Related Manuals for KKT Compact-Line Series
Summary of Contents for KKT Compact-Line Series
- 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 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...
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Page 3: Introduction
KKT chillers reserves the right to change technical details without prior notice. The illustrations in this document are not to scale! As the Compact-Line units can be adapted to specific projects, this document only contains information that is generally valid for all units in the series. -
Page 4: Table Of Contents
Contents Introduction ....................................3 Product description ..............................7 1.1. Intended use ..............................7 1.2. Elements ................................. 10 1.3. Explanation of terms ............................11 Function and main components ..........................11 2.1. Compressor ..............................11 2.2. Evaporator ..............................12 2.3. Condenser ............................... 12 2.4. - Page 5 3.30. Remote control panel (accessories) ......................22 3.31. Special languages (accessories) ........................22 3.32. Wooden crate (accessories) ........................... 23 3.33. Seaworthy crate packaging (accessories) ..................... 23 3.34. Water pump redundancy ..........................23 3.35. Closed water loop ............................23 3.36. Energy meter ..............................24 3.37.
- Page 6 6.2.13. Frost protection measures ........................40 6.2.14. Flushing the cold water circuit ......................41 6.2.15. Filling..............................41 6.2.16. Venting ..............................42 6.2.17. Electrical installation ..........................42 Commissioning................................. 43 7.1. Installation checklist ............................44 Operation .................................. 44 8.1. Switching on..............................44 8.2.
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Page 7: 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 Contact details). 1.1. Intended use The cBoxX is a factory-tested, fully automatic compressor chiller. -
Page 11: 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 12: Evaporator
R410A is a fluorinated greenhouse gas consisting of the zeotropic mixture of 50% R32 and 50% 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 Contact details). -
Page 13: Temperature Sensors
2.9. Temperature sensors The temperature sensors used are equipped with a platinum measuring cell. The sensors register the temperature continuously in different places within the refrigerant and cold water circuit. The values are used to control the system. 2.10. Control unit/ main circuit board The control unit is programmed in the factory. -
Page 14: Cold Water Cycle
2.15. Cold water cycle The cold water is drawn out of the chiller's internal tank by the internal pump 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 Version without tank, with pump, and Chapter Version without tank, without pump). - Page 15 Table 6: Materials used for the non-ferrous metal-free version Component Material (cBoxX 30 – cBoxX100) Device connections (turned parts) Stainless steel Hose Synthetic rubber band Evaporator Stainless steel Tank Stainless steel Tank nozzle Stainless steel Pump Stainless steel Mechanical seal EPDM Sealing plugs yellow Polyamide PA 6...
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Page 16: 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 or provide an accordant inhibitor based on a biologic water analysis. -
Page 17: Options And Accessories
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 Contact details). Details of your machine's equipment are given in the separate summary documentation. -
Page 18: Heater For Compressor And Control Cabinet
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 temperatures. When the compressor is started up this refrigerant would be liberated from the oil as gas and make the oil foam up. -
Page 19: Higher Pressure Pump
If several consumers with different water specifications are to be cooled with one unit, the unit can also be optionally designed with a second cold water circuit. Please ask your KKT chillers contact person about this. 3.10. Additional evaporator pump The evaporator is optimised for the nominal volumetric flow rate of cold water. -
Page 20: 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. -
Page 21: High-Temperature Package
The filter is fixed in place by means of the Velcro strips in the condenser protection grid. 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 Contact details). 3.23. Levelling feet (accessories) The levelling feet are used for vibration isolation and for height adjustment. -
Page 22: Filter Assembly Group Cooling Water Circuit (Accessories)
(Chapter Level package) and a corresponding connection kit with the hydraulic balance between the tanks. The refrigerating capacity of the individual units can then be added together. Contact your KKT chillers contact to arrange the appropriate project planning for this option. -
Page 23: Wooden Crate (Accessories)
3.32. 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. -
Page 24: Energy Meter
4.00m/s ². The Anti-Vibration Kit comprises marine dampers, which are attached to the ground, and the associated attachment material. If the seismic safety requirements are higher, please contact the KKT chillers Service Team (see: Contact details). 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. -
Page 25: Hazard Warnings
4.2. Hazard warnings A number of warning labels are applied to the machine. Keep these warnings clean at all times. Damaged or missing warnings must be replaced. 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. -
Page 26: Residual Energy
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 the refrigerant and cold water circuit and electrical equipment can be very cold during operation and even for a while after. -
Page 27: Safety Devices, Guards And Safeguards
Note: After switching off the unit at the main switch, if you wait for 5 minutes before opening the unit risks due to rotational energy and electrical power can be reduced. In this case only the residual thermal energy must be considered. 4.4. -
Page 28: Flow Monitoring
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 warning"... -
Page 29: Airborne Sound Emissions
The optionally available “anti-vibration kit” (Chapter Anti-Vibration Kit) must be installed to ensure extended safety for a ground acceleration of 4.00m/s ². Should an even higher requirement for earthquake resistance be necessary, please contact the KKT chillers Service Team (see: contact details). -
Page 30: Residual Risks
4.9. Residual risks 4.9.1. 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 31: Dangerous Substances
4.10. Dangerous substances 4.10.1. 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 32: Reasonably Foreseeable Misuse
After swallowing: can cause vomiting. Have the mouth rinsed out with water and give the patient two glasses ▪ of water to drink. Get medical advice. ▪ Notes for the doctor: symptomatic treatment and assistive therapy as indicated. Fire-fighting measures: Low fire risk. -
Page 33: Information For Emergencies
Then contact the KKT chillers Service Team. If you detect a refrigerant or oil leak, proceed as described in Chapter Dangerous substances. Handling and storage The chiller is fixed on a wooden pallet in the factory for delivery. - Page 34 Figure 10: centre of gravity cBoxX 30 - 60 Figure 11: centre of gravity cBoxX 70 – 100 Figure 12: centre of gravity cBoxX 120 – 160 Figure 13: centre of gravity cBoxX 180 – 200 34 / 90 83000102.Kr...
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Page 35: 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. -
Page 36: Unpacking
5.3. Unpacking ATTENTION! Packing straps are mechanically stressed and can snap back when cut. Risk of injuries! Remove all straps, films, corner protectors and spacers carefully. Optional accessories may be located under the film. Ensure that they are not damaged. The packaging can be recycled according to the local regulations. -
Page 37: Placement And Installation
Placement and installation 6.1. Overview Several tasks are necessary to place and 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 ▪... -
Page 38: Effect Of Surrounding Air Flow
6.2.4. Effect of surrounding air flow The chiller emits heat to the surrounding area, the machine also draws in cooling air. The machine controls the quantity of cooling air automatically via the speed of the fan. Air currents surrounding the machine, such as the wind, can affect this control and endanger operation of the machine. -
Page 39: 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 cBoxX 120-200... -
Page 40: Hydraulic Installation
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 41: Flushing The Cold Water Circuit
6.2.14. Flushing the cold water circuit Contamination of external pipes and components can damage the chiller. Before the chiller is connected hydraulically with the cold water circuit this must be flushed several times. If there are dirt traps in the cold water circuit they must be cleaned after the flushing. -
Page 42: 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 43: Commissioning
Figure 18: Main supply (here: cBoxX 30 – cBoxX 100) 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 (cBoxX 30 –... -
Page 44: Installation Checklist
7.1. Installation checklist ▪ The device has been set up for at least 12 hours at >+5°C? ▪ Unit installed horizontal and stable? ▪ Any vibration damping and floor anchors installed? ▪ Spaces / clearances around the unit are adequate according to the requirements? ▪... -
Page 45: Control Panel
8.5. Control panel The following Figure 19 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 46: Start Screen
8.5.1. Start screen Figure 20: Example Start screen with tank and without alarm Figure 21: Example 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 47: Information
8.5.3. Information In the information menu you branch into different submenus, which provide an overview of the current status of the system: Measured values Values of the analogue inputs Status States of the digital inputs and outputs as well as some controller internal states Energy meter Operating hours Operating hours of the individual components of the system... -
Page 48: Control Panel
8.5.6. Control panel Customer-specific settings are stored in the Control panel menu. Language Settings IP address Serial number Save parameters Load parameters Password 8.5.7. Software update The control software can be updated via the Software Update menu. 8.5.8. Datalog export Via the Datalog export menu, the data currently stored in the control software can be exported. -
Page 49: Electronic Level Monitoring
This results in the following control sequence: • Cyclic activation of the pump every 60 min. for at least 5 min. • 1 min. after activating the pump (circulation process), the tank heater or compressor is released. • The pump switches off when the runtime has elapsed and the tank heater and compressor are no longer required by the temperature. -
Page 50: Cold Water Flow Temperature Control
The pressure and flow monitoring takes place with two timing elements: • Delay at start; the pressure or the flow monitoring does not trigger an alarm. • Delay during operation; in order to ignore short-term fluctuations in pressure or flow, the alarm is delayed. When the system is switched off the temperature control is locked immediately and therefore the compressor is switched off. -
Page 51: 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. If no intake pressure has built up by the time the time expires the low-pressure fault alarm is triggered. -
Page 52: Multi-Function Output
8.8.3. Multi-function output With the multi-function output it is possible to pick off relevant messages (alarm/warning) at an additional potential-free contact DO4 and to display them centrally. Display selection Relay energised if: Alert 0=ok an alarm is queued Alert 1=ok no alarm is queued Warn 0=ok a warning is queued... -
Page 53: Cleaning
(Chapter Filter assembly group coolant circuit) 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 (Contact details). -
Page 54: Spare Parts
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 (Contact details). -
Page 55: 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 (Contact details). -
Page 56: Menu Navigation
Menu navigation Attention: The parameters specified here serve only as an example. For the parameterization relevant to your chiller, please refer to the parameter set included in the unit. Main menu Information Information Settings Measuring Measuring Alarm menu Energy meter Pressure pump 1 Control Panel Operating hours... - Page 57 Main menu Information Information Settings Measuring Alarm menu Status Status Control Panel Energy meter DI resetswitch Software update Operating hours DI remote start 1 Datalog export Digital inputs DI remote start 2 Datalog stop Digital outputs DI phase monitoring Analogue inputs DI mpcb Pump 1 Analogue outputs DI flow pump 1...
- Page 58 Main menu Information Information Settings Measuring Alarm menu Status Control Panel Energy meter Energy meter Software update Operating hours U L1 N Datalog export Digital inputs U L2 N Datalog stop Digital outputs U L3 N Analogue inputs I L1 Analogue outputs P L1 N Software status...
- Page 59 Main menu Information Information Settings Measuring Alarm menu Status Control Panel Energy meter Software update Operating hours Datalog export Digital inputs Digital inputs Datalog stop Digital outputs DI1 clip 1,2 Analogue inputs DI1 clip 3,4 Analogue outputs DI1 clip 5,6 Software status DI1 clip 7,8 Test point 1...
- Page 60 Main menu Information Information Settings Measuring Alarm menu Status Control Panel Energy meter Software update Operating hours Datalog export Digital inputs Datalog stop Digital outputs Analogue inputs Analogue inputs Analogue outputs AI1 clip 1,2 Inc. Software status AI1 clip 1,4 Inc.
- Page 61 Main menu Information Information Settings Measuring Alarm menu Status Control Panel Energy meter Software update Operating hours Datalog export Digital inputs Datalog stop Digital outputs Analogue inputs Analogue outputs Software status Software status Test point 1 Display 3.24 Error memory Controller ES910 3.24 Test point 1...
- Page 62 Main menu Information Settings Settings Alarm menu Limit monitoring Limit monitoring Control Panel Control Limit temperature cooling water Software update Control pump Time delay Datalog export Control compressor Outlet temp. Datalog stop Chiller configuration Running delay Sensor configuration Outlet max STOP 32.0 °C Outlet max warning...
- Page 63 Settings Limit monitoring Control Control Control pump Thermost. pump start Thermost. pump start Control compressor Control pump 1 pressure Interval Basics Control pump 2 pressure Time delay Chiller configuration Control cold water Runtime temperature Sensor configuration Control hot gas bypass Minimum Control cold water valve Setpoint...
- Page 64 Settings Limit monitoring Control Control Control pump Thermost. pump start Control compressor Control pump 1 pressure Basics Control pump 2 pressure Chiller configuration Control cold water Control hot gas bypass temperature Sensor configuration Control hot gas bypass Start relief sec. Control cold water valve Output control 2point Control tank heating...
- Page 65 Settings Limit monitoring Control Control Control pump Thermost. pump start Control compressor Control pump 1 pressure Basics Control cold water temperature Chiller configuration Control hot gas bypass Sensor configuration Control cold water valve Control tank heating Control EEV superheating Control condensation Control condensation Control cooling water Control cooling water...
- Page 66 Settings Limit monitoring Control Control Control pump Thermost. pump start Control compressor Control pump 1 pressure Basics Control cold water temperature Chiller configuration Control cold water temperature Sensor configuration Control hot gas bypass Control cold water valve Control tank heating Control condensation Control cooling water Control ESS free cooling...
- Page 67 Main menu Information Settings Settings Alarm menu Limit monitoring Control Panel Control Software update Control pump Control pump Datalog export Control compressor Delay control sec. Datalog stop Basics After-run time sec. Chiller configuration Pump after-run time sec. Sensor configuration Switch flow sensor Delay start sec, Delay running...
- Page 68 Main menu Information Settings Settings Alarm menu Limit monitoring Control Panel Control Software update Control pump Datalog export Control compressor Control compressor Datalog stop Basics Compressor type Chiller configuration Year of construction 2018 Sensor configuration Time between 2 starts sec. Min timeout sec.
- Page 69 Main menu Information Settings Settings Alarm menu Limit monitoring Control Panel Control Software update Control pump Datalog export Control compressor Datalog stop Basics Chiller configuration Chiller configuration Sensor configuration Number of compressors Heat exchanger Steel Thermost. Pump start Pump 1? Consumer Pump 1 VFD? Pump 1 flow?
- Page 70 Main menu Information Settings Settings Alarm menu Limit monitoring Control Panel Control Software update Control pump Datalog export Control compressor Datalog stop Basics Chiller configuration Sensor configuration Sensor configuration AI pump pressure 1 Measuring 4 mA -0.5 Measuring 20 mA 10.0 AI pump pressure 2 Measuring 4 mA...
- Page 71 Main menu Information Settings Alarm menu Alarm menu Control Panel AI pump pressure 1 Temp. cooling water on max STOP Software update AI pump pressure 2 Temp. cooling water on min STOP Datalog export AI cold water pressure evaporator Temp. cooling water on max STOP Datalog stop AI press.
- Page 72 Main menu Information Settings Alarm menu Control Panel Control Panel Software update Language Language Datalog export Settings Deutsch Datalog stop IP address English Serial number Français Save parameters Română Load parameters Čeština Password Magyarul Dansk Eesti Português Lietuviskai Polski Slovenščina Svenska Suomi Türkçe...
- Page 73 Main menu Information Settings Alarm menu Control Panel Control Panel Software update Language Datalog export Settings Datalog stop IP address Serial number Serial number Save parameters Entry of serial number Load parameters 9000-0000 Password Result Saving to controller:OK Saving to USB:OK Load parameters XXXXXXXX.par Password...
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Page 88: Maintenance Intervals In Accordance With The Vdma
III. 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... - Page 89 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 are replaced Check all pipes carrying refrigerant for corrosion and damage...
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Page 90: Product Registration
All documents such as operating instructions, diagrams, circuit plans, system log are present Rating plate and labels are clearly legible Battery - time/date Battery Every 5 years Leakage control of the refrigeration circuit in accordance with (EC) 517/2014 Product registration https://www.kkt-chillers-service.de/produktregistrierung.html 90 / 90 83000102.Kr...
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