure on the intake side of the compressor (low pressure side). 162 LP STOP 3x Group fault alarm The minimum S.h. LP STOP permissible pressure on the suction side of the compressor (low pressure side) was 3 times lower. 171…

EV refill time limit The solenoid valve of the tank refill does not close within the specified time. The freshwater supply is interrupted. Check the function of the solenoid valve tank refill. Open the shut-off devices integrated in the supply line. Check the supply line for leakage. Solenoid valve…

Outlettemp. max STOP Group fault alarm Maximum outlet temperature exceeded. No refrigeration, Thermal overload. Check function of the chiller circuit, Check installed heat load. 352 Outlettemp. min STOP Group fault alarm Outlet temperature is below the minimum. Check function of the tank heater…

Press pump 1 max STOP Group fault alarm Press pump 2 max STOP Pressure of the liquid External slide is closed, outlet pressure too high Filter soiled, Open external gate valve, clean filter, check overflow valve setting Press pump 1 min STOP Press pump 2 min STOP Group fault alarm Pressure of the…

AI Freecooler inlet Combined fault from Version 2.60 Sensor defective, sensor break or sensor short-circuit Sensor defective, sensor break or sensor short-circuit Check electrical connections of the sensor, check sensor using the characteristic curve Free cooling is blocked. All other components…

AI pump pressure 2 Combined fault from Version 2.60 Sensor defective, sensor break or sensor short-circuit Sensor defective, sensor break or sensor short-circuit Check electrical connections of the sensor, check sensor using the characteristic curve Pump 1 & 2 = Consumer pump - Pump 2 switches off…

AI cool. water temp. Combined fault from Version 2.60 Sensor defective, sensor break or sensor short-circuit Sensor defective, sensor break or sensor short-circuit Check electrical connections of the sensor, check sensor using the characteristic curve Cooling water circuit is blocked. Refrigeration…

Flow, start pump 1 Group fault alarm Flow switch did not Flow too low switch through after the pump start-up phase Check flow, check shut-off valves, check pump, check the setting of the reed contact at the flow monitor 614 Flow, pump 1 oper. Group fault alarm Flow switch did not switch through…

DI mpcb Pump 2 Group fault alarm Motor protection switch has tripped 617 Flow, start pump 2 Group fault alarm Flow switch did not Flow too low switch through after the pump start-up phase 92 / 99 Motor current above the permissible range, Motor runs only on two phases, direction of rotation, poor…

Flow, pump 2 oper. Group fault alarm Flow switch did not switch through during the pump operating phase Flow too low Check flow, check shut-off valves, Pump 1 & 2 = Consumer pump check the setting of the reed - Pump 2 switches off, contact at the flow monitor - Pump 1 and compressor continue to run.…

DI high-pr. limiter Group fault alarm High-pressure limiter has tripped. Unable to remove the waste heat of the refrigeration circuit. Clean the condenser and filter. Check the function of the fan. Check the cooling water circuit. Install the cover panels. Press the Reset button and acknowledge at…

V

Maintenance intervals in accordance with the VDMA Explanation Annual Sixmonthly As required Remark Compressor 1 Optical check for dirt, damage and corrosion x x 2 Check fixing, check running noises x 3 Measure the intake pressure x 4 Measure the suction gas temperature upstream of the compressor x 5…

Explanation

Annual Sixmonthly x as required Remark X If components in the refrigeration circuit are replaced Parts in the refrigeration circuit/water circuit 40 Optical check for dirt, damage and corrosion x 41 Check insulation for damage x 42 Check filter dryer for blockage x 43 Replace filter dryer 45 Check…

No.: Explanation

Annual Sixas Remark monthly required Tank / water tank 80 Optical check for dirt, damage and corrosion x 81 Check fixing x 82 Check level x Control cabinet 90 Optical check for dirt, damage and corrosion x 91 Check fixing x 92 Check all threaded connections x 93 Check all indicator lights and error…

VI

Product Registration PDF download: http://www.kkt-chillers.com/en/downloads/product-registration/ 98 / 99 83000102.l

VII

Инструкция на Чиллеры KKT chillers Compact-Line cBoxX 30–200

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