KKT chillers ECO122L Configuration guide

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Install Instructions
odels: ECO122L with IFP
ECO133L with IFP
0036
Customer Siemens Helthcare
Allee am Röthelheimpark 2
91052 Erlangen
anufacturer ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone]
F [phone]
E[email protected]
W www.kkt-chillers.com
Service Center KKT chillers, Inc. Servicehotline USA:
765 Dillon Drive
Wood Dale, IL 60191
TF [phone]/7 Hotline
F [phone]
E[email protected]
Safety first:
The owner of this unit is responsible that everyone who is working on the unit observ the
safety rules and read the whole anual/Install instructions and understand it.
A wrong or sloppy maintained unit could cause high body risk or even risk of death.

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Contents
1 Technical Data .................................................................................................................. 4
2 Basics .............................................................................................................................. 5
3 Installation site ................................................................................................................ 7
3.1 Ambient temperatures .................................................................................................. 7
3.2 Clearance ...................................................................................................................... 7
3.3 Servicin and repair access ............................................................................................ 7
3.4 Air flow ........................................................................................................................ 7
3.5 Load capacity of the base .............................................................................................. 7
4 Transport route/transport .............................................................................................. 10
4.1 Transport measurements ............................................................................................. 10
4.2 Transport wei ht ......................................................................................................... 10
4.3 Transport safety locks ................................................................................................. 10
4.4 Crane transport ........................................................................................................... 10
4.5 Dimensions in mm/inch ............................................................................................... 12
4.6 Wei hts Chiller ............................................................................................................ 13
4.7 Wei hts IFP ................................................................................................................. 13
5 Power supply/electrical connection ................................................................................ 13
5.1 Follow local re ulations ............................................................................................... 13
5.2 Volta e, frequency, tolerances .................................................................................... 13
5.3 Type of cable ............................................................................................................... 13
5.4 Len th and cable width ................................................................................................ 13
5.5 Strain relief ................................................................................................................. 13
5.6 Clamps ........................................................................................................................ 13
5.7 Fuse ............................................................................................................................ 15
5.8 Phase sequence ........................................................................................................... 16
5.9 EMC Compatibility and Groundin ............................................................................... 17
5.10 Data cable .................................................................................................................. 18
6 Interface filter panel (IFP) .............................................................................................. 20
6.1 Installation of IFP 098 (sample) ............................................................................... 22
6.2 Hi h differences – Fill pressure ................................................................................... 27
7 Water connection ............................................................................................................ 29
7.1 Pipe material .............................................................................................................. 29
7.2 Relation of pipe diameter to distance between chiller and IFP ..................................... 29
7.3 Dimensions of the connections .................................................................................... 29
7.4 Inflow and outflow ..................................................................................................... 29
7.5 Water quality .............................................................................................................. 31
7.6 Glycol .......................................................................................................................... 31
7.7 Fillin .......................................................................................................................... 31
7.8 Fans and air chambers ............................................................................................... 33
8 Initial start-up ................................................................................................................ 34
9 Settin s .......................................................................................................................... 35
10 Control .......................................................................................................................... 35
10.1 Pump .......................................................................................................................... 35
10.2 Water pressures ......................................................................................................... 36
10.3 Compressor ................................................................................................................ 36
10.4 Fans ........................................................................................................................... 36
10.5 Refri erant pressures ................................................................................................. 36
10.6 Temperatures ............................................................................................................. 36
11 Overview water chiller and IFP ....................................................................................... 37

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12 Maintenance ................................................................................................................. 38
13 Warranty ....................................................................................................................... 38
14 Safety Warnin s ........................................................................................................... 39

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1 Technical Data
odel Outdoor
Dimensions Depth 1100 mm
Width 2100 mm
Height 2050 mm
Weight see page 13
Quantity of air max. 20000 m³/h ECO122L
Quantity of air max. 25000 m³/h ECO133L
Refrigerant R407C
GWP 1774
Required quantity of refrigerant 13kg
CO2 equivalent 23,1 t CO2
High-pressure switch 31 bar
Water connection inlet internal 2“ G" female thread
Water connection outlet internal 2“ G" female thread
Cold water temperature outlet Set /min/max 20 / 19 / 22°C ±0.5 K
Cold water temperature inlet max. 30°C
Operating liquid (water circuit) distilled water and 35-38% Ethylene Glycol
Rated water capacity min. 7.8 m³/h
Rated water pressure at IFP max. 6.0 bar
Safety valve water circuit/Chiller 3.0 bar
Ambient temperature min.-20 °C
max.+48 °C
Cooling capacity 45.0 kW ECO122L
Cooling capacity 60.0 kW ECO133L
Rated cold water outlet temperature 20 °C
Temperature of surroundings 48 °C
ain supply ROW 380-480V / 3Ph / 50-60Hz
ain supply USA 460V/3Ph/60Hz
Control voltage 24 VDc
Fluctuations in main voltage max. -14/+10 %
Fluctuations in frequency max. ±1 Hz
Power input max. 21 kW ECO122L
Power input max. 28,5 kW ECO133L
Noise level at 5 m max. 61 db(A)
at max cooling capacity and max. ambient temperature

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2 Basics
ost important notice:
Attention: A too high static pressure at the IFP cause damage in the Siemens
equippment!
KKT or Siemens will not pay the expenses of such operations!
LEAK-TEST
DO NOT PRESSURIZE THE IFP WITH ORE THAN
2,9BAR/42PSI
WHEN THE SIE ENS SYSTE IS CONNECTED!
Scope of Chiller supply:
-ECO122L or ECO133L inclusive IFP
-Install Instruction on switch cabinet
- anual inside switch cabinet (CD)
-Data transfer cable 50m (164feet) POF
-Spare parts in a box near the pump:
–3 piece Fuse 10A
–3 piece Fuse 50A
–Coil for Solenoid Valve
–Temperature Sensor PT1000
–Pressure Sensor 30bar
–Pressure Sensor 10bar
–filter pad large for fan switch cabinet
–filter pad small for air switch cabinet outlet
–water strainer inlet
–Brass fittings for the connection Chiller inlet/outlet and piping (on the pump)
–IFP
–Brass fittings for the connection piping and IFP inlet/outlet (on IFP)
Carefully read the operating instructions located in the control cabinet before beginning
installation.
Check the equipment for damage on arrival and report any defects immediately.
Claims submitted later cannot be honored.

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Please observe the following notes and warnings.
1. Removing the operating instructions from the cooling block voids the warranty!
2. The volume of the water circulation system of the cooling block is approx. 12 liters
(~3.2 gal) Please consider this by filling the water system with clean water
(distilled water quality) with Ethylene-glycol.
3. Always operate the water circulation system at a volume of 35-38% ethylene
glycol.
This is regardless of the ambient temperature.
Non-compliance voids the warranty.
Use of automobile anti-freeze and propylene glycol is prohibited.
Fill with clean water (distilled water quality) with Ethylene-glycol at the rate of min.
35% to max. 38%.
Use ethylene-glycol of only one manufacturer.
(e.g.: DOWTHER SR1-Dow Chemical, Safeflow EG - Clariant)
Do not mix two ore more different manufacturer for one water-ethylene-glycol
circuit.
Open front panel and fill to a pressure of min.1,0 bar (14.5PSI) to 1,3bar (21.7PSI)
via the feed cock when the pump is off.
After filling, check all connections for leakage.
4. The static pressure at the IFP-pressure gauge (pump is OFF) shall have the
following value:
Chiller same level or above the RI 1.7 – 1.8bar
Chiller lower than the RI 1.2 – 1.3bar
5. The cooling block operates dependently of the R system via Heartbeat.
6. Voltage is still present in the control cabinet when the R system is turned off.
Risk of death!
7. Even with the cooling block turned off, high surface temperatures can cause
burns. Risk of death!
Only trained and qualified personnel are permitted to install, start up, and repair the
cooling block.

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3 Installation site
3.1 Ambient temperatures
The chiller is designed to operate at ambient temperatures between –20°C (-4°F)
minimum and +48°C (+118.4°F) maximum.
alfunctions can occur outside these specifications.
If the chiller is used at high ambient temperatures (higher than 40°C = 104°F) the chiller
should be installed that the switch cabinet is not fully exposed to the sun radiation when
the maximum ambient temperature is prevent. If this is not possible please install a sun
protection!
Support from KKT chillers could be requested.
3.2 Clearance
aintain at least 100 cm (39.4 in.) around all four sides of the chiller for air intake and
servicing/repair.
Under no circumstances install a roof above the chiller.
3.3 Servicing and repair access
See Clearance
3.4 Air flow
Never obstruct the air intake to the condensers on the upper third of the chiller.
The diameter of the tubes may not be smaller than the size specified.
3.5 Load capacity of the base
Verify that the installation surface has sufficient load capacity.
A concrete foundation or sectional steel construction is recommended.
A concrete foundation needs to be 200 mm (7.8 in.) wider and 200 mm (7.8 in.) longer
than the cooling block. Final dimensions: approx. 2,300 mm (7.55 feet) long by 1,300
mm (4.26 ft) wide.
The operating weight of the ECO133L is approx. 780 kg (1,720 lbs.).
The operating weight of the ECO122L is approx. 727 kg (1,603 lbs.).
It is important that the cooling block be installed on a level surface.

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4 Transport route/transport
4.1 Transport measurements
Length: approx. 2,100 mm (approx. 83 inches)
Width: approx. 1,100mm (approx. 43.3 inches)
Height: approx. 2,050mm (approx. 80.7 inches)
You also need to add the height of the transport equipment, such as pallets, lift truck,
transport rollers, etc.
4.2 Transport weight
Weight: ECO133L approx. 1,230 kg (approx. 2,712 lbs.)
Weight: ECO122L approx. 1,177 kg (approx. 2,595 lbs.)
4.3 Transport safety locks
There are no transport safety locks to remove.
4.4 Crane transport
If a crane will be used to transport the chiller, note the following:
Lift the chiller only from its base. Insert two steel rods through the holes in the base. The
rods must be specifically designed for this purpose and able to support the weight (800
kg./1,764 lbs.).
Secure the rods with locking pins to prevent shifting.
Use only straps or rope for lifting from the rods.
The straps or ropes must be held in place with a frame to keep them from pressing into
the side walls, gutters, and condenser body. (Refer to the following graphic).

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4.5 Dimensions in mm/inch

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4.6 Weights Chiller
ECO122L ECO133L
Net weight 707kg (1,559lbs) 760kg (1,675lbs)
Operating weigt 727kg (1603lbs) 780kg (1,720lbs)
Transport weight 1177kg (2,595lbs) 1230kg (2,712lbs)
Refrigerant 13kg (28.7lbs) 13kg (28.7lbs)
4.7 Weights IFP
Net weight: 67 kg. (147.7 lbs.)
Operating weight: approx. 72 kg. (158.7 lbs.)
Transport weight: is packed with the chiller
5 Power supply/electrical connection
5.1 Follow local regulations
Strictly adhere to the regulations of the local power company and authorities. Only
trained, authorized persons are permitted to connect the power.
5.2 Voltage, frequency, tolerances
Voltage range: 380 - 480 Volt –14%+10%
Frequency range: 50 – 60Hz +/-1Hz
5.3 Type of cable
ake sure to use appropriately designed and approved cables when routing.
5.4 Length and cable width
A cable width of at least 16mm² per phase is required for cables up to 50 meters (164
ft.) in length.
Therefore, a 5 x 16mm² cable is required.
5.5 Strain relief
The input cable must be fitted on both sides with a strain relief.
5.6 Clamps
Insert the input cable through the cable feed-through (see photograph) next to the water
connections.

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Do not drill any hole into the unit!

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Use the clamps on the main switch(see photograph).
Attention!!
Do not pass the power supply line across the switch cabinet!!
Use cable opening in the lower left hand side of cabinet!!
Drilling holes into and running cables into the cabinet can cause interferences with the
regulation electronics!!
5.7 Fuse
aximum 80A slow-blowing fuse for pre-fusing.

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5.8 Phase sequence
Observe the correct phase sequence when routing the wires, otherwise the cooling block
will not start. A phase sequence relay (4A1) is installed for this purpose.
The monitoring relay has ist own power supply, measured voltage = supply voltage.
The relay monitors the phase sequence an the phase failure of one of the three phases in
a 3-phase network. No settings are necessary.
When the line voltage is switched on, the green LED lights up. IF the correct phase
sequence is applied to the terminals L1-L2-L3, the output relay picks up.
If the wrong phase sequence is applied, the red LED blinks an the output relay does not
pick up. If a phase failure occurs, the red LED lights up an the output relay drops out.
Attention: The red LED is an error diagnosis indicator an does not show the current state
of the relay.

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5.9 E C Compatibility and Grounding
This comments are compiled to help the field electrician to install the grounding of the
power supply and to get a E C Compatibility.
All electrical equipment produces radio and line-borne interference at various
frequencies. The cables pass this on to the environment like an aerial.
The basic countermeasures are isolation of the wiring of control and power components,
proper grounding and shielding of cables.
A large contact area is necessary for low-impedance grounding of HF interference. The
use of grounding straps instead of cables is therefore definitely advisable.
oreover, cable shields must be
connected with purpose-made ground
clips.
The grounding surface must be highly
conductive bare metal. Remove any
coats of varnish and paint.
The width of the grounding wire must be min. 16mm² (AWG 6) or of the same width of the
power supply.
The grounding must be an isolated ground and must connected on the ground terminal
(X1) in the switch cabinet. The ground resistance must be less than 5 Ohm.
etal cable conduits are not allowed for grounding.
The piping of the chiller (supply and return) have to be grounded too.
Do not share the ground wire with other devices.
Always use a ground wire that complies with technical standards on electrical equipment
and minimize the length of the ground wire.
When using more than one Inverter, be careful not to loop the ground wire.

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5.10 Data cable
Attach the POF-cable end to the RX an TX connector (see photograph) at the PCB in the
control cabinet of the chiller and at the PCB in the control cabinet of the IFP.
Also use the RX TX connector on the IFP PCB.
Feed-through
- Run the POF cable from the chiller to the IFP panel.

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Plastic optical fiber (POF) (or Polymer optical fibre)
Following Pictures are for example and not part of delivery from your ECO-System.
1. Step
The connectors are usually protected with a rubber end cap and shall not be removed
during installation.
2. Step
Unroll the cable before installation.
3. Step
The tensile strength of the CABLE is max. 100N
The tensile strength of the WIRE is max. 5N
4. Step
Never slide/draggle the cable on the ground or around edges.

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5. Step
The bend radius is minimum 12 X outer diameter.
Outer diameter of the cable is 8mm
Bend radius = 8mm x 12
Bend radius = 96mm à compared to 3.77“
6 Interface filter panel (IFP)
Drawing and foot print