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Related Manuals for KKT Compact-Line cBoxX Series
Summary of Contents for KKT Compact-Line cBoxX Series
- Page 1 Compact Compact Compact Compact- - - - Line Line Line Line 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...
- Page 2 T +49 9228 9977 7190 F +49 9228 9977 7474 E service@kkt-chillers.com W www.kkt-chillers.com Service USA KKT chillers, Inc. 765 Dillon Drive Wood Dale, IL 60191 T +1 847 734 1600 F +1 847 734 1601 TF +1 833 558 4357 E support@kkt-chillersusa.com...
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Page 3: Introduction
Introduction 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 correct faults. -
Page 4: Table Of Contents
Contents Introduction ............................. 3 Product description ........................8 1.1. Intended use ........................8 1.2. Technical data ........................9 1.3. Elements ........................... 11 1.4. Explanation of terms ......................12 Function and main components ..................... 13 2.1. Compressor ........................13 2.2. Evaporator ........................14 2.3. - Page 5 3.18. Special paint finish ......................24 3.19. Air filter mat (accessories) ....................24 3.20. Levelling feet (accessories) ..................... 25 3.21. Level package (accessories) ................... 25 3.22. Filter assembly group coolant circuit (accessories) ............25 3.23. Filter assembly group cooling water circuit (accessories) ..........26 3.24.
- Page 6 5.3. Unpacking ......................... 41 5.4. Storage ..........................41 Installation ..........................42 6.1. Overview ........................... 42 6.2. Installation site ......................... 42 6.2.1. General information ....................42 6.2.2. Minimum room volume .................... 42 6.2.3. Ambient temperature ....................43 6.2.4. Effect of surrounding air flow .................. 43 6.2.5.
- Page 7 8.7.8. Group fault alarm ..................... 62 8.8. Operating modes ......................62 8.8.1. ECO mode ......................... 62 8.8.2. Comfort mode ......................63 Cleaning ........................... 63 9.1. Air filter mat ........................63 9.2. Condenser ........................63 9.3. Water filter ........................63 9.4. Complete cleaning of the cold water circuit ..............
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Page 8: Product Description
If commissioning/startup and operation. If you have further questions about your machine, please contact the KKT you have further questions about your machine, please contact the KKT chillers chillers Service Team (see... -
Page 9: Technical Data
1.2. 1.2. 1.2. 1.2. Technical data Technical data Technical data Technical data Table Table 3 3 3 3 : Technical data Table Table : Technical data : Technical data : Technical data Compact-Line cBoxX 30 cBoxX 40 cBoxX 50 cBoxX 60 cBoxX 70 cBoxX 80 cBoxX 90... - Page 10 Compact-Line cBoxX 120 cBoxX 160 cBoxX 180 cBoxX 200 Refrigerating capacity @ tw2=20°C / tu=32°C Refrigerant R410A Refrigerant capacity 23,5 23,5 Cooling medium (liquid/secondary Wasser oder Wasser / Glykol refrigerant) Ambient temperature range °C +5 bis +45 (optional -25 bis +50°C) Liquid feed temperature °C +8 bis +30 (optional bis -10)
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Page 11: Elements
1.3. 1.3. 1.3. 1.3. Elements Elements Elements Elements 1 1 1 1 Metal cladding, top, operator side a a a a Safety instructions 2 2 2 2 Metal cladding, bottom, operator side b b b b Water connections 3 3 3 3 Metal cladding, top, service side c c c c Rating plate... -
Page 12: Explanation Of Terms
1.4. 1.4. 1.4. 1.4. Explanation of terms Explanation of terms Explanation of terms Explanation of terms A few important terms which appear in this document are briefly explained here for improved understanding. Table 4 4 4 4 : Explanation of terms Table : Explanation of terms Table... -
Page 13: Function And Main Components
2. 2. 2. 2. Function and main components Function and main components Function and main components 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 Figure 1 Figure 1 Figure 1). -
Page 14: Evaporator
R410A is a zeotropic mixture of 50% each R32 and R125 with virtually negligible temperature glide. R410A has a very high volumetric refrigerating capacity and has no ozone depletion potential (ODP=0). A corresponding safety data sheet can be obtained from our KKT chillers Service Team (see... -
Page 15: Oil
The total oil quantity of the respective unit is given in the technical data. A corresponding safety data sheet can be obtained from our KKT chillers Service Team (see see Table 1... -
Page 16: Control Cabinet
2.12. 2.12. 2.12. 2.12. Control cabinet Control cabinet Control cabinet 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. -
Page 17: Materials Used In The Water Circuit
with pump with pump, an with pump with pump , an , an , and Chapter d Chapter d Chapter d Chapter 3.2 Version without tank, without pump Version without tank, without pump Version without tank, without pump Version without tank, without pump). In the process circuit the cold water absorbs heat. - Page 18 If equipped with the optional Water circuit in non Water circuit in non Water circuit in non- - - - ferrous metal Water circuit in non ferrous metal ferrous metal ferrous metal- - - - free version free version free version the material free version composition is as shown in Table Table...
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Page 19: Water Quality
In order to avoid a restriction of the plate heat exchanger the above listed limit values have to be guaranteed imperatively. Furthermore mucilage bacteria are not allowed in the cooling water. If that is not possible, KKT chillers can recommend an accordant inhibitor based on a biologic water analysis. -
Page 20: Permitted Cooling Media
The items marked "accessories" are enclosed with the unit, unattached, and can be reordered at any time using the appropriate product number. The installer of the machine is responsible for installing the accessories. You can also ask our KKT chillers Service Team to arrange for this installation (see Table 1... -
Page 21: Version With Water Cooled Condenser
3.3. 3.3. 3.3. 3.3. Version with water cooled condenser Version with water cooled condenser Version with water cooled condenser Version with water cooled condenser Whereas the basic versions of the Compact-Line is specified with an air cooled condenser, the units are also available with an water cooled condenser. Thereby the condenser is a plate heat exchanger with copper brazed stainless steel plates. -
Page 22: Tank Heater With Thermostatic Pump Start
3.6. 3.6. 3.6. 3.6. Tank heater with thermostatic Tank heater with thermostatic Tank heater with thermostatic pump start Tank heater with thermostatic pump start pump start pump start The tank heater maintains a minimum temperature in the tank. The pump circulates the cold water, while the tank heater controls the temperature in the system. -
Page 23: Second Consumer Circuit
Ask your KKT chillers contact. KKT chillers contact. -
Page 24: Di Package
The filter is cleaned by removing it and washing it with water or a slightly alkaline solution. Heavily-contaminated filters must be replaced by new ones. Please contact the KKT chillers Service Team (see Table 1 Table 1... -
Page 25: Levelling Feet (Accessories)
3.20. 3.20. 3.20. 3.20. Levelling feet Levelling feet Levelling feet Levelling feet (accessories) (accessories) (accessories) (accessories) The levelling feet are used for vibration isolation and for height adjustment. They consist of a threaded rod and a grey cast iron shell with an elastic element attached. The threaded rod enables the height to be adjusted and compensates for floors sloping by up to 5°. -
Page 26: Filter Assembly Group Cooling Water Circuit (Accessories)
The refrigerating capacity of the individual units can then be added together. Please contact your KKT chillers contact to arrange the appropriate project planning for this option. 3.25. -
Page 27: Remote Control Panel (Accessories)
3.27. 3.27. 3.27. 3.27. Remote Remote Remote Remote Control Panel Control Panel Control Panel Control Panel (accessories) (accessories) (accessories) (accessories) For the case that the chiller shall be operated not from the machine itself but from a different operating place the chiller can be delivered with a remote control panel. Thereby the same display is mounted together with the operating voltage supply in one miniature housing. -
Page 28: Closed Water Loop
3.32. 3.32. 3.32. 3.32. Closed Water Loop Closed Water Loop Closed Water Loop Closed Water Loop The water chiller is designed as a closed water loop system with an expansion tank. The expansion tank is pressurized in accordance with the volume of the entire system volume (including installation).The expansion tank balances temperature swings and related system pressure of the water loop. - Page 29 Table Table 9 9 9 9 : Definition of the safety symbols Table Table : Definition of the safety symbols : Definition of the safety symbols : Definition of the safety symbols : Definition of the safety symbols : Definition of the safety symbols : Definition of the safety symbols : Definition of the safety symbols Note and follow the instructions for use!
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Page 30: Residual Energy
In particular, the following hazard warnings apply to the machine: In particular, the following hazard warnings apply to the machine: Table 10 Table 10: Hazard warnings : Hazard warnings Table Table : Hazard warnings : Hazard warnings ATTENTION! Work on the chiller must be carried out by properly qualified, ATTENTION! Work on the chiller must be carried out by properly qualified, ATTENTION! Work on the chiller must be carried out by properly qualified, ATTENTION! Work on the chiller must be carried out by properly qualified,... -
Page 31: Safety Devices, Guards And Safeguards
Refrigeration circuit is pressurised Refrigeration circuit is pressurised o Provided it is not damaged the refrigeration circuit is closed. Therefore, a hazard is not damaged the refrigeration circuit is closed. Therefore, a hazard is not damaged the refrigeration circuit is closed. Therefore, a hazard is not to be assumed. -
Page 32: High-Pressure Monitoring
4.4.2. High High High High- - - - pressure monitoring pressure monitoring pressure monitoring pressure monitoring If the high pressure in the refrigeration circuit of your machine increases to a maximum value, the compressors are switched off via the High High- - - - pressure limiter pressure limiter (see Chapter Chapter 4.4.1 High... -
Page 33: Airborne Sound Emissions
work is carried out on the chiller the protective equipment described in work is carried out on the chiller the protective equipment described in Table Table Table Table Table 9: Definition of the Table Table Table 9: Definition of the 9: Definition of the 9: Definition of the safety symbols... -
Page 34: Notes On Reducing Noise And Vibration
4.7. 4.7. 4.7. 4.7. Notes on reducing noise and vibration Notes on reducing noise and vibration Notes on reducing noise and vibration Notes on reducing noise and vibration 4.7.1. Noise Noise Noise Noise Details of your chiller's airborne sound emissions are given in Chapter Chapter 4.6. -
Page 35: Other
4.8.4. Other Other Other Other ATTENTION! Risk of suffocation if the chiller is installed in a room that is too ATTENTION! Risk of suffocation if the chiller is installed in a room that is too ATTENTION! Risk of suffocation if the chiller is installed in a room that is too ATTENTION! Risk of suffocation if the chiller is installed in a room that is too small. -
Page 36: Oil Poe 160Sz
Handling and storage: Handling: fire and explosion protection: heating results in increased pressure and a risk of bursting. Cool containers at risk with water. Open the containers slowly and carefully. 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. -
Page 37: Reasonably Foreseeable Misuse
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 information: Inform the police or competent authorities in case of penetration in the sewers or bodies of water. -
Page 38: Information For Emergencies
Then contact the KKT chillers Service Team. If you detect a refrigerant or oil leak, proceed as described in Chapter Chapter Chapter Chapter 4.9 Dangerous substances... -
Page 39: Forklift Truck
5.2.1. Forklift truck Forklift truck Forklift truck 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 Figure 10 and Figure... -
Page 40: Crane
5.2.2. Crane Crane Crane Crane When it is unpacked the machine can be lifted by means of a crane and an adequately dimensioned lifting beam. Figure 14 Figure 14 Figure 14 Figure 14 shows the regulations for transport by crane. Please also refer to the Table Table 12 12 for the dimensions and descriptions of the Figure 14... -
Page 41: Unpacking
5.3. 5.3. 5.3. 5.3. Unpacking Unpacking Unpacking Unpacking ATTENTION! Packing straps are mechanically stressed and can snap back when ATTENTION! Packing straps are mechanically stressed and can snap back when ATTENTION! Packing straps are mechanically stressed and can snap back when ATTENTION! Packing straps are mechanically stressed and can snap back when ATTENTION! Packing straps are mechanically stressed and can snap back when ATTENTION! Packing straps are mechanically stressed and can snap back when... -
Page 42: Installation
6. 6. 6. 6. Installation Installation Installation Installation 6.1. 6.1. 6.1. 6.1. Overview Overview Overview Overview Several tasks are necessary to install the chiller. The following work schedule shows the order in which they are carried out: Prepare the installation site Install the machine Flush the cold water circuit Hydraulic installation... -
Page 43: Ambient Temperature
Table Table 14 Table Table 14: Minimum volume of the installation room with regard to maximum refrigerant : Minimum volume of the installation room with regard to maximum refrigerant : Minimum volume of the installation room with regard to maximum refrigerant : Minimum volume of the installation room with regard to maximum refrigerant concentration in case of a leakage if installed indoors concentration in case of a leakage if installed indoors... -
Page 44: Process Level
30 air duct cBoxX 30 Duct systems with a pressure loss higher than 5 Pa require external ventilation with a variable air flow rate. Please contact our KKT chillers Service Team (see Table 1 Table 1 Table 1 Contact... -
Page 45: Stability
6.2.9. Stability Stability Stability Stability The normal situation is for the machine and the baseplate to be stood firmly on the ground. It is not necessary to anchor the machine to the ground. However, if this is necessary due to the surrounding conditions, the machine can be equipped with the optionally available levelling feet (3.20 Levelling feet Levelling feet . -
Page 46: Installation
6.2.12. Installation Installation Installation Installation Filling and feed (topping up) Filling and feed (topping up) Draining Unit outlet cold water circuit 1 (supply line supply line) Unit outlet cold water circuit 1 (return line return line) Unit outlet cold water circuit 2 (supply line) (supply line) Unit outlet cold water circuit 2 (return line) (return line) -
Page 47: Frost Protection Measures
6.2.14. Frost protection measures Frost protection measures Frost protection measures Frost protection measures The chiller is exposed to the risk of frost in two different situations. Both with an ambient temperature < 0 °C and a feed temperature < 8 °C there is a risk of freezing of parts of the cold water circuit system. - Page 48 Procedure for chillers with automatic top Procedure for chillers with automatic top-up: If your machine is equipped with the optional If your machine is equipped with the optional 3.11 Automatic Automatic water feed water feed, the cold water , the cold water circuit Automatic Automatic water feed...
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Page 49: Venting
6.2.17. Venting Venting Venting 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. -
Page 50: Electrical Installation
6.2.18. Electrical installation Electrical installation Electrical installation Electrical installation ATTENTION! The electrical installation, testing and commissioning may only be ATTENTION! The electrical installation, testing and commissioning may only be ATTENTION! The electrical installation, testing and commissioning may only be ATTENTION! The electrical installation, testing and commissioning may only be carried out by qualified personnel. -
Page 51: Commissioning
Use an external control cable to set the chiller's release (see Chapter Chapter Chapter Chapter 8.3 External release External release External release) ) ) ) ; this External release cable is laid parallel with the supply cable and is wired at the corresponding terminals in the control cabinet. -
Page 52: Operation
8. 8. 8. 8. Operation Operation Operation Operation The chiller is designed for fully automatic operation. 8.1. 8.1. 8.1. 8.1. Switching on Switching on Switching on Switching on First, switch on the machine at the main switch (component 5 in Figure Figure Figure 19 Figure... -
Page 53: Control Panel
8.5. 8.5. 8.5. 8.5. Control panel Control panel Control panel Control panel The following Figure 19 Figure 19 shows the chiller's display elements and controls. Figure 19 Figure 19 Figure Figure 19 Figure Figure 19: C6842 Display elements and controls : C6842 Display elements and controls : C6842 Display elements and controls : C6842 Display elements and controls... -
Page 54: Start Screen
8.5.1. Start Start Start Start screen screen screen screen Figure Figure 20 Figure Figure 20: Start screen without alarm : Start screen without alarm : Start screen without alarm : Start screen without alarm Figure Figure 21 Figure Figure 21: Start screen with alarm : Start screen with alarm : Start screen with alarm : Start screen with alarm... -
Page 55: Main Menu
8.5.2. Main menu Main menu Main menu Main menu Figure 22 Figure 22: Main menu : Main menu Figure Figure : Main menu : Main menu From the Main menu you can move into the submenus or return to the Start screen. 8.5.3. - Page 56 In the Status menu the states of the digital inputs and outputs and several internal control states can be called up. Figure Figure 25 Figure Figure 25: Status menu : Status menu : Status menu : Status menu The alarms are listed in the Alarm menu. A detailed description is given in Chapter 8.5.5 Alarm Alarm Alarm Alarm...
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Page 57: Settings
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 Figure 29 Figure Figure 29: Analog inputs : Analog inputs : Analog inputs... -
Page 58: Alarm Menu
8.5.5. Alarm menu Alarm menu Alarm menu Alarm menu The alarm is acknowledged if the "OK" button is pressed for longer than five seconds. Alarm messages can have three states: active: The alarm is still active. (e.g. DI MSS …) The motor protection switch has triggered. •... -
Page 59: Controller Description
8.7. 8.7. 8.7. 8.7. Controller description Controller description Controller description Controller description 8.7.1. Electronic level monitoring Electronic level monitoring Electronic level monitoring Electronic level monitoring Before switching on the chiller the electronic level monitoring starts up. The level is monitored for three states: Tank min level STOP;... -
Page 60: Cold Water Flow Temperature Control
When the system is switched on the primary pumps are switched on with a 3.5 s delay. After a further 3.5 s the fan control is released. When the primary pump is switched on a timing element starts for each pump, which activates the monitoring of the minimum and maximum cold water pressure at the pump outlet. -
Page 61: Compressor Control
Different operating states reduce the number of cooling levels required by one cooling level: High pressure warning • Low pressure warning • Difference between high and low pressure is too large. • 8.7.4. Compressor control Compressor control Compressor control Compressor control The control is defined for a refrigeration circuit with a maximum of four compressors. -
Page 62: Fan Speed Control
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 element is started with the request for the compressor. -
Page 63: Comfort Mode
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 1 Table 1... -
Page 64: Service
KKT chillers. In this way you ensure the reliability and you ensure the reliability and quality of the machine. If you have any questions about spare parts, please contact our KKT chillers of the machine. If you have any questions about spare parts, please contact our KKT chillers of the machine. -
Page 65: Taking Out Of Service
11. Taking out of Taking out of Taking out of Taking out of service service service service ATTENTION! ATTENTION! ATTENTION! ATTENTION! Decommissioning must only be carried out by Decommissioning must only be carried out by professional and professional and professional and professional and ATTENTION! ATTENTION! -
Page 66: Recycling
A specialised disposal company must be contracted to dispose of these wastes. They issue a proof of disposal which must be archived. The chiller can be returned to KKT chillers for disposal. Please contact our KKT chillers Service Team for details (Table 1... -
Page 67: Lists
14. Lists Lists Lists Lists 14.1. 14.1. 14.1. 14.1. List of List of List of List of illustrations illustrations illustrations illustrations Figure 1: C6848 refrigeration diagram ....................13 Figure 2: Demounting the side panel of the switch cabinet .............. 16 Figure 3: C6856 thermostatic pump start with overflow valve (recommended installation) .. -
Page 68: List Of Tables
14.2. 14.2. 14.2. 14.2. List of tables List of tables List of tables List of tables Table 1: Contact details ......................... 2 Table 2: Safety instructions ........................8 Table 3: Technical data .......................... 9 Table 4: Explanation of terms ......................12 Table 5: Materials used - standard version .................. -
Page 69: Troubleshooting
I. I. I. I. Troubleshooting Troubleshooting Troubleshooting Troubleshooting Fault description and Fault Fault correction cause Sensor break, AI pump Testing the supply cable / connector / AI pump pressure 1 pressure 1 sensor Sensor break, AI pump Testing the supply cable / connector / AI pump pressure 2 pressure 2 sensor... -
Page 70: Cboxx
Check compressor 2: Check supply Compressor 2 motor cable! Compressor blocked? Current protection has triggered. measurement of individual phases? DI MSS compressor 2 Motor current is outside the Continuity measurement of the permitted range. windings? Load contactor is not working correctly Check compressor 3: Check supply Compressor 3 motor cable! Compressor blocked? Current... -
Page 71: Cboxx
Overheating cannot be permanently adjusted to the Overheating defined value. There is a Contact the KKT chillers Service. problem in the refrigeration circuit. The low-pressure of the refrigeration circuit is approaching the critical Low pressure warning Check the flow through the evaporator. -
Page 72: Cboxx
The low-pressure of the refrigeration circuit lies Low pressure STOP 3x continuously within the Contact the KKT chillers Service. critical range for the system configuration. The high-pressure of the High pressure warning refrigeration circuit is See also: "High-pressure stop". approaching critical range. -
Page 73: Maintenance Intervals In Accordance With The Vdma
II. II. II. II. Maintenance intervals in accordance with the VDMA Maintenance intervals in accordance with the VDMA Maintenance intervals in accordance with the VDMA Maintenance intervals in accordance with the VDMA Explanation Explanation Explanation Explanation Annual Annual Annual Annual Six- - - - as as as as Remark... -
Page 74: Cboxx
Explanation Explanation Annual Annual Six- - - - as as as as Remark Remark Explanation Explanation Annual Annual Remark Remark monthly monthly required required monthly monthly required required Parts in the refrigeration circuit/water circuit Parts in the refrigeration circuit/water circuit Parts in the refrigeration circuit/water circuit Parts in the refrigeration circuit/water circuit Optical check for dirt, damage and corrosion... -
Page 75: Cboxx
No.: No.: Explanation Explanation Annual Annual Six- - - - as as as as Remark Remark No.: No.: Explanation Explanation Annual Annual Remark Remark monthly monthly monthly monthly required required required required Tank / water tank Tank / water tank Tank / water tank Tank / water tank Optical check for dirt, damage and corrosion... -
Page 76: Product Registration
III. III. III. III. Product Registration Product Registration Product Registration Product Registration PDF download: http://www.kkt-chillers.com/en/downloads/product-registration/ 76 / 77 83000102.Kf... -
Page 77: Ec Declaration Of Conformity
IV. IV. EC Declaration of Conformity EC Declaration of Conformity EC Declaration of Conformity EC Declaration of Conformity 77 / 77 83000102.Kf...
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