Related Manuals for KKT chillers Vario vBoxX 6
Summary of Contents for KKT chillers Vario vBoxX 6
-
Page 1: Vario Line
Vario Line Translation of the original operating manual vBoxX 6 vBoxX 8 vBoxX 10 vBoxX 12 vBoxX 15 vBoxX 18 vBoxX 24 vBoxX 28 1 / 88 83000602Km... - Page 2 Germany 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 +1 833 558 4357 F +1 847 734 1601 TF +1 866 517 6867 E support@kkt-chillersusa.com...
-
Page 3: Introduction
Allow yourself sufficient time to read through this manual carefully and to take in all the information it contains. If you have any further questions you can contact the KKT chillers service team; refer to the contact details. If properly used for its intended use and correctly maintained, the chiller ensures sustained, fault-free operation. -
Page 4: Table Of Contents
Contents Vario Line ............................1 Introduction ............................. 3 Product description........................8 1.1. Intended use ........................8 1.2. Elements ...........................10 1.3. Explanation of terms ......................11 Function and main components .....................12 2.1. Compressor ........................12 2.2. Evaporator ........................13 2.3. Condenser ........................13 2.4. Expansion valve........................13 2.5. - Page 5 3.16. Water circuit in non-ferrous metal version ..............23 3.17. DI package ........................24 3.18. Conductivity monitoring ....................24 3.19. Conductivity control ......................24 3.20. Special voltage .........................24 3.21. Phase monitoring ......................24 3.22. UL version .........................24 3.23. Special paint finish ......................24 3.24. Air filter mat (accessories) ....................25 3.25.
- Page 6 4.11. Information for emergencies ...................37 Handling and storage ......................38 5.1. Dangerous goods ......................38 5.2. Transport ..........................38 5.2.1. Forklift truck......................38 5.3. Unpacking .........................39 5.4. Storage ..........................39 Installation..........................40 6.1. Overview ...........................40 6.2. Installation site .........................40 6.2.1. General information ....................40 6.2.2. Minimum room volume ....................40 6.2.3.
- Page 7 8.7.4. Compressor control ....................56 8.7.5. Fan speed control .....................56 8.7.6. Electronic expansion valve control ................56 8.7.7. Temperature limit monitoring ..................56 8.7.8. Group fault message + warning message ..............57 Cleaning ............................58 9.1. Air filter mat ........................58 9.2. Condenser ........................58 9.3. Water filters ........................58 9.4.
-
Page 8: Product Description
Please read through all the points of this instruction manual before starting up the machine. You should pay particular attention to the points on safety, commissioning/startup and operation. Should you have see Table any further questions concerning your machine, please contact the KKT chillers Service Team ( 1: Contact details 1.1. Intended use The vBoxX is a factory-tested, fully automatic compression chiller. -
Page 11: Explanation Of Terms
1.3. Explanation of terms For the sake of better understanding, we have listed some relevant terms that are used frequently in this document. Table 4: Explanation of terms Term Explanation Application The source of heat hydraulically connected to the chiller. Process circuit Application and piping to the chiller. -
Page 12: Function And Main Components
2. Function and main components The chiller consists of the main compressor, condenser, expansion valve and evaporator Figure 1 components, which are arranged in a circuit ( ). Refrigerant circulates in this circuit. In the evaporator, it absorbs heat from the cold water and emits it in the condenser into the drawn in air. -
Page 13: Evaporator
R125 with virtually negligible temperature glide. R410A has a very high volumetric cooling capacity and has no ozone depletion potential (ODP=0). A corresponding safety data sheet can be see Table 1: Contact details requested from our KKT chillers Service Team ( 13 / 88 83000602Km... -
Page 14: Oil
Polyolester (POE) oil FV505 is used for this purpose. The oil is soluble in the refrigerant and distributes itself with it throughout the entire refrigeration circuit. A corresponding safety data sheet can be requested from our KKT chillers Service Team see Table 1: Contact details 2.7. -
Page 15: Pump
Figure 2: Opening the control cabinet 2.13. Pump The pump of the chiller provides for the necessary circulation of the cold water. This is drawn out of the chiller’s internal tank and is pumped through the process circuit. Optionally, the units can also be supplied as circulating coolers without tank, with pump or without tank, without pump Chapter 3.1 Version without tank, with pump Chapter 3.2 Version without tank, without... -
Page 16: Materials Used In The Water Circuit
2.16. Materials used in the water circuit The basic features result from the material composition shown in Table 5: Table 5: Materials used, basic configuration Component Material Unit connections V2A 1.4305 Evaporator V2A 1.4301 and copper (99.9%) Tank V2A 1.4301 Tank nozzle V4A 1.4305 Pump... -
Page 17: Water Quality
Furthermore, slime-forming bacteria must be prevented in the cooling water. If this is not possible, KKT chillers can recommend or provide an appropriate inhibitor to remove the slime forming agents on the basis of a biological water analysis carried out in advance. -
Page 18: Permitted Coolant Media
2.18. Permitted coolant media Water and mixtures of water / Antifrogen N (AFN) or water / Antifrogen L (AFL) as defined in Chapter 2.17 Water quality are allowed. The following table shows the requirements for the mix ration of water with antifreezes AFN and AFL. These values must be kept to as accurately as possible in order to maintain your machine's efficiency and prevent damage to components. -
Page 19: Options And Accessories
The positions marked with "accessory" are included with the unit, unattached, and can be re- ordered at any time with the respective product number. The installation of the accessory is the responsibility of the installer of the machine. You can also ask our KKT chillers Service Team to Table 1: Contact details arrange for this installation (see Information on your machine’s features can be found in the separately enclosed quick start... -
Page 20: Control Cabinet Heating
The cooling water temperature is registered by an additional temperature sensor in the cooling water inlet and is displayed on the controller display. The water quality listed under Table 7: Water quality must be complied with – the manufacturer does not accept any liability for any damage caused by a different water specification! The project-specific data and the adjusted PI flowchart and dimensioned diagram can be found in the enclosed quick guide. -
Page 21: Tank Heater With Thermostatic Pump Start
3.6. Tank heater with thermostatic pump start The tank heater is used to maintain a minimum temperature in the tank. The pump circulates the cold water, while the tank heater controls the temperature in the system. We recommend a Figure 4 hydraulic installation as shown in . -
Page 22: Higher Pressure Pump
3.8. Higher pressure pump The standard Vario-Line units have a 3 bar pump, which is designed for the nominal volumetric flow rate of the respective unit. Optionally, the units can also be built with higher pressure pumps, within the limits of the minimum or maximum flow rate. The pump characteristic curve of the pump(s) used in your device are included with the device. -
Page 23: Second Medium
3.13. Second medium If several loads are to be supplied with different refrigerants, an optional second tank can be provided for the secondary circuit, which is filled with a different medium to the primary circuit. Both circuits are separated from each other hydraulically by an additional plate heat exchanger. Similar to the above-named option, a partial flow of the primary circuit is added by a control valve until the required setpoint is reached in the secondary circuit. -
Page 24: Di Package
3.17. DI package The DI package comprises the water circuit option in non-ferrous metal version (see 3.7) as well as a replaceable DI cartridge with conductivity monitoring and conductivity control. The DI cartridge used is intended exclusively for maintaining the conductivity and not for water treatment. -
Page 25: Air Filter Mat (Accessories)
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 details) contact the KKT chillers Service Team ( 3.25. Vario Foot (accessories) The four Vario Foot levelling feet can be used for rolling, vibration isolation and height adjustment. -
Page 26: Remote Control Panel (Accessories)
3.30. Remote control panel (accessories) If the chiller is not to be operated directly at the unit but from a different operator station, your unit can be delivered with the so-called remote control panel. Thereby the same display that is already installed in the chiller is mounted together with a rail to the operating voltage supply in one miniature housing. - Page 27 Table 9: Definition of the safety symbols Note and follow the instructions for use! The machine must be safely disconnected from the power supply before it is opened! Then wait for at least 2 minutes before opening the machine. Warning! Electric shock! If the machine is only switched off at its main switch, dangerous electrical voltage is still applied at several terminals in the control cabinet.
- Page 28 The following hazard warnings apply in particular to the machine: Table 10: Hazard warnings WARNING! 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.
-
Page 29: Residual Energy
4.3. Residual energy Even if all the hazard warnings in Chapter 4.2 are taken into account, the following residual energy situations can result in a hazard: Rotational energy of the decelerating fan o Despite the installed wire guard, hair or pieces of clothing can still be drawn in and caught. -
Page 30: Safety Devices, Guards And Safeguards
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 the compressor via its load contactor when the maximum permitted system operating pressure is reached. It is part of the safety chain. The PZH is mounted Figure 7: Position of the high-pressure on the refrigerant receiver of the vBoxX type units (see limiter (PZH) -
Page 31: Oil Temperature Monitor
4.4.5. Oil temperature monitor All Vario-Line units are equipped with a so-called oil temperature monitor so that the compressor starts up easily, even at low ambient temperatures. To this end, the hot gas temperature is monitored. If the hot gas temperature is below the limit value of 6°C, the oil is heated by the frequency inverter until the limit value is reached once more. - Page 32 Figure 8: Airborne sound emission (see Chapter 4.7.1 Noise) In partial load mode or under favourable ambient conditions the speed and therefore the sound emissions reduce automatically. 32 / 88 83000602Km...
-
Page 33: Notes On Reducing Noise And Vibration
4.7. Notes on reducing noise and vibration 4.7.1. Noise Chapter 4.6 Details of your chiller's airborne sound emissions are given in To reduce noise pollution caused by airborne sound emissions it is advisable to install the chiller out of doors and out of the range of workplaces. If this is not possible we recommend that when the unit is installed attention is paid to ensuring that the air intake side is not pointed directly at a workplace/workstation. -
Page 34: Other
4.8.4. Other WARNING! Risk of suffocation if the chiller is installed in a room that is too small. Please note and follow Chapter 6.2.2. WARNING! In the EU you must follow the provisions of EN 378-3. You must also comply with the local installation regulations and provisions, especially (in Germany) the VAwS and the BGR500 Chapter 2.35. -
Page 35: Oil
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 36: 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 method: Clean the contaminated area with water. Caution! Slipping hazard! ... -
Page 37: Information For Emergencies
Then contact the KKT chillers Service Team. If you detect a refrigerant or oil leak, proceed as Chapter 4.9 Hazardous substances described in... -
Page 38: Handling And Storage
5. Handling and storage The chiller is fixed on a wooden pallet in the factory for delivery. The machine is additionally protected against damage by polystyrene corner protectors and stretch film. Therefore you should remove the packaging as late as possible. 5.1. -
Page 39: Unpacking
5.3. Unpacking WARNING! Packing straps are mechanically stressed and can snap back when cut. Risk of injuries! Remove carefully all tapes, films, protection corners and spacers. Optional accessories may also be located under the film. Ensure that these are also not damaged. The packaging can be recycled according to the local regulations. -
Page 40: Installation
6. Installation 6.1. 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 41: Ambient Temperature
Table 13: Minimum volume of the installation space with regard to maximum refrigerant concentration in case of leakage if installed indoors vBoxX [m³] Rmin refrigerant [m³] 18.7 21.0 Rmin setup instructions If the calculation of the minimum room volume required is only based on the respective refrigerant fill quantity, a room volume of 7 would be sufficient for size I (vBoxX 6 - vBoxX 12) or 11m³... -
Page 42: Process Level
6.2.6. Process level The chiller may not be installed more than 500 mm below the process level, There is a risk of cold water discharging via the chiller’s internal tank while the unit is not in operation. If this however is 3.26 Level package necessary, the level package option ( ) must be installed. -
Page 43: Installation
6.2.11. Installation The unit-specific connection assignment is shown in the flow diagram enclosed with the chiller. Filling and feeding Draining Unit outlet cold water circuit 1 (VL) Unit inlet cold water circuit 1 (RL) Unit outlet cold water circuit 2 (VL) Unit inlet cold water circuit 2 (RL) vBoxX 6 - 28 43 / 88... -
Page 44: Hydraulic Installation
6.2.12. Hydraulic installation The plant designer is responsible for choosing the material and cross-section of the hydraulic connections between the chiller and application. The dependencies are, among other things, the accepted pressure loss in the connection pipes and the available pump pressure. When designing the connections attention must also be paid to the minimum flow rate required and sufficient pressure resistance to the maximum pump pressure. -
Page 45: Filling
6.2.15. Filling If the hydraulic installation of the whole system has been completed, the unit can be filled. Open all the stopcocks in the cold water circuit. WARNING! Only use approved refrigerants, see Chapter 2.15! 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! Procedure for chillers with integrated tank: The filling can be carried out via the tank without pressurised methods. -
Page 46: Venting
6.2.16. Venting Vent the pump before commissioning. When doing so, open the vent screw before switching on the pump and keep it open during ongoing operation until all air has escaped from the pump body Figure 12 (see example Pump venting Figure 12: Position of the pump venting (horizontal type example) If your chiller is equipped with an internal tank, the further water circulation ensures that any residual air in the overall system can escape via the tank open to the atmosphere. - Page 47 Figure 13: Main supply The load cable and fuses must be dimensioned according to the machine's technical specifications and the regulations of the local power supply company. The supply cable must be laid into the inside of the machine. Recesses are provided in the baseplate for this purpose.
-
Page 48: Initial Startup
After checking the above checklist you can continue with Use the enclosed Product registration form to register your chiller. This ensures that you receive support quickly and easily in a service case, as KKT chillers already has all the relevant data. 48 / 88... -
Page 49: Operation
8. Operation The chiller is designed for fully automatic operation. 8.1. Switching on Firstly, switch on the unit by flipping the main switch. A start screen appears on the display. 8.2. Selecting the operating mode In the Start screen you can choose between the following three operating modes: Standby: This operating mode is to be selected if the chiller was disconnected from the ... -
Page 50: Control Panel
8.5. Control panel Button functions: Pressing any button activates the display lighting. Screen display LED status displays Pressing this button allows you to scroll within a menu level from the currently shown display to the previous display of this menu level. -
Page 51: Start Screen
8.5.1. Start screen The general operating status of the system is displayed on the Start screen. Current system operating mode (here: System standby) Changing the operating mode see Chapter 8.5.2 Changing the operating mode The other menu fields of the Start screen are ... -
Page 52: Change Of Operating Mode
8.5.2. Change of operating mode If the screen lighting is off (= display is in idle), first press any button to switch on the screen lighting. If the display lighting is switched on, press the button to release the “current system operating Refrigerating system mode”... -
Page 53: Navigating To The Menu Levels
8.5.3. Navigating to the menu levels Starting from the start screen, you move to the main setting and control software menu. Appendix I From there to submenus (for overview of the menu levels see ). If the screen lighting is off (= display is in idle), first press any button to switch on the screen lighting. If the lighting of the control panel is switched Refrigerating system on, you can navigate further to the main... -
Page 54: Parameter
A daily password is required to change blocked parameters. For enquiries Contact details regarding the daily password, please contact our KKT chillers Service Team ( ). The password level of the individual parameters is given in the parameter list enclosed in the machine documentation. -
Page 55: Cold Water Feed Temperature Control
The condenser fan is released if: the compressor is released. No motor protection switch faults are queued. No fault is queued at the digital fault input (e.g. control unit group fault). When the system is switched on, the primary pump / evaporator pump is switched on with a 3.5 s time delay. -
Page 56: Compressor Control
8.7.4. Compressor control The control is designed for a refrigeration circuit with a speed-controlled compressor. The compressor is requested depending on the controller output signal and according to the load demand. The compressor switches off if refrigerating capacity is no longer required. The high pressure is monitored on the hardware side by means of the high-pressure limiter. -
Page 57: Group Fault Message + Warning Message
8.7.8. Group fault message + warning message A group fault alarm is triggered if an alarm occurs. All alarms are included in the group fault, but not the warnings. The group fault signalling relay has a floating changeover contact and is energised in fault-free operation, in order to ensure wire break monitoring. -
Page 58: Cleaning
The appropriate air filter mats can be ordered at any time Contact details as an original spare part – please contact our KKT chillers Service Team ( 9.2. Condenser To maintain high performance, the microchannel heat exchanger must be cleaned if there is any visible contamination, but at least annually. -
Page 59: Service
/ maintenance agreements. Use the enclosed Product registration form to register your chiller. This ensures that you receive support quickly and easily in a service case, as KKT chillers already has all the relevant data. 10.2. -
Page 60: Spare Parts
To ensure that the performance of your chiller is not impaired, we recommend that you only use original spare parts from KKT chillers. In this way you ensure the reliability and quality of the machine. For enquiries regarding spare parts, please contact our KKT chillers Service Team Contact details Use the enclosed Product registration form to register your chiller. -
Page 61: Withdrawing From Service
11. Withdrawing from service WARNING! The machine must be withdrawn from service by professional and qualified technicians. They must also be familiar with the local regulations. Chapter 4.3 Residual For safety-related notes regarding any residual energy, please refer to energy 11.1. -
Page 62: Recycling
A specialised disposal company must be used for the disposal of these wastes. They will issue a proof of disposal that must be archived. The chiller can be returned to KKT chillers for disposal. Contact details Please contact our KKT chillers Service Team for details ( 13. -
Page 63: Overview Of The Menu Levels
Overview of the menu levels Main structure 63 / 88 83000602Km... - Page 64 64 / 88 83000602Km...
- Page 65 Status 65 / 88 83000602Km...
- Page 66 66 / 88 83000602Km...
- Page 67 Parameter 67 / 88 83000602Km...
- Page 68 68 / 88 83000602Km...
- Page 69 69 / 88 83000602Km...
- Page 70 70 / 88 83000602Km...
- Page 71 71 / 88 83000602Km...
-
Page 86: Maintenance Intervals In Accordance With The Vdma
III. Maintenance intervals in accordance with the VDMA Explanation Annual Six-monthly as required Comment Compressor Visual inspection for dirt, damage and corrosion Check fixing, check running noises Measure the intake pressure Measure the suction gas temperature upstream of the compressor Measure the compression end temperature at the discharge port Check oil level... - Page 87 Explanation Annual Six-monthly as required Comment Parts in the refrigeration circuit/water circuit Visual inspection for dirt, damage and corrosion Check insulation for damage Check filter dryer for blockage Replace filter dryer When component s in the refrigeratio n circuit are replaced Check all pipes carrying refrigerant for corrosion and damage...
-
Page 88: Product Registration
No.: Explanation Annual Six-monthly Comment required Tank / Water tank Visual inspection for dirt, damage and corrosion Check fixing Check filling level Control cabinet Visual inspection for dirt, damage and corrosion Check fixing Check all threaded connections Check all indicator lights and error messages Check that the temperature and pressure sensors are functioning properly Check the function of the motor protection...
Need help?
Do you have a question about the Vario vBoxX 6 and is the answer not in the manual?
Questions and answers