KKT chillers cBoxX 60 User manual

Compact-Line Healthcare
Operating instructions
cBoxX 60
cBoxX 70
cBoxX 80
cBoxX 100
cBoxX 120

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Table 1: Contact details
Manufacturer
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone]
F [phone]
E [email protected]
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 [email protected])

3 / 91 83001602.Ke
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.
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 ...................................................................................................................7
1.1. Intended use ...................................................................................................................... 7
1.2. Elements...........................................................................................................................13
1.3. Explanation of terms........................................................................................................14
2. Function and main components.............................................................................................14
2.1. Compressor ......................................................................................................................15
2.2. Evaporator........................................................................................................................15
2.3. Condenser ........................................................................................................................15
2.4. Expansion valve ...............................................................................................................15
2.5. Refrigerant........................................................................................................................15
2.6. Oil......................................................................................................................................16
2.7. Filter dryer ........................................................................................................................16
2.8. Pressure sensors .............................................................................................................16
2.9. Temperature sensors.......................................................................................................16
2.10. Control unit / main circuit board.....................................................................................16
2.11. Display ..............................................................................................................................16
2.12. Control cabinet.................................................................................................................16
2.13. Pump.................................................................................................................................17
2.14. Fan....................................................................................................................................17
2.15. Closed cold water circuit .................................................................................................17
2.16. Materials used in the water circuit .................................................................................18
2.17. Water quality ....................................................................................................................19
2.18. Permitted coolant media.................................................................................................20
3. Options and accessories.........................................................................................................20
3.1. Heater for the compressor and control cabinet.............................................................20
3.2. Insulating cold pipes........................................................................................................21
3.3. Pump redundancy............................................................................................................21
3.4. Phase monitoring.............................................................................................................21
3.5. Hot gas bypass for output control <1K...........................................................................21
3.6. Low-temperature package (ambient temperature < -25 ° C).......................................21
3.7. Levelling feet (accessories).............................................................................................21
3.8. Filter assembly group coolant circuit (accessories).......................................................22
3.9. Anybus-Gateway (accessories)........................................................................................22
3.10. Remote control panel (accessories)...............................................................................23
3.11. Special languages (accessories).....................................................................................23
3.12. Seaworthy crate packaging (accessories)......................................................................23
3.13. Earthquake kit (accessories)...........................................................................................24
3.14. CIP Chiller interface panel (accessories)........................................................................25
4. Safety........................................................................................................................................25
4.1. General information.........................................................................................................25
4.2. Hazard warnings ..............................................................................................................25
4.3. Residual energy................................................................................................................28

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4.4. Safety devices, guards and safeguards .........................................................................29
4.4.1. High-pressure limiter................................................................................................29
4.4.2. High-pressure monitoring ........................................................................................30
4.4.3. Low-pressure monitoring .........................................................................................30
4.4.4. Flow monitoring........................................................................................................30
4.4.5. Personal protective equipment when operating the machine ..............................30
4.5. Personal protective equipment for servicing work ........................................................31
4.6. Airborne sound emissions...............................................................................................32
4.7. Notes on reducing noise and vibration...........................................................................32
4.7.1. Noise .........................................................................................................................32
4.7.2. Vibration....................................................................................................................33
4.8. Residual risks...................................................................................................................33
4.8.1. Electrical ...................................................................................................................33
4.8.2. Mechanical ...............................................................................................................33
4.8.3. Chemical...................................................................................................................33
4.8.4. Other .........................................................................................................................33
4.9. Dangerous substances....................................................................................................34
4.9.1. Refrigerant R410A ...................................................................................................34
4.9.2. Öl POE 160SZ...........................................................................................................35
4.10. Reasonably foreseeable misuse.....................................................................................36
4.11. Information for emergencies...........................................................................................37
5. Handling and storage ..............................................................................................................37
5.1. Dangerous goods.............................................................................................................37
5.2. Transport ..........................................................................................................................37
5.2.1. Forklift truck .............................................................................................................38
5.3. Unpacking.........................................................................................................................39
5.4. Storage .............................................................................................................................39
6. Installation ...............................................................................................................................40
6.1. Overview ...........................................................................................................................40
6.2. Installation site.................................................................................................................40
6.2.1. General information.................................................................................................40
6.2.2. Minimum room volume............................................................................................40
6.2.3. Ambient temperature...............................................................................................41
6.2.4. Effect of surrounding air flow ..................................................................................41
6.2.5. Minimum clearances ...............................................................................................41
6.2.6. Surface and foundation...........................................................................................42
6.2.7. Stability .....................................................................................................................42
6.2.8. Levelling....................................................................................................................42
6.2.9. Vibration isolation ....................................................................................................42
6.2.10. Installation................................................................................................................42
6.2.11. Hydraulic installation ...............................................................................................43
6.2.12. Frost protection measures ......................................................................................43
6.2.13. Flushing the cold water circuit ................................................................................43
6.2.14. Filling.........................................................................................................................44
6.2.15. Venting......................................................................................................................44

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6.2.16. Electrical installation................................................................................................45
7. Commissioning ........................................................................................................................46
7.1. Installation checklist........................................................................................................46
8. Operation..................................................................................................................................47
8.1. Switching on.....................................................................................................................47
8.2. Selecting the operating mode.........................................................................................47
8.3. External release ...............................................................................................................47
8.4. Control ..............................................................................................................................48
8.5. Control panel....................................................................................................................48
8.5.1. Start screen ..............................................................................................................50
8.5.2. Main menu................................................................................................................51
8.5.3. Information ...............................................................................................................51
8.5.4. Settings.....................................................................................................................53
8.5.5. Alarm menu ..............................................................................................................54
8.6. Parameters.......................................................................................................................54
8.7. Controller description ......................................................................................................55
8.7.1. Switching the chiller on/off .....................................................................................55
8.7.2. Cold water feed temperature control......................................................................56
8.7.3. Compressor control..................................................................................................57
8.7.4. Fan speed control ....................................................................................................57
8.7.5. Electronic expansion valve control..........................................................................57
8.7.6. Temperature limit monitoring..................................................................................57
8.7.7. Group fault alarm .....................................................................................................58
8.8. Operating modes..............................................................................................................58
8.8.1. ECO mode .................................................................................................................58
8.8.2. Comfort mode...........................................................................................................58
9. Cleaning ...................................................................................................................................58
9.1. Air filter mat......................................................................................................................58
9.2. Condenser ........................................................................................................................58
9.3. Water filter........................................................................................................................58
9.4. Complete cleaning of the cold water circuit...................................................................59
10. Service......................................................................................................................................59
10.1. Maintenance ....................................................................................................................59
10.2. Disposal............................................................................................................................59
10.3. Spare parts.......................................................................................................................60
11. Decommissioning/Taking out of service................................................................................60
11.1. Draining ............................................................................................................................61
12. Recycling ..................................................................................................................................61
13. Products, solutions and services............................................................................................62
I. Menu navigation......................................................................................................................63
II. Troubleshooting.......................................................................................................................76
III. II. Maintenance intervals in accordance with the VDMA.......................................................88
IV. Product registration.................................................................................................................91

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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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Technical data
Table 3: Technical data
Chillertyp
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
cBoxX 60
SAP-Nummer
909060-00238
909060-00239
909060-00240
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
41kW
Ambient temperature range
-25 - +45°C
-25 - +45°C
-40 - +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
50Vol% 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
2,8bar
5bar
5bar
2,8bar
5bar
Operating voltage
400V/3/50Hz
400V/3/50Hz
400V/3/50Hz
400V/3/60Hz
460V/3/60Hz
460V/3/60Hz
460V/3/60Hz
460V/3/60Hz
460V/3/60Hz
Protection class
IP54
Air flow rate (max.)
20.000 m³/h
Sound pressure level at 5 m distance
69 dB(A)
Height
2030 mm
2030 mm
2030 mm
2030 mm
2030 mm
2030 mm
2030 mm
2030 mm
2030 mm
Width
830 mm
830 mm
830 mm
830 mm
830 mm
830 mm
830 mm
830 mm
830 mm
Length
1240 mm
1240 mm
1240 mm
1240 mm
1240 mm
1240 mm
1240 mm
1240 mm
1240 mm
Net weight without refrigerant
515 kg
540 kg
515 kg
515 kg
540 kg
540 kg
540 kg
540 kg
584 kg
Pumps Quantity
1
2
1
1
2
2
2
2
2
Certificates
CE
CE
CE
CE
CE
CE/UL/CSA
CE/UL/CSA
CE
CE/UL/CSA/
seismic

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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
400V/3/50Hz
400V/3/50Hz
400V/3/60Hz
460V/3/60Hz
460V/3/60Hz
400V/3/60Hz
460V/3/60Hz
Protection class
IP54
Air flow rate (max.)
36.500 m³/h
Sound pressure level at 5 m distance
71 dB(A)
Height
2030 mm
2030 mm
2030 mm
2030 mm
2030 mm
2030 mm
2030 mm
Width
830 mm
830 mm
830 mm
830 mm
830 mm
830 mm
830 mm
Length
1840 mm
1840 mm
1840 mm
1840 mm
1840 mm
1840 mm
1840 mm
Net weight without refrigerant
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/UL/CSA
CE
CE/UL/CSA/
seismic

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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 - +50°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
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
2030 mm
2030 mm
Width
830 mm
830 mm
Length
1840 mm
1840 mm
Net weight without refrigerant
680 kg
680 kg
Pumps Quantity
2
2
Certificates
CE
CE

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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 50Vol% 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
460V/3/60Hz (+/-10%)
400V/3/50Hz (+/-10%)
400V/3/60Hz (+/-10%)
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
2030 mm
2030 mm
2030 mm
2030 mm
2030 mm
Width
830 mm
830 mm
830 mm
830 mm
830 mm
Length
1840 mm
1840 mm
1840 mm
1840 mm
1840 mm
Net weight without refrigerant
701 kg
751 kg
701 kg
. 751 kg
751 kg
Pumps Quantity
2
2
2
2
2
Certificates
UL/CSA
UL/CSA/seismic*
UL/CSA
CE
CE
*seismic certification is pending

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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
Water 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
10,8 m³/h
7,8 m³/h
7,8 m³/h
Free pump pressure (min)
5,9 bar
5,5 bar
5,0 bar
5,0 bar
Operating voltage
400V/3/50Hz (+/-10%)
400V/3/60Hz (+/-10%)
460V/3/60Hz (+/-10%)
460V/3/60Hz (+/-10%)
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
2030 mm
2030 mm
2030 mm
2030 mm
Width
1100 mm
1100mm
1100mm
1100mm
Length
2665 mm
2665 mm
2665 mm
2665 mm
Net weight without refrigerant
1046 kg
1046 kg
1046 kg
1046 kg
Pumps Quantity
2
2
2
2
Certificates
CE
CE
UL/CSA
UL/CSA

13 / 91 83001602.Ke
1.2. 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

14 / 91 83001602.Ke
1.3. Explanation of terms
For the sake of better understanding, we have listed some relevant terms that are used
frequently in this document.
Table 4: Explanation of terms
Term
Explanation
Application
The source of heat hydraulically connected to the chiller.
Process circuit
Application and piping to the chiller.
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 (Illustration 1). 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 1: C6848 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

15 / 91 83001602.Ke
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 8.7.4
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 3.19 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

16 / 91 83001602.Ke
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 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 (cBoxX 30 –cBoxX 100) 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.

17 / 91 83001602.Ke
Figure 2: Demounting the side panel
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.

18 / 91 83001602.Ke
2.16. Materials used in the water circuit
In the standard version, the material compilation is depicted as shown in Table 5:
Table 5: Materials used in the standard version
Component
Material (cBoxX 60 –cBoxX120)
Unit connections
V2A 1.4305
Evaporator
V2A 1.4301 and copper (99.9%)
Pump
Mechanical seal
Grey cast iron and V2A 1.4301
EPDM
Sealing plugs yellow
Polyamide PA 6
Sealing plugs black
Polyoxymethylene (POM)
Bends, tees, couplings
Gunmetal CC499K
Fittings
V4A 1.4408
Hose nozzle
Brass, nickel-plated
Temperature sensor PT1000
V2A 1.4301
Pressure sensor XSK AC10I-U188
V2A 1.4301

19 / 91 83001602.Ke
2.17. Water quality
The following limit values must be adhered to to ensure the safe operation of the devices:
Table 6: Water quality
Property /
Constituents
Unit
Value range
Standard model
Value range
Non-ferrous metal version
pH-value (20°C)
-
7-9
6-9
Saturation index
-
-0.2 < 0 < +0.2
-0.2 < 0 < +0.2
Conductivity
µS/cm
80-500
5-500
Water hardness
°dH
<5.6
<5.6
Carbonate
hardness
mol/m³
<0.5
<0.5
Total germ count
K/ml
<10,000
<10,000
Grain size
µm
< 250
< 250
Glycole fraction
(AFN)
Vol%
20-40
20-40
Oil fraction
Vol%
0
0
Chloride(Cl-)
mg/l
<50
<50
Sulphate
mg/l
<50
<50
Nitrate
mg/l
<100
<100
Copper
mg/l
<0.1
<0.1
Iron
mg/l
<0.2
<0.2
Free carbonic acid
mg/l
<20
<20
Manganese
mg/l
<0.1
<0.1
Ammonia
mg/l
<2
<2
Free chloride
mg/l
<0.5
<0.5
Sulphide
mg/l
<0.03
<0.03
To prevent clogging of the plate heat exchangers, the prescribed limit values must be observed.
Furthermore, any occurrence of mucilage bacteria in the cooling water must be ruled out. If this is
not possible, KKT chillers can suggest or provide a suitable inhibitor on the basis of a biological
water analysis to remove the mucilage agents.

20 / 91 83001602.Ke
2.18. Permitted coolant media
Permitted are water fluids and mixtures consisting of water / Antifrogen N (AFN) or
water/ Antifrogen L (AFL) pursuant to the specification defined in Chapter 2.17 Water quality. The
following table depicts the definitions of the mixing ratios between water and anti-freeze AFN or
AFL. To maintain the performance capacity of your machine and to prevent damage to the
components, these values must be complied with to the greatest extent possible.
Table 7: Mixing ratios AFN and AFL (or comparable)
Setting
Frost-free to
AFN mixing ratio
AFL mixing ratio
Glycol 35 - 38 %
-25°C
35 - 38 %
37 - 40%
Glycol 50 %
-40°C
50 %
52 %
3. Options and accessories
The chiller can be equipped in the factory with the options described in the following.
The positions marked with "accessory" are included with the device, unattached, and can be re-
ordered at any time with the respective product number. The installation of the accessory is the
responsibility of the installer of the machine. You can also ask our KKT chillers Service Team to
arrange for this installation (see Contact details).
Information on the features of your machine can be found in the separately enclosed summary
documentation.
3.1. Heater for the compressor and control cabinet
The oil sump heater prevents the deposit of refrigerant in the oil when the temperature is low. When
the compressor is started up this refrigerant would be liberated from the oil as gas and make the
oil foam up. Under these conditions the lubrication of components subject to friction in the
compressor would be poor, which could lead to the damage of the compressor.
The control cabinet heater is thermostatically controlled and prevents moisture from the drawn-in
ambient air in the event of lower ambient temperatures from condensing on electrical and
electronic components of the control cabinet and hence from damaging them.
To enable the activation of both heaters, the chiller may not be disconnected from the power supply
(8.2 Selecting the operating mode).
ATTENTION! Do not use mixtures of different anti-freeze products. This can lead to
undesired chemical reactions as well as silting.