KKT chillers Compact-Line cBoxX 30 Original Operating Instructions
  1. Manuals
  2. Brands
  3. KKT chillers Manuals
  4. Chiller
  5. Compact-Line cBoxX 30
  6. Original operating instructions

KKT chillers Compact-Line cBoxX 30 Original Operating Instructions

Hide thumbs
Table of Contents

Advertisement

Quick Links

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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Compact-Line cBoxX 30 and is the answer not in the manual?

Questions and answers

Related Manuals for KKT chillers Compact-Line cBoxX 30

Summary of Contents for KKT chillers Compact-Line cBoxX 30

  • Page 1 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...
  • 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. 1280 Landmeier Road Elk Grove Village IL 60007 T +1 833 558 4357 F +1 847 734 1601 TF +1 866 517 6867 E support@kkt-chillersusa.com...

  • Page 3: 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. Elements ........................... 11 1.3. Explanation of terms ......................12 Function and main components ..................... 13 2.1. Compressor ........................13 2.2. Evaporator ........................14 2.3. Condenser ........................14 2.4.
  • Page 5 3.19. Special paint finish ......................24 3.20. Air filter mat (accessories) ....................25 3.21. Levelling feet (accessories) ..................... 25 3.22. Level package (accessories) ................... 25 3.23. Filter assembly group coolant circuit (accessories) ............26 3.24. Filter assembly group cooling water circuit (accessories) ..........26 3.25.
  • Page 6 5.2.2. Crane ......................... 43 5.3. Unpacking ......................... 44 5.4. Storage ..........................45 Installation ..........................46 6.1. Overview ........................... 46 6.2. Installation site ......................... 46 6.2.1. General information ....................46 6.2.2. Minimum room volume .................... 46 6.2.3. Ambient temperature ....................47 6.2.4.
  • Page 7 8.7.8. Temperature limit monitoring .................. 67 8.7.9. Group fault alarm ..................... 67 8.1. Execution types ........................ 68 8.1.1. ECO mode ......................... 68 8.1.2. Comfort mode ......................68 Cleaning ........................... 69 9.1. Air filter mat ........................69 9.2. Condenser ........................69 9.3.

  • Page 8: 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 Team (see Table 1: Contact details).
  • Page 9 Technical data Table 3: Technical data Compact-Line cBoxX 30 cBoxX 40 cBoxX 50 cBoxX 60 cBoxX 70 cBoxX 80 cBoxX 90 cBoxX 100 Refrigerating capacity @ tw2=20°C / tu=32°C Refrigeration circuit hermetically tight Refrigerant R410A 2088 Refrigerant capacity CO2 equivalent t CO2 12,5 12,5...
  • Page 10 Compact-Line cBoxX 120 cBoxX 160 cBoxX 180 cBoxX 200 Refrigerating capacity @ tw2=20°C / tu=32°C Refrigeration circuit hermetically tight Refrigerant R410A 2088 Refrigerant capacity 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)

  • Page 11: Elements

    1.2. Elements Metal cladding, top, operator side Safety instructions Metal cladding, bottom, operator side Water connections Metal cladding, top, service side Rating plate Metal cladding, bottom, service side Display Metal cladding, condenser protective grating Main switch Cladding, hydraulics 11 / 110 83000102.Km...

  • Page 12: Explanation Of Terms

    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 process circuit and chiller in hydraulic piping.

  • Page 13: Function And Main Components

    2. 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 ambient air in the condenser.

  • Page 14: Evaporator

    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 Table 1: Contact details). 14 / 110...

  • Page 15: Oil

    2.6. Oil The components of the compressor subject to friction are lubricated by oil, which is added to the refrigerant in the factory. The polyolester-160SZ is used for this. The oil is soluble in the refrigerant and is distributed with it throughout the refrigeration circuit. The total oil quantity of the respective unit is given in the technical data.

  • Page 16: Pump

    Figure 2: Demounting the side panel of the switch cabinet 2.13. Pump The chiller's pump ensures the necessary circulation of the cold water. The water is drawn out of the chiller's internal tank and is pumped through the process circuit. Optionally, the units can also be designed as a continuous flow cooler without tank, with pump or without tank, without pump (see Chapter 3.1 Version without tank, with pump, and Chapter 3.2 Version without tank, without pump).

  • Page 17: Materials Used In The Water Circuit

    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 – cBoxX100) Unit connections V2A 1.4305 Hose Synthetic rubber band Evaporator V2A 1.4301 and copper (99.9%) Tank...
  • Page 18 Table 6: Materials used for the non-ferrous metal-free version Component Material (cBoxX 30 – cBoxX100) Device connections (turned parts) V2A 1.4305 Hose Synthetic rubber band Evaporator V2A 1.4401 Tank V2A 1.4301 Tank nozzle V4A 1.4571 Pump V2A 1.4301 Mechanical seal EPDM Sealing plugs yellow Polyamide PA 6...

  • Page 19: Water Quality

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

  • Page 20: Options And Accessories

    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 Contact details).

  • Page 21: Heater For Compressor And Control Cabinet

    Thereby the condenser is a plate heat exchanger with copper brazed stainless steel plates. The 3way valve is mounted in the cooling water outlet and is adjusted by an actuator depending on the condensing pressure. The operation mode can be switched from the 3way operation to a 2way operation by closing the pre mounted bypass valve.

  • Page 22: Overflow Valve For Standby Mode

    Frost-free area cBoxX Application Figure 3: C6856 thermostatic pump start with overflow valve (recommended installation) 3.7. Overflow valve for standby mode The optional overflow valve should be installed if it is possible for the flow of the cold water to reduce sharply or be completely prevented while the unit is running.

  • Page 23: Additional Evaporator Pump

    3.10. Additional evaporator pump The evaporator is optimised for the nominal volumetric flow rate of cold water. The nominal volumetric flow rate is given in Table 3 Technical data. If the operating volumetric flow rate of the cold water is more than 50 % smaller, an evaporation pump must be installed.

  • Page 24: Water Circuit In Non-Ferrous Metal-Free Version

    120 to cBoxX 200 it is located in the existing housing. For exact specifications, please refer to the circuit diagram. Please get in touch with your KKT chillers contact person for further information on implementing this option. 3.16.

  • Page 25: Air Filter Mat (Accessories)

    The filter is fixed using the Velcro tapes attached in the condenser protective grille. 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 Contact details).

  • Page 26: Filter Assembly Group Coolant Circuit (Accessories)

    (3.22 Level package) and a corresponding connection kit for the flow balance between the tanks. 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.

  • Page 27: Remote Control Panel (Accessories)

    3.28. Remote Control Panel (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. The remote control panel is connected to the chiller with clips and takes over the complete function of the controller in the main device.

  • Page 28: Closed Water Loop

    3.33. 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: Safety

    4. 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 accordance with the EC Declaration of Conformity (see Appendix VII).
  • Page 30 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 switch, dangerous electrical voltage is still present at several terminals in the control cabinet.
  • Page 31 In particular, the following hazard warnings apply to the machine: 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.

  • Page 32: Residual Energy

    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.

  • Page 33: 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 all compressors via their load contactors when the maximum permitted system operating pressure is reached. It is part of the safety chain. The PZH is installed on the refrigerant collector for the chiller types cBoxX 30 –...

  • Page 34: High-Pressure Monitoring

    4.4.2. High-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-pressure limiter (see Chapter 4.4.1 High-pressure limiter). A manual reset is required. The high-pressure monitoring on the other hand reduces the compressor output before the PZH's switch-off value is reached.

  • Page 35: Personal Protective Equipment For Servicing Work

    4.5. Personal protective equipment for servicing work Servicing work on the machine includes all work for which the machine is opened and one or more cladding panels are dismantled. In particular, this includes cleaning work in accordance with Chapter 9 Cleaning and maintenance work in accordance with Chapter 10 Service. Before work is carried out on the chiller the protective equipment described in Table 9: Definition of the safety symbols must be used.

  • Page 36: Notes On Reducing Noise And Vibration

    Figure 9: Airborne sound emissions In partial load mode or under favourable ambient conditions (see Chapter 4.7.1 Noise) the fan speed and therefore the sound emissions reduce automatically. 4.7. Notes on reducing noise and vibration 4.7.1. Noise Details of your chiller's airborne sound emissions are given in Chapter 4.6. 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.

  • Page 37: Residual Risks

    4.8. Residual risks 4.8.1. Electrical ATTENTION! The mains voltage must comply with the quality features of EN 50160 and the defined standard voltages of IEC 60038. The electrical connection on the building side is the responsibility of the operator. The operator must ensure that the permissible limit values in DIN EN 60204-1 (occurrence of a leakage current to earth at any mains connection of more than 10 mA AC or DC) are complied with, and that measures are taken to reduce them to non-critical values if they are exceeded.

  • Page 38: Dangerous Substances

    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.

  • Page 39: Oil Poe 160Sz

    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 international / national standards. Only use breathing apparatus, no filtering devices.

  • Page 40: 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! ▪...

  • Page 41: Information For Emergencies

    Then contact the KKT chillers Service Team. If you detect a refrigerant or oil leak, proceed as described in Chapter 4.9 Dangerous substances. 5. Handling and storage The chiller is fixed on a wooden pallet in the factory for delivery.

  • Page 42: Forklift Truck

    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.

  • Page 43: Crane

    5.2.2. Crane When it is unpacked the machine can be lifted by means of a crane and an adequately dimensioned lifting beam. Figure 14 & 15 show the regulations for transport by crane. Please also refer to the Table 12 for the dimensions and descriptions of the Figure 14. Figure 14: Crane transport cBoxX 30 - 100 Table 12: Description of figure 14 Transport sling or rope (do not use chains)

  • Page 44: Unpacking

    Figure 15: Crane transport cBoxX 120 – 200 The crane cross beam can be ordered pre-assembled ex works under the chiller (909000.0105), as well as packed loose for assembly on site (909000.0106). 5.3. Unpacking ATTENTION! Packing straps are mechanically stressed and can snap back when cut.

  • Page 45: Storage

    Table 13: Materials in the packaging Element Material Recycling code Polystyrene corner Polystyrene protectors Stretch film Polyethylene Edge protection / corner Cardboard protectors Packaging tape Polypropylene Strapping seals Zinc-plated steel Untreated raw wood, spruce or pine Wooden pallet without bark 5.4.

  • Page 46: 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 47: Ambient Temperature

    Table 14: Minimum volume of the installation room with regard to maximum refrigerant concentration in case of a leakage if installed indoors cBoxX chiller 100 120 160 180 200 Minimum volume of the installation room (in m³) 6.2.3. Ambient temperature The chiller is cooled by the ambient air and the lower the temperature of this cooling air the more economically the chiller works.

  • Page 48: Surface And Foundation

    6.2.7. Surface and foundation The surface on which the machine is installed must be flat and horizontal. All the machine's feet must have uniform contact with the ground. Ensure that the ground/subsoil has sufficient load bearing capacity. According to the installation instructions (see annex III) a continuous concrete foundation with the given minimum size is recommended.

  • Page 49: Installation

    6.2.11. Installation The unit-specific terminal assignment can be seen in the flow diagram enclosed with the chiller. Filling and feed (topping up) Draining Unit outlet cold water circuit 1 (supply line) Unit outlet cold water circuit 1 (return line) Unit outlet cold water circuit 2 (supply line) Unit outlet cold water circuit 2 (return line) cBoxX 30-100 49 / 110...

  • Page 50: Hydraulic Installation

    cBoxX 120-200 6.2.12. 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 designing the connections attention must also be paid to the minimum flow rate to be maintained and sufficient resistance to the maximum pump pressure.

  • Page 51: Frost Protection Measures

    In the case of chillers equipped with an internal tank the cold water cycle must be hydraulically closed. ATTENTION! Galvanised pipes must not be used if water-glycol mixtures are used! Formation of decomposition products, which result in silting up of the system! 6.2.13.
  • Page 52 (the shut-off valve to the level sensor must also be closed and the cotter pin (if present) on the tank cap must be released) Attention: the cotter pin (if present) must be reattached to the tank cap after filling. ATTENTION! The spring cotter (if present) must be reattached to the fuel filler cap after filling.

  • Page 53: Venting

    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 open while the unit is running until all air has completely escaped from the pump body (see Figure 17).

  • Page 54: Electrical Installation

    6.2.17. Electrical installation ATTENTION! The electrical installation, testing and commissioning may only be carried out by qualified personnel. Note and follow the local regulations. ATTENTION! Do not switch on the chiller until the hydraulic installation is completed and the machine has been filled as specified in Chapter 6.2.15. Otherwise the machine could be damaged.
  • Page 55 The supply cable must be routed into the machine. Cut-outs are provided for this purpose in the baseplate and in the compressor mount (cBoxX 30 – cBoxX 100). Feed the supply cable, protected by rubber grommets, through these openings (see Figure 18 Main supply). Please note that the dimensions described in DIN VDE 0298-4 must be observed.

  • Page 56: Commissioning

    7. Commissioning Before commissioning the chiller the checklist must be used to check whether all the necessary work in Chapter 6 Installation has been carried out properly. The chiller must be installed for at least 12 hours at >+5 °C, so that the compressor oil can heat up and the refrigerant can be liberated from the oil.

  • Page 57: Operation

    8. Operation The chiller is designed for fully automatic operation. 8.1. Switching on First, switch on the machine at the main switch (component 5 in Figure 19: C6842 Display elements and controls). The 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: ▪...

  • Page 58: Control Panel

    8.5. Control panel The following Figure 18 shows the chiller's display elements and controls. Figure 19: C6842 Display elements and controls Table 15: Description of C6842 Number Function Key Function "UP" button Navigation button "OK" button Navigation button & acknowledgement button for warning and fault messages "AB"...

  • Page 59: Start Screen

    8.5.1. Start screen : Start screen with tank and without alarm Figure 20 Figure 21: 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 •...

  • Page 60: Main Menu

    8.5.2. Main menu Figure 22: Main menu From the Main menu you can move into the submenus or return to the Start screen. 8.5.3. Information In the Information menu you can move into various submenus to obtain an overview of the state of the chiller.
  • Page 61 In the Status menu the states of the digital inputs and outputs and several internal control states can be called up. Figure 25: Status menu The alarms are listed in the Alarm menu. A detailed description is given in Chapter 8.5.5 Alarm menu.

  • Page 62: 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 29: Analog inputs The analog outputs show the signal upstream of the digital - analog converter. The value 10000 corresponds to an output voltage of 10 volts.

  • Page 63: Alarm Menu

    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 start menu) • active: The alarm is still active. (e.g. DI MSS …) The motor protection switch has triggered. •...

  • Page 64: Controller Description

    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 applications: 1.

  • Page 65: Switching The Chiller On/Off

    8.7.3. Switching the chiller On/off The following conditions must be fulfilled for the chiller Standby state: • The control has completed its initialization routine, • Release of at least one primary pump, • Release of the cold water feed or return sensor, •...

  • Page 66: Cold Water Flow Temperature Control

    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.

  • Page 67: Fan Speed Control

    The compressors are requested depending on the controller output signal. The compressor with the least number of operating hours switches on first. If no more refrigerating capacity is required the compressor that switched on first also switches off first. The compressors are switched on with a time delay (comment: only applies if several compressors exist) In the event of a fault in a compressor (motor protection switch) a fault changeover is activated.

  • Page 68: Execution Types

    8.1. Execution types Basically, you can choose between two types of construction: 8.1.1. ECO mode The default setting of the Compact-Line provides for operation in ECO mode ("Run" parameter is set to "0"). As a result, the increase in fan speed reduces the condensing pressure to the minimum necessary value in the respective operating point –...

  • Page 69: Cleaning

    (3.23 Filter assembly group coolant) It must be checked for contamination at least once a month. The appropriate filter unit can be ordered as an original spare part at any time – please contact our KKT chillers Service Team for this (Table 1 Contact details).

  • Page 70: Service

    To ensure that the performance of your chiller is not impaired, we recommend that you only use original spare parts purchased from KKT chillers. In this way you ensure the reliability and quality of the machine. For spare parts enquiries, please contact our KKT chillers Service Team spareparts@kkt-chillers.com or (Table 1 Contact details).

  • Page 71: Taking Out Of Service

    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.

  • Page 72: 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 Contact details).

  • Page 73: Main Dimensions

    Main dimensions 73 / 110 83000102.Km...
  • Page 74 74 / 110 83000102.Km...
  • Page 75 75 / 110 83000102.Km...
  • Page 76 76 / 110 83000102.Km...

  • Page 77: Installation Instructions

    Installation instructions 77 / 110 83000102.Km...
  • Page 78 78 / 110 83000102.Km...
  • Page 79 79 / 110 83000102.Km...
  • Page 80 80 / 110 83000102.Km...

  • Page 81: Menu Navigation

    III. Menu navigation Attention:: The parameters specified here are given as an example only. Please refer to the parameter set included in the unit for the parameter settings that are relevant for your chiller. Main menu Information Information Settings Measuring Measuring Alarm menu Status...
  • Page 82 Main menu Information Information Measuring Status Settings Status Alarm menu DI resetswitch Digital inputs Control Panel DI remotecontrol Digital outputs DI phase monitoring Analogue inputs DI mpcb Pump 1 Analogue outputs DI pump 1 flow-switch Alarm menu DI mpcb Pump 2 DI pump 2 flow-switch DI compressor 1 mpcb DI compressor 2 mpcb...
  • Page 83 Main menu Information Information Measuring Digital inputs Settings Status Alarm menu DI1 clip 1,2 Digital inputs Control Panel DI1 clip 3,4 Digital outputs DI1 clip 5,6 Analogue inputs DI1 clip 7,8 Analogue outputs DI1 clip 9,10 Alarm menu DI2 clip 1,2 DI2 clip 3,4 DI2 clip 5,6 DI3 clip 1,2...
  • Page 84 Main menu Information Information Measuring Digital outputs Settings Status Alarm menu DO1 clip 1,2 Digital inputs Control Panel DO1 clip 3,4 Digital outputs DO1 clip 5,6 Analogue inputs DO1 clip 7,8 Analogue outputs DO2 clip 1,2 Alarm menu DO3 clip 1,2 DO4 clip 1,2 DO4 clip 3,4 DO4 clip 5,6...
  • Page 85 Main menu Information Information Measuring Analogue inputs Settings Status Alarm menu AI1 clip 1,2 Digital inputs Control Panel AI2 clip 1,2 Digital outputs AI2 clip 3,4 Analogue inputs AI2 clip 5,6 Analogue outputs AI3 clip 1,2 Alarm menu AI3 clip 3,4 AI3 clip 5,6 AI4 clip 1,2 AIO1 clip 1,2...
  • Page 86 Main menu Information Information Measuring Alarm menu Settings Status Alarm menu AI pump pressure 1 Digital inputs Control Panel AI pump pressure 2 Digital outputs AI cold water press Analogue inputs AI tank pressure Analogue outputs AI temp. inlet (VP) Alarm menu AI coldwater temp outlet AI coldwater temp outlet 2...
  • Page 87 Main menu Settings Information Settings Limit monitoring Limit monitoring Alarm menu Control Limit outlettemperature Control Panel Control pump Time delay min. Control compressor Outlettemp. max STOP 32.0 °C Chillerconfiguration Outlettemp. max warning 30.0 °C Sensor configuration Outlettemp. min STOP -20.0 °C Limit tank pressure Tank max level mbar...
  • Page 88 Main menu Settings Information Settings Control Limit monitoring Alarm menu Control Thermost. Pump start Control Panel Control pump Control pump 1 pressure Control compressor Control pump 2 pressure Chillerconfiguration Control cold water temperature Sensor configuration Control cold water valve Control cooling water Control tank heater Thermost.
  • Page 89 Main menu Settings Information Settings Control pump Limit monitoring Alarm menu Control Time delay controlling sec. Control Panel Control pump Time delay sec. Control compressor Time delay pump sec. Chillerconfiguration Flow switch Sensor configuration Time delay start sec. Time delay running sec.
  • Page 90 Main menu Settings Information Settings Chillerconfiguration Limit monitoring Alarm menu Control Control number Control Panel Control pump Compressor type Control compressor Year of construction 2018 Chillerconfiguration Thermost. Pump start Sensor configuration Pump 1? Consumer Pump 1 VFD? Pump 1 flow-switch? Pump 2? Pump 2 VFD? Pump 2 flow-switch?
  • Page 91 Main menu Settings Information Settings Sensor Limit monitoring Alarm menu configuration Control AI pump pressure 1 Control Panel Control pump Measuring 4 mA -0.5 Control compressor Measuring 20 mA 10.0 Chillerconfiguration AI pump pressure 2 Sensor configuration Measuring 4 mA -0.5 Measuring 20 mA 10.0...
  • Page 92 Main menu Alarm menu Information Settings AI pump pressure 1 Alarm menu AI pump pressure 2 Control Panel AI cold water press AI tank pressure AI temp. inlet (VP) AI coldwater temp outlet AI coldwater temp outlet 2 AI cool. water temp. AI high pressure DI mpcb freecool.fan AI low pressure...
  • Page 93 Main menu Control Panel Information Settings Settings Language Alarm menu Settings Units Metric Control Panel IP address Remote maintenance Serial number DHCP Save parameters GLT data transfer Auto Load parameters Password IP address 172.017.010.070 Subnetmask 255,255,254,000 Broadcast 172.017.011.255 Gateway 172.017.011.254 Serial number Serial number 9000 - 0000...

  • Page 94: Troubleshooting

    Troubleshooting Error Display view Type of message Message description Cause of the message Troubleshooting Reaction of the chiller code HP warning Group warning Condensation pressure Condensation pressure Clean the condenser and filter. All components continue to run. has exceeded the threatens to run against the Check the function of the fan.
  • Page 95 LP STOP Group fault alarm Pressure has fallen Liquid flow through the Check liquid flow. Check the After starting the compressor, the low below the minimum evaporator is too low. function of the expansion valve. pressure is bridged. Then all allowable pressure on Refrigerant loss.
  • Page 96 EV refill time limit Group fault alarm The solenoid valve of The freshwater supply is Check the function of the Solenoid valve for tank refill closes. the tank refill does not interrupted. solenoid valve tank refill. All other components continue to run, close within the Open the shut-off devices Alarm is saved,...
  • Page 97 Outlettemp. max STOP Group fault alarm Maximum outlet No refrigeration, Check function of the chiller Chiller switches off immediately. temperature exceeded. Thermal overload. circuit, Alarm is saved. Check installed heat load. Manual reset. Outlettemp. min STOP Group fault alarm Outlet temperature is Check function of the tank Check tank heater function, Chiller switches off immediately, (Until...
  • Page 98 Press pump 1 max STOP Group fault alarm Pressure of the liquid External slide is closed, Open external gate valve, clean Pump switches off immediately. Press pump 2 max STOP outlet pressure too high Filter soiled, filter, check overflow valve Alarm is saved.
  • Page 99 AI Freecooler inlet Combined fault Sensor defective, Sensor defective, Check electrical connections of Free cooling is blocked. from Version 2.60 sensor break sensor break the sensor, All other components continue to run, or sensor short-circuit or sensor short-circuit check sensor using the Alarm is saved, (From V.260) characteristic curve Manual reset.
  • Page 100 AI pump pressure 2 Combined fault Sensor defective, Sensor defective, Check electrical connections of Pump 1 & 2 = Consumer pump from Version 2.60 sensor break sensor break the sensor, - Pump 2 switches off, or sensor short-circuit or sensor short-circuit check sensor using the - Pump 1 and compressor continue to characteristic curve...
  • Page 101 AI cool. water temp. Combined fault Sensor defective, Sensor defective, Check electrical connections of Cooling water circuit is blocked. from Version 2.60 sensor break sensor break the sensor, Refrigeration circuit goes to high or sensor short-circuit or sensor short-circuit check sensor using the pressure fault.
  • Page 102 Flow, start pump 1 Group fault alarm Flow switch did not Flow too low Check flow, check shut-off valves, Pump 1 & 2 = Consumer pump switch through after the check pump, check the setting of - Pump 1 switches off, pump start-up phase the reed contact at the flow - Pump 2 and compressor continue to...
  • Page 103 DI mpcb Pump 2 Group fault alarm Motor protection switch Motor current above the Check the motor power Pump 1 & 2 = Consumer pump has tripped permissible range, consumption, check the - Pump 2 switches off, Motor runs only on two phases, operating point, check the - Pump 1 and compressor continue to direction of rotation,...
  • Page 104 Flow, pump 2 oper. Group fault alarm Flow switch did not Flow too low Check flow, check shut-off valves, Pump 1 & 2 = Consumer pump switch through during check the setting of the reed - Pump 2 switches off, the pump operating contact at the flow monitor - Pump 1 and compressor continue to...
  • Page 105 DI high-pr. limiter Group fault alarm High-pressure limiter Unable to remove the waste Clean the condenser and filter. Pumps continue to run, has tripped. heat of the refrigeration circuit. Check the function of the fan. Compressor (KK) stops immediately Check the cooling water circuit. Fault is stored and must be reset Install the cover panels.

  • Page 106: Maintenance Intervals In Accordance With The Vdma

    Maintenance intervals in accordance with the VDMA Explanation Annual Six- Remark monthly required Compressor Optical check 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 the oil level Check the acid content of the oil (acid test)
  • Page 107 Explanation Annual Six- Remark monthly required Parts in the refrigeration circuit/water circuit Optical check for dirt, damage and corrosion Check insulation for damage Check filter dryer for blockage Replace filter dryer If com- ponents in the refrig- eration circuit replaced Check all pipes carrying refrigerant for corrosion and damage Fans...
  • Page 108 No.: Explanation Annual Six- Remark monthly required Tank / water tank Optical check for dirt, damage and corrosion Check fixing Check level Control cabinet Optical check for dirt, damage and corrosion Check fixing Check all threaded connections Check all indicator lights and error messages Check the temperature and pressure sensors are functioning properly Check the function of the motor protection...

  • Page 109: Product Registration

    Product Registration https://www.kkt-chillers-service.de/produktregistrierung.html 109 / 110 83000102.Km...

  • Page 110: Ec Declaration Of Conformity

    VII. EC Declaration of Conformity 110 / 110 83000102.Km...

This manual is also suitable for:

Compact-line cboxx 40Compact-line cboxx 50Compact-line cboxx 60Compact-line cboxx 70Compact-line cboxx 80Compact-line cboxx 90 ... Show all

Table of Contents