KKT chillers cBoxX 40 User manual

Compact-Line Healthcare
Operating instructions
cBoxX 40
cBoxX 60
cBoxX 70
cBoxX 80
cBoxX 100
cBoxX 120
cBoxX 160
cBoxX 1
8
0

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Table 1: Contact details
Manufacturer
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone]
F [phone]
E [e-mail]
W www.kkt-chillers.com
Service
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone] *
F [phone]
E [e-mail]
W www.kkt-chillers.com *
Service USA
KKT chillers, Inc.
765 Dillon Drive
Wood Dale
IL 60191
TF [phone] *
F [phone]
E [e-mail] *
Service East Asia
KKT chillers East Asia
Sales and Service Office
5-1-D, No. 333 Xingpu Road
Modern Industrial Park
Suzhou 215021, Jiangsu Province, P.R.C.
S [phone]*
F [phone]
E [e-mail] *
The operating instructions in digital form can be requested under (E [e-mail])

3 / 97 83001602.g
Introduction
These operating instructions have been drawn up by KKT chillers. They contain all important information and
instructions for the installation and safe operation of the chiller. It also contains suggestions on how to
prevent or correct faults.
Please take enough time to carefully read this instruction manual and to process all the information that it
contains. For further questions, please contact the KKT chillers Service Team by means of the
aforementioned contact details.
If properly used for its intended use and correctly maintained, the chiller ensures sustained, fault-free
operation. The methods and procedures described in this manual were designed to help you identify
problems at an early state and to initiate corresponding countermeasures.
By observing the described maintenance program, you ensure that the reliability and safety of the machine
is maintained. Plus this keeps operating costs low and increases the service life of the components.
To ensure that the performance of your chiller is not impaired, we recommend that you only use original spare
parts from KKT chillers. By doing so, you ensure the reliability and quality of the machine.
KKT chillers reserves the right to change technical data without prior announcement. Illustrations in this
document are not set to scale!
As the devices of the Compact-Line can be adapted project specifically, this document contains only
information that is of general relevance for all devices of the series.
The separate documentation "Installation guidelines" is part of this operating manual. The information it
contains must be observed and specifications must be complied with.
All project-specific data is enclosed with the unit in separate summary documentation.
 Machine configuration
 Parameter list
 P&I diagram
 Pump characteristic curve(s)
 Circuit diagram
 All other project-specific details
ATTENTION! A black exclamation mark on a yellow background in a triangle indicates
important information and instructions to which you must pay particular attention and
must always follow.

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Contents
Introduction ............................................................................................................................................. 3
1. Product description ................................................................................................................... 8
1.1. Intended use ...................................................................................................................... 8
1.2. Technical data .................................................................................................................... 9
1.3. Elements ........................................................................................................................... 16
1.4. Explanation of terms ........................................................................................................ 17
2. Function and main components ............................................................................................. 17
2.1. Compressor ...................................................................................................................... 18
2.2. Evaporator ........................................................................................................................ 18
2.3. Condenser ........................................................................................................................ 18
2.4. Expansion valve ............................................................................................................... 18
2.5. Refrigerant ........................................................................................................................ 18
2.6. Oil ...................................................................................................................................... 18
2.7. Filter dryer ........................................................................................................................ 19
2.8. Pressure sensors ............................................................................................................. 19
2.9. Temperature sensors....................................................................................................... 19
2.10. Control unit / main circuit board ..................................................................................... 19
2.11. Display .............................................................................................................................. 19
2.12. Control cabinet ................................................................................................................. 19
2.13. Pump ................................................................................................................................. 20
2.14. Fan .................................................................................................................................... 20
2.15. Closed cold water circuit ................................................................................................. 20
2.16. Materials used in the water circuit ................................................................................. 21
2.17. Water quality .................................................................................................................... 22
2.18. Permitted coolant media ................................................................................................. 23
3. Options and accessories ......................................................................................................... 23
3.1. Heater for the compressor and control cabinet ............................................................. 23
3.2. Insulating cold pipes ........................................................................................................ 24
3.3. Pump redundancy ............................................................................................................ 24
3.4. Phase monitoring ............................................................................................................. 24
3.5. Hot gas bypass for output control <1K........................................................................... 24
3.6. Low-temperature package (ambient temperature < -25 ° C) ....................................... 24
3.7. Levelling feet (accessories) ............................................................................................. 24
3.8. Filter assembly group coolant circuit (accessories) ....................................................... 25
3.9. Anybus-Gateway (accessories) ........................................................................................ 25
3.10. Remote control panel (accessories) ............................................................................... 25
3.11. Special languages (accessories) ..................................................................................... 25
3.12. Seaworthy crate packaging (accessories) ...................................................................... 26
3.13. Earthquake kit (accessories) ........................................................................................... 26
3.14. CIP Chiller interface panel (accessories) ........................................................................ 27
4. Safety........................................................................................................................................ 27
4.1. General information ......................................................................................................... 27
4.2. Hazard warnings .............................................................................................................. 27

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4.3. Residual energy................................................................................................................ 30
4.4. Safety devices, guards and safeguards ......................................................................... 31
4.4.1. High-pressure limiter ................................................................................................ 31
4.4.2. High-pressure monitoring ........................................................................................ 32
4.4.3. Low-pressure monitoring ......................................................................................... 32
4.4.4. Flow monitoring ........................................................................................................ 32
4.4.5. Personal protective equipment when operating the machine .............................. 32
4.5. Personal protective equipment for servicing work ........................................................ 33
4.5.1. Electronic level monitoring ...................................................................................... 33
4.5.2. Switching the chiller On/off ..................................................................................... 33
4.5.3. Cold water flow temperature control ...................................................................... 34
4.5.4. Compressor control .................................................................................................. 35
4.5.5. Fan speed control .................................................................................................... 36
4.5.6. Electronic expansion valve control .......................................................................... 36
4.5.7. Temperature limit monitoring .................................................................................. 36
4.5.8. Group fault alarm ..................................................................................................... 36
4.6. Execution types ................................................................................................................ 36
4.6.1. ECO mode ................................................................................................................. 36
4.6.2. Comfort mode ........................................................................................................... 36
4.7. Airborne sound emissions ............................................................................................... 37
4.8. Notes on reducing noise and vibration ........................................................................... 38
4.8.1. Noise ......................................................................................................................... 38
4.8.2. Vibration .................................................................................................................... 38
4.9. Residual risks ................................................................................................................... 38
4.9.1. Electrical ................................................................................................................... 38
4.9.2. Mechanical ............................................................................................................... 38
4.9.3. Chemical ................................................................................................................... 38
4.9.4. Other ......................................................................................................................... 39
4.10. Dangerous substances .................................................................................................... 39
4.10.1. Refrigerant R410A ................................................................................................... 39
4.10.2. Öl POE 160SZ ........................................................................................................... 40
4.11. Reasonably foreseeable misuse ..................................................................................... 41
4.12. Information for emergencies ........................................................................................... 41
5. Handling and storage .............................................................................................................. 41
5.1. Dangerous goods ............................................................................................................. 41
5.2. Transport .......................................................................................................................... 42
5.2.1. Forklift truck ............................................................................................................. 43
5.3. Unpacking ......................................................................................................................... 44
5.4. Storage ............................................................................................................................. 44
6. Installation ............................................................................................................................... 45
6.1. Overview ........................................................................................................................... 45
6.2. Installation site ................................................................................................................. 45
6.2.1. General information ................................................................................................. 45
6.2.2. Minimum room volume ............................................................................................ 45
6.2.3. Ambient temperature ............................................................................................... 46

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6.2.4. Effect of surrounding air flow .................................................................................. 46
6.2.5. Minimum clearances ............................................................................................... 46
6.2.6. Surface and foundation ........................................................................................... 47
6.2.7. Stability ..................................................................................................................... 47
6.2.8. Levelling .................................................................................................................... 47
6.2.9. Vibration isolation .................................................................................................... 47
6.2.10. Installation ................................................................................................................ 47
6.2.11. Hydraulic installation ............................................................................................... 48
6.2.12. Flushing the cold water circuit ................................................................................ 48
6.2.13. Filling ......................................................................................................................... 48
6.2.14. Venting ...................................................................................................................... 49
6.2.15. Electrical installation ................................................................................................ 49
7. Commissioning ........................................................................................................................ 50
7.1. Installation checklist ........................................................................................................ 51
8. Operation.................................................................................................................................. 51
8.1. Switching on ..................................................................................................................... 51
8.2. Selecting the operating mode ......................................................................................... 51
8.3. External release ............................................................................................................... 52
8.4. Control .............................................................................................................................. 52
8.5. Control panel .................................................................................................................... 52
8.5.1. Start screen .............................................................................................................. 53
8.5.2. Main menu ................................................................................................................ 54
8.5.3. Information ............................................................................................................... 54
8.5.4. Settings ..................................................................................................................... 54
8.5.5. Alarm menu .............................................................................................................. 55
8.5.6. Control panel ............................................................................................................ 55
8.5.7. Software update ....................................................................................................... 55
8.5.8. Datalog export .......................................................................................................... 55
8.5.9. Datalog stop ............................................................................................................. 55
8.6. Parameters ....................................................................................................................... 55
8.7. Controller description ...................................................................................................... 56
8.7.1. Thermostatic pump start ......................................................................................... 56
8.7.2. Electronic level monitoring ...................................................................................... 56
8.7.3. Switching the chiller On/off ..................................................................................... 56
8.7.4. Cold water flow temperature control ...................................................................... 57
8.7.5. Compressor control .................................................................................................. 58
8.7.6. Fan speed control .................................................................................................... 58
8.7.7. Electronic expansion valve control .......................................................................... 58
8.7.8. Temperature limit monitoring .................................................................................. 58
8.7.9. Group fault alarm ..................................................................................................... 59
8.8. Execution types ................................................................................................................ 59
8.8.1. ECO mode ................................................................................................................. 59
8.8.2. Comfort mode ........................................................................................................... 59
9. Cleaning ................................................................................................................................... 59
9.1. Air filter mat ...................................................................................................................... 59

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9.2. Condenser ........................................................................................................................ 59
9.3. Water filter ........................................................................................................................ 59
9.4. Complete cleaning of the cold water circuit ................................................................... 59
10. Service ...................................................................................................................................... 60
10.1. Maintenance .................................................................................................................... 60
10.2. Fault correction ................................................................................................................ 60
10.3. Spare parts ....................................................................................................................... 60
11. Taking out of service ............................................................................................................... 61
11.1. Draining ............................................................................................................................ 61
12. Recycling .................................................................................................................................. 62
13. Products, solutions and services ............................................................................................ 62
I. Menu navigation ...................................................................................................................... 63
II. Troubleshooting ....................................................................................................................... 81
III. Maintenance intervals in accordance with the VDMA ........................................................... 95
IV. Product registration ................................................................................................................. 97

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1. 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. Should you have any
further questions concerning 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. The machine is only used for cooling liquids
in accordance with EN 378-1. A sufficient supply of cooling air must be provided. Only approved liquids may
be used. The cBoxX corresponds to protection class IP 54 (when the housing is closed) and is suitable for
both indoor and outdoor installation (observe option packages).
The operator is responsible for complying with the specified operating, servicing and maintenance conditions
according to these operating instructions.
The owner of the chiller, not the manufacturer, is responsible and liable for all personal injuries and damage
to property caused by improper use of the unit (misuse).
Table 2 contains the general safety instructions of the chiller. These instructions are attached to the machine
in a clear and readily visible position. A complete description of all hazard warnings is given in Chapter 4.2
Hazard warnings.
Table 2: Safety instructions
Note and follow the instructions for use!
Before opening the machine, disconnect the machine from the power supply. After
disconnecting the machine from the power supply, always wait for at least 5 minutes
before opening it.
Beware of dangerous electrical voltage! If the machine is only turned off by means of the
main switch, some of the terminals in the control cabinet will still be under dangerous
voltage.

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1.2. Technical data
Table 3: Technical data
Chillertyp
cBoxX 40
cBoxX 40
cBoxX 40
SAP
-
Nummer
909040-00743 909040-00744 909040-00819
Refrigerating capacity
@ tw2=13°C / tu=50°C / 4,0 m3/h -
22 kW
Refrigerating capacity
@ tw2=11°C / tu=45°C / 4,1 m3/h 27kW
-
Refrigerating capacity
@ tw2=18°C / tu=45°C/ 2,4 m3/h 34kW
-
Ambient temperature range
-
25
-
+50°C
-
40
-
+50°C
-
25
-
+50°C
Hermetically sealed refrigeration circuit
no
no
Refrigerant
R410A
R410A
GWP
2088
2088
Refrigerant capacity
6
6
CO2 equivalent
12,5 t CO2
12,5 t CO2
Cooling medium
Water with
35Vol% AFN
Water with
50Vol% AFN
Water with
35Vol% AFN
Liquid feed temperature
+7°C…+25°C
+9°C…+25°C
Target
constancy at full load
+/
-
1°K
+/
-
2K
Flow rate 1 at free pump pressure (min)
4.1 m3/h at 3.0bar
4
,0 m3/h at 2,8bar
Flow rate 2 at free pump pressure (min)
2.4 m3/h at 5.5bar
-
Operating voltage
(+/-10%)
460V/3/60Hz
460V/3/60Hz
400V/3/50Hz
Protection class Electrical cabinet
IP54
IP54
Air flow rate (max.)
20.000 m³/h
12.600 m³/h
Sound pressure level at 5 m distance
69 dB(A)
55 dB(A)
Height Chiller
2030 mm
2030 mm
Width Chiller
830 mm
830 mm
Length Chiller
1240 mm
1240 mm
Socket
dimensions (Weight / Length)
796 mm / 1186 mm
796 mm / 1186 mm
Net weight without cooling medium
475 kg
480 kg
475 kg
Pumps Quantity
2
2
2
Certificates
ETL/CSA
ETL/CSA
CE

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Chillertyp
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
SAP
-
Nummer
909060-00238 909060-00239 909060-00241 909060-00242 909060-00243 909060-00244 909060-00377 909060-00424
Refrigerating capacity
@ tw2=13°C / tu=45°C
41kW 41kW 41kW 41kW 41kW 41kW 41kW 41kW
Ambient temperature range
-
25
-
+45°C
-
25
-
+45°C
-
25
-
+45°C
-
25
-
+45°C
-
25
-
+45°C
-
40
-
+45°C
-
25
-
+45°C
-
25
-
+45°C
Hermetically sealed refrigeration circuit
no
Refrigerant
R410A
GWP
2088
Refrigerant capacity
7kg
CO2 equivalent
14,6 t CO2
Cooling medium
Water with
35Vol% AFN
Water with
35Vol% AFN
Water with
35Vol% AFN
Water with
35Vol% AFN
Water with
35Vol% AFN
Water with
50Vol% AFN
Water with
35Vol% AFN
Water with
35Vol% AFN
Liquid feed temperature
13°C
Target constancy
+/
-
2K
Coolant circulation
5,0 m³/h
Free pump
pressure (min)
2,8bar
2,8bar
2,8bar
2,8bar
5bar
5bar
2,8bar
5bar
Operating voltage
(+/-10%)
400V/3/50Hz
400V/3/50Hz
400V/3/60Hz
460V/3/60Hz
460V/3/60Hz
460V/3/60Hz
400V/3/60Hz
460V/3/60Hz
Protection class Electrical cabinet
IP54
Air flow rate
(max.)
20.000 m³/h
Sound pressure level at 5 m distance
69 dB(A)
Height Chiller
2030 mm
Width Chiller
830 mm
Length Chiller
1240 mm
Socket dimensions
(Weight / Length)
796 mm / 1186 mm
Net weight without cooling medium
515 kg
540 kg
515 kg
540 kg
540 kg
540 kg
540 kg
584 kg
Pumps Quantity
1
2
1
2
2
2
2
2
Certificates
CE
CE
CE
CE
CE/ETL/CSA
CE/ ETL /CSA
CE
CE/ ETL /CSA/
seismic

11 / 97 83001602.g
Chillertyp
cBoxX 70
cBoxX 70
cBoxX 70
cBoxX 70
cBoxX 70
cBoxX 70
cBoxX 70
SAP
-
Nummer
909070-00245 909070-00246 909070-00247 909070-00248 909070-00249 909070-00255 909070-00425
Refrigerating capacity
@ tw2=13°C / tu=45°C 45kW 45kW 45kW
45kW 45kW 45kW 45kW
Ambient temperature range
-
25
-
+55°C
-
25
-
+55°C
-
25
-
+55°C
-
25
-
+55°C
-
25
-
+55°C
-
25
-
+55°C
-
25
-
+55°C
Hermetically sealed refrigeration
circuit
no
Refrigerant
R410A
GWP
2088
Refrigerant capacity
8kg
CO2 equivalent
16,7 t CO2
Cooling medium
Water with
35Vol%
AFN
Water with
35Vol%
AFN
Water with
35Vol%
AFN
Water with
35Vol%
AFN
Water with
35Vol%
AFN
Water with
35Vol%
AFN
Water with
35Vol%
AFN
Liquid feed temperature
13°C
Target constancy
+/
-
2K
Coolant circulation
5,0 m³/h
Free pump pressure (min)
2,8bar
2,8bar
2,8bar
2,8bar
5bar
2,8bar
5bar
Operating voltage
(+/-10%)
400V/3/50
H
z
400V/3/50Hz
400V/3/60Hz
460V/3/60Hz
460V/3/60Hz
400V/3/60Hz
460V/3/60Hz
Protection class Electrical cabinet
IP54
Air flow rate (max.)
36.500 m³/h
Sound pressure level at 5 m distance
71 dB(A)
Height Chiller
2030 mm
Width Chiller
830 mm
Length Chiller
1840 mm
Socket dimensions
(Weight / Length)
796 mm / 1786 mm
Net weight without cooling medium
665 kg
680 kg
680 kg
680 kg
680 kg
665 kg
724 kg
Pumps Quantity
1
2
2
2
2
1
2
Certificates
CE
CE
CE
CE
CE/ ETL /CSA
CE
CE/ ETL /CSA/
seismic

12 / 97 83001602.g
Chillertyp
cBoxX 80
cBoxX 80
SAP
-
Nummer
909080-00284 909080-00529
Refrigerating capacity
@ tw2=9°C / tu=45°C
50kW 59 kW
Ambient temperature range
-
25
-
+5
0
°C
-
25
-
+50°C
Hermetically sealed refrigeration
circuit
no
no
Refrigerant
R410A
GWP
2088
Refrigerant capacity
8kg
8kg
CO2 equivalent
16,7 t CO2
16,7 t CO2
Cooling medium
Water with 40Vol% AFN
Water with 40Vol% AFN
Liquid feed temperature
9
Target constancy
+/
-
2K
Coolant circulation
7,8 m³/h 7,2 m³/h
Free
pump pressure (min)
4,5 bar
5,5 bar
Operating voltage
(+/-10%)
400V/3/50Hz
400V/3/60Hz
Protection class
IP54
Air flow rate (max.)
36.500 m³/h
36.500 m³/h
Sound pressure level at 5 m distance
71 dB(A)
71 dB(A)
Height Chiller
2030 mm
Width
Chiller
830 mm
Length Chiller
1840 mm
Socket dimensions
(Weight / Length)
796 mm / 1786 mm
Net weight without cooling medium
680 kg
680 kg
Pumps Quantity
2
2
Certificates
CE
CE

13 / 97 83001602.g
Chillertyp
cBoxX 100
cBoxX 100
cBoxX 100
cBoxX 100
cBoxX 100
SAP
-
Nummer
909100-00468 909100-00469 909100-00470 909100-00218 909100-00510
Refrigerating capacity
@ tw2=9°C / tu=45°C
63 kW 63 kW 63 kW 60 kW 73 kW
Ambient temperature range
-
25
-
+50°C
-
25
-
+50°C
-
40
-
+50°C
-
25
-
+50°C
-
25
-
+50°C
Hermetically sealed refrigeration
circuit
no
Refrigerant
R410A
GWP
2088
Refrigerant capacity
8
8
8
8
8
CO2 equivalent
16,7 t CO2
16,7 t CO2
16,7 t CO2
16,7 t CO2
16,7 t CO2
Cooling medium
Water with
35Vol% AFN
Water with
35Vol% AFN
Water with
50
Vol% AFN
Water with
40Vol% AFN
Water with
40Vol% AFN
Liquid feed temperature
9°C
Target constancy
+/
-
2K
Coolant circulation
6,0 m³/h 6,0 m³/h 6,0 m³/h 7,8 m³/h 9,1 m³/h
Free pump pressure (min)
5,0 bar
5,0 bar
5,0 bar
5,9 bar
5,5 bar
Operating voltage
(+/-10%)
460V
/3/60H
z
400V/3/50Hz
400V/3/
6
0Hz
Protection class
IP54
Air flow rate (max.)
36.500 m³/h
36.500 m³/h
36.500 m³/h
36.500 m³/h
36.500 m³/h
Sound pressure level at 5 m distance
71 dB(A)
71 dB(A)
71 dB(A)
71 dB(A)
71 dB(A)
Height Chiller
2030 mm
Width Chiller
830 mm
Length Chiller
1840 mm
Socket dimensions
(Weight / Length)
796 mm / 1786 mm
Net weight without cooling medium
701 kg
751 kg
701 kg
. 751 kg
751 kg
Pumps Quantity
2
2
2
2
2
Certificates
ETL
/CSA
ETL
/CSA/seismic
ETL
/CSA
CE
CE

14 / 97 83001602.g
Chillertyp
cBoxX 120
cBoxX 120
cBoxX 120
cBoxX 120
SAP
-
Nummer
909120-00313 909120-00528 909120-00471 909120-00472
Refrigerating capacity
@ tw2=9°C / tu=45°C
74 kW 88 kW 75 kW 75 kW
Ambient temperature range
-
25
-
+50°C
-
25
-
+50°C
-
25
-
+50°C
-
40
-
+50°C
Hermetically sealed refrigeration circuit
no
Refrigerant
R410A
GWP
2088
Refrigerant capacity
17
17
17
17
CO2 equivalent
35,5 t CO2
35,5 t CO2
35,5 t CO2
35,5 t CO2
Cooling medium
Wa
ter
with
40Vol% AFN
Water with 40Vol% AFN
Water with
35Vol% AFN
Water with
50Vol% AFN
Liquid feed temperature
9°C
Target constancy
+/
-
2K
Coolant circulation
7,8 m³/h 7,8 m³/h 7,8 m³/h 7,8 m³/h
Free pump pressure (min)
5,5 bar
5,5 bar
5,5 bar
5,5 bar
Operating
voltage
(+/-10%)
400V/3/50Hz
400V/3/60Hz
460V/3/60Hz
460V/3/60Hz
Protection class
IP54
Air flow rate (max.)
45.550 m³/h
45.550 m³/h
45.550 m³/h
45.550 m³/h
Sound pressure level at 5 m distance
66 dB(A)
66 dB(A)
66 dB(A)
66 dB(A)
Height Chiller
2030
mm
Width Chiller
1100
mm
Length Chiller
2665 mm
Socket dimensions
(Weight / Length
)
1086 mm / 2569 mm
Net weight without cooling medium
1046 kg
1046 kg
1046 kg
1046 kg
Pumps Quantity
2
2
2
2
Certificates
CE
CE
ETL
/CSA
ETL
/CSA

15 / 97 83001602.g
Chillertyp
cBoxX 160 cBoxX 180
SAP
-
Nummer
909160-00690 909180-00701
Refrigerating capacity
@ tw2=9°C / tu=45°C
94 kW 100 kW
Ambient temperature range
-
25
-
+50°C
-
25
-
+5
0
°C
Hermetically sealed refrigeration
circuit
no
no
Refrigerant
R410A
GWP
2088
Refrigerant capacity
17kg
23,5kg
CO2 equivalent
35,5 t CO2
49,1 t CO2
Cooling medium
Water with 40Vol% AFN
Water with 40Vol% AFN
Liquid feed temperature
9
Target constancy
+/
-
2K
Coolant circulation
7,4 m³/h 7,4 m³/h
Free pump pressure
(min)
5 bar
5 bar
Operating voltage
(+/-10%)
400V/3/60Hz
400V/3/50Hz
Protection class
IP54
Air flow rate (max.)
45.550
m³/h
49
.
100
m³/h
Sound pressure level at 5 m distance
67
dB(A)
67
dB(A)
Height Chiller
2030 mm
Width Chiller
1200
mm
Length
Chiller
2665
mm
3965
mm
Socket dimensions
(Weight / Length)
1086 mm / 2569 mm
1086 mm / 3894 mm
Net weight without cooling medium
1200 kg
1300 kg
Pumps Quantity
2
2
Certificates
CE
CE

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1.3. Elements
Figure 1: Elements
1
Cover panel operating side top
a
Safety instructions
2
Cover panel operating side bottom
b
Water connections
3
Cover panel service side top
c
Nameplate
4
Cover panel service side bottom
d
Display
5
Cover panel condenser protection grilles
e
Main switch
6
Cover panels hydraulics
1
2
3
4
5
6
a
b
c
d
e

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1.4. 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.
Cold water circuit
Process
circuit and chiller in hydraulic piping.
Cold water
Refrigerant in cold water circuit.
Cooling air
Heat absorbing ambient air drawn through the machine.
Net weight
Machine ready for operation without cooling water.
Gross weight
Machine ready for
operation with cooling water.
2. Function and main components
The chiller consists of the main components compressor, condenser, expansion valve, evaporator, which are
arranged in a circuit (Figure 2). 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.
Figure 2: refrigeration diagram
In addition, diverse pressure and temperature sensors, a control unit, a high-pressure switch, one or more
pumps and one or more fans are also installed for control and operation of the chiller.
Compressor
Condenser and fan
Evaporator
Expansion
valve
Heat
Cold

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2.1. Compressor
The compressor generates the needed pressure difference for evaporation and condensation between heat
sink and heat source in the refrigerant circuit. Vaporised refrigerant coming from the evaporator is drawn in
and compressed in the compressor to the condensing pressure.
The compressors used work on the basis of the scroll principle. Scroll compressors are maintenance-free,
quiet and have a very high degree of efficiency.
The flow temperature is controlled by switching on or off one or more compressors (see 8.7.5 Compressor
control). Sequential changeover ensures that all compressors are loaded uniformly.
2.2. Evaporator
The evaporator is a plate heat exchanger that transfer heat from the cold water to the refrigerant. In order
for the transfer of heat to take place, the refrigerant in the evaporator must have a lower temperature than
the cold water and changes its physical state upon heat absorption from liquid to gaseous.
If the cold water is polluted, deposits can accumulate on the transfer surfaces of the evaporator. This impairs
the transfer of heat to the refrigerant and has negative effects on the refrigerating capacity of the machine.
Therefore always make sure to use the prescribed water quality and do not make use of any other additives
than prescribed.
2.3. Condenser
The condenser is a microchannel heat exchanger that transfers heat from the refrigerant to the ambient air.
In order for the transfer of heat to take place, the refrigerant in the condenser must have a higher temperature
than the drawn-in ambient air changes its physical state upon heat dissipation from gaseous to liquid.
Contaminated cooling air can cause deposits to accumulate on the condenser surface. This impairs the
transfer of the heat to the refrigerant. This restricts the operating limit of the machine and reduces the
refrigerating capacity of the machine. How to clean the condenser is described in Chapter 9 Cleaning. If you
operate your chiller in an environment contaminated with dust or oil vapours, make use of the optionally
available air filter mat (see 9.1: Air filter mat).
2.4. Expansion valve
The expansion valve regulates the admission of liquid refrigerant to the evaporator and restricts the pressure
of the refrigerant before entering the evaporator. In this process, the refrigerant cools down to the evaporating
temperature.
The expansion valve used in the machine is regulated electronically. The electronic regulation ensures that
the evaporator is constantly optimally supplied with refrigerant. This improves the COP (coefficient of
performance) and reduces pressure fluctuations in the refrigeration circuit.
2.5. Refrigerant
The refrigerant R410A circulates in the refrigeration circuit. It "transports" the heat from the evaporator the
condenser and continuously changes its physical state in doing so.
R410A is a fluorinated greenhouse gas consists of the zeotropic mixture 50% R32 and 50% 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 requested from our KKT chillers
Service Team (see: Contact details).
2.6. Oil
The compressor components subject to friction are lubricated by oil that is added to the refrigerant at the
factory. Polyolester-160SZ is used for this purpose. The oil is soluble in the refrigerant and distributes itself
with it throughout the entire refrigeration circuit. The total oil quantity of the specific unit can be taken from

19 / 97 83000102.Ko
the technical data. A corresponding safety data sheet can be requested from our KKT chillers Service Team
(see: Contact details).
2.7. Filter dryer
The task of the filter dryer is to absorb any contamination or moisture from the cooling circuit. Both refrigerant
and oil are hygroscopic. When installing the refrigeration circuit, the oil may absorb moisture. This moisture
can lead to corrosion and impair the cooling process. The filter dryer bonds this moisture and also has a
mechanical filter effect. If work is being performed on the refrigeration circuit, for which it has to be opened,
the filter dryer must be replaced.
2.8. Pressure sensors
The pressure sensors used are compact pressure transmitters with piezoresistive measurement cell. The
sensors continuously record the system pressure at various locations in the refrigerant and cold water
circuits. The values are used to regulate the system and for visualisation on the controller display.
2.9. Temperature sensors
The temperature sensors employed are equipped with a platinum measurement cell. The sensors
continuously record the temperature at various locations in the refrigerant and cold water circuits. The values
are used to control the system.
2.10. Control unit / main circuit board
The control unit is a control that is programmed at the factory. This is where all system-technical
measurement values and information come together. In addition, the electrical components are controlled
via algorithms.
2.11. Display
The display is used to visualise the necessary information and processes of the system for the user. Plus, it
can be used to make entries. The display communicates with the control unit. Further information on
operation can be found in Chapter 8.5 Control panel.
2.12. Control cabinet
The control cabinet conforms to the requirements of EN 60204 and contains the electrical and electronic
components for controlling the chiller. The control cabinet can be accessed by removing the operating panel.
To prevent damage to the main switch when disassembling the side panel, it must be tilted at least 10 cm
before it can be removed. It can be opened by means of a standard two-way key. A corresponding circuit
diagram is included with the device.
Figure 3: Demounting the side panel

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2.13. Pump
The pump of the chiller provides for the necessary circulation of the cold water.
2.14. Fan
The fan draws in the cooling air from the environment via the condenser and discharges the heated air
upward from the chiller. To prevent injuries, the fan is protected against accidental contact by protective
grilles. The fan's speed is variable and is regulated from the main circuit board. The speed of the fan is
essentially determined by the condensing pressure. The fan is protected against thermal overload. In units
with two fans the speed of fan1 is always the same as the speed of fan2.
2.15. Closed cold water circuit
Cold water is conveyed through the process circuit by means of the internal pump. In the process circuit, the
cold water absorbs heat. The circuit closes when the cold water is conveyed back into the chiller. It goes
through the evaporator in which is discharges the heat. Then the cycle starts again.
Furthermore, the closed system is designed with a membrane expansion vessel that is under a certain initial
pressure depending on the system volume. The membrane expansion vessels balances out the temperature
fluctuations and the associated system pressure in the cold water circuit. If the water pressure increases,
the membrane expansion vessel absorbs the expansion volume of the water. If the water temperature
decreases, the membrane expansion vessel takes the expansion water back to the cold water circuit.