KKT chillers nBoxX 1.5 User manual

Nano
NanoNano
Nano-
--
-Line
LineLine
Line
nBoxX 1.5
nBoxX 3.0
nBoxX 4.5
nBoxX 6.0
Operating Instruction

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Content
ContentContent
Content
1 Notes on documentation.......................................................................................4
1.1 Other applica le documents ...................................................................................................................... 4
1.2 CE conformity .............................................................................................................................................. 4
1.3 Storing the documents ............................................................................................................................... 4
1.4 Sym ols used .............................................................................................................................................. 4
2 Safety instructions ................................................................................................5
2.1 Risks in case of failure to o serve the safety instructions ....................................................................... 5
2.2 Safety instructions for the operator ........................................................................................................... 5
2.3 Safety instructions for assem ly, inspection and maintenance work ...................................................... 5
2.4 Unauthorised operation .............................................................................................................................. 6
2.5 Health risks due to the refrigerant R134a and the antifreeze ................................................................. 6
2.5.1 First aid measures.........................................................................................................................6
2.5.2 Fire-fighting measures ..................................................................................................................6
2.5.3 Protective measures during repairs ..............................................................................................6
3 Device description.................................................................................................6
3.1 General functional description ................................................................................................................... 9
3.1.1 Controller.....................................................................................................................................10
3.1.2 Safety devices.............................................................................................................................10
3.2 Proper use ................................................................................................................................................ 10
4 Transportation .....................................................................................................11
5 Assembly and connection ..................................................................................12
5.1 Installation site requirements ................................................................................................................. 12
5.2 Installing the cooling unit ......................................................................................................................... 13
5.3 Making the hydraulic connection ............................................................................................................ 13
5.4 Making electrical connection................................................................................................................... 14
5.4.1 Connecting the power supply......................................................................................................14
5.4.2 Connecting the alarm relay interrogation device.........................................................................15
5.4.3 External activation....................................................................................................................... 15
5.4.4 Connecting the cooling unit to the PLC.......................................................................................15
6 Commissioning....................................................................................................17
6.1 Antifreeze .................................................................................................................................................. 17
6.2 Filling the cooling system with cooling medium ..................................................................................... 17
6.3 Bleeding the cooling medium pump ....................................................................................................... 18
7 Operation..............................................................................................................19
7.1 Controls ..................................................................................................................................................... 19
7.2 Key functions ............................................................................................................................................ 20
7.2.1 Key functions during operation....................................................................................................20
7.2.2 Key functions during parameter adjustment................................................................................21

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7.3 Fixed value control or com ined control ................................................................................................. 22
7.4 Meaning of the control parameters ........................................................................................................ 23
7.5 Meaning of the error codes ..................................................................................................................... 27
7.6 Alarm relay contacts ................................................................................................................................ 29
7.7 PLC outputs .............................................................................................................................................. 30
7.8 Setting the digital real-time clock ............................................................................................................ 31
8 Inspection and maintenance ..............................................................................32
8.1 Maintaining the refrigerant circuit ........................................................................................................... 33
8.2 Water quality ............................................................................................................................................ 33
8.3 Cleaning the condenser ........................................................................................................................... 36
8.4 Cleaning the filter mat (optional) ............................................................................................................. 37
8.5 Draining the cooling medium tank .......................................................................................................... 37
9 Troubleshooting ..................................................................................................38
10 Shutting down and disposal...............................................................................38
10.1 Shutting down for an extended period .................................................................................................... 38
10.2 Shutting down and disposal .................................................................................................................... 39
11 Manufacturer’s guarantee and customer service .............................................40
12 Annex....................................................................................................................42
P+ID-diagram
Technical data
Electrical schematic
Parameter list
Spare part list
Declaration of conformity

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1
11
1Notes on documentation
Notes on documentationNotes on documentation
Notes on documentation
These instructions are aimed at installers and operators who are familiar with the installation and
the operation of the cooling unit.
There y it is imperative that you o serve the following:
You must read and o serve these operating instructions prior to commissioning. The manufacturer
will not accept any lia ility for damage or operating pro lems resulting from failure to o serve these
operating instructions.
1.1
1.11.1
1.1 Other applica le documents
Other applica le documentsOther applica le documents
Other applica le documents
In conjunction with these instructions the flow diagram and electrical wiring diagram for the related
model apply.
1.2
1.21.2
1.2 CE conformity
CE conformityCE conformity
CE conformity
The declaration of conformity is included in the appendix of these installation and operating instruc-
tions.
1.3
1.31.3
1.3 Storing the documents
Storing the documentsStoring the documents
Storing the documents
These instructions and all associated documents constitute an integral part of the product. They
must e supplied to the operator. The plant operator is responsi le for storage of the documents so
they are readily availa le when needed.
1.4
1.41.4
1.4 Sym ols used
Sym ols usedSym ols used
Sym ols used
Please o serve the following safety instructions and other notes in this guide:
Danger!
Danger!Danger!
Danger!
Immediate danger to life and lim !
Immediate danger to life and lim !Immediate danger to life and lim !
Immediate danger to life and lim !
Risk of urns!
Risk of urns!Risk of urns!
Risk of urns!
Risk of injury due to contact with hot fluids!
Risk of injury due to contact with hot fluids!Risk of injury due to contact with hot fluids!
Risk of injury due to contact with hot fluids!
Risk of cuts!
Risk of cuts!Risk of cuts!
Risk of cuts!
Risk of injury on touching the fins on the condenser!
Risk of injury on touching the fins on the condenser!Risk of injury on touching the fins on the condenser!
Risk of injury on touching the fins on the condenser!
Danger!
Danger!Danger!
Danger!
Danger of death due to electric shock!
Danger of death due to electric shock!Danger of death due to electric shock!
Danger of death due to electric shock!
Caution!
Caution!Caution!
Caution!
Possi le hazard for the cooling unit.
Possi le hazard for the cooling unit. Possi le hazard for the cooling unit.
Possi le hazard for the cooling unit.

5 / 48 83000902.Ka
Caution!
Caution!Caution!
Caution!
Possi le hazard due to discharge of refrigerant.
Possi le hazard due to discharge of refrigerant.Possi le hazard due to discharge of refrigerant.
Possi le hazard due to discharge of refrigerant.
Note!
Note!Note!
Note!
Useful information and special features.
Useful information and special features.Useful information and special features.
Useful information and special features.
Sym ol for an instructed action:
Sym ol for an instructed action:Sym ol for an instructed action:
Sym ol for an instructed action:
The ullet point indicates that you should perform an action.
2
22
2Safety instructions
Safety instructionsSafety instructions
Safety instructions
Please o serve the following general safety instructions when operating and installing the cooling
unit: Assem ly, installation and maintenance must only e carried out y qualified personnel.
Only use original spare parts and accessories authorised y the manufacturer to ensure the protec-
tion and safety of the cooling unit. The usage of other parts will render any lia ility void. Do make any
changes to the cooling unit that have not een agreed with and approved y the manufacturer.
It is also imperative that you o serve the special safety instructions for the individual activities in the
individual chapters.
2.1
2.12.1
2.1 Risks in case of failure to o serve the safety instructions
Risks in case of failure to o serve the safety instructionsRisks in case of failure to o serve the safety instructions
Risks in case of failure to o serve the safety instructions
In case of failure to o serve the safety instructions, people, the environment and the unit may e
placed at risk. Failure to comply with the safety notes makes all claims for compensation void.
2.2
2.22.2
2.2 Safety instructions for the operator
Safety instructions for the operatorSafety instructions for the operator
Safety instructions for the operator
Any existing contact hazard protection for moving parts must not e removed from units while opera-
tional. Hazards due to electrical power, do not remove any switch ox cover!
2.3
2.32.3
2.3 Safety instructions for a
Safety instructions for aSafety instructions for a
Safety instructions for assem ly, inspection and maintenance work
ssem ly, inspection and maintenance workssem ly, inspection and maintenance work
ssem ly, inspection and maintenance work
Cleaning and maintenance work on the unit must only e performed with the unit shut down. For this
purpose, it is vital to ensure that the unit is disconnected from the power supply and is secured
against switching ack on.
It is imperative that you o serve the procedure for shutting down the cooling unit descri ed in the
operating instructions. All safety devices and protective equipment must e reattached or put in a
functional condition immediately after the work is complete.
Modifications or changes to the cooling unit are not allowed. Only appropriately qualified personnel
as defined y BGR500 chap. 2.35 / EN 378 are allowed to work on the refrigerant circuit.

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Caution!
Caution!Caution!
Caution!
Possi le hazard for the cooling unit.
Possi le hazard for the cooling unit. Possi le hazard for the cooling unit.
Possi le hazard for the cooling unit.
Do not install the unit without protection outside of covered areas, or in an explosive or aggressive
environment. Do not install the unit on an unsta le surface or a surface that is not designed for the
weight of the cooling unit. Do not ypass any electrical safety devices to make it possi le to operate
the cooling unit.
2.4
2.42.4
2.4 Unauthorised operation
Unauthorised operationUnauthorised operation
Unauthorised operation
The safety of the cooling unit supplied is only ensured if it is used properly, see chapter 3.2. Under
no circumstances should the limit values specified in the technical specifications e exceeded.
The unit must not e used for the direct cooling of liquids that are used for foodstuffs (e.g. drinking
water).
Exp
ExpExp
Explosion hazard!
losion hazard!losion hazard!
losion hazard!
The use of the
The use of the The use of the
The use of the cooling system for cooling inflamma le or pyrophoric su stances is pr
cooling system for cooling inflamma le or pyrophoric su stances is prcooling system for cooling inflamma le or pyrophoric su stances is pr
cooling system for cooling inflamma le or pyrophoric su stances is pro-
o-o-
o-
hi ited.
hi ited. hi ited.
hi ited.
2.5
2.52.5
2.5 Health risks due to the refrigerant R134a and the antifreeze
Health risks due to the refrigerant R134a and the antifreezeHealth risks due to the refrigerant R134a and the antifreeze
Health risks due to the refrigerant R134a and the antifreeze
The refrigerant is a liquefied gas under pressure. The enclosed R134a safety data sheet must e
o served. The antifreeze is a liquid fluid. The enclosed Antifrogen N safety data sheet is to e o -
served.
2.5.1
2.5.12.5.1
2.5.1 First aid measures
First aid measuresFirst aid measures
First aid measures
(see safety data sheets R134a and Antifrogen N)
2.5.2
2.5.22.5.2
2.5.2 Fire
FireFire
Fire-
--
-fighting measures
fighting measuresfighting measures
fighting measures
All known extinguishing agents can e used.
2.5.3
2.5.32.5.3
2.5.3 Protective measures
Protective measuresProtective measures
Protective measures during repairs
during repairsduring repairs
during repairs
Protective measures
Protective measuresProtective measures
Protective measures:
::
:
•Ensure adequate ventilation.
Personal protection equipment
Personal protection equipmentPersonal protection equipment
Personal protection equipment:
::
:
•Hand protection: Protective gloves
•Eye protection: Safety glasses
•Body protection: Wear safety shoes when handling pressurised gas ottles.
3
33
3Device
Device Device
Device description
descriptiondescription
description
The cooling units are used for the central and economical cooling and supply of a cooling medium
(water + glycol, see chapter Water Quality) in the event of physical separation etween the place
where cooling is required and the refrigeration. The cooling medium is supplied using a pipe system.

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Fig. 1 nBoxX1.5 View from front (left) and rear (right)
Key to figures 1
Key to figures 1 Key to figures 1
Key to figures 1
1 Rating plate
2 Display
3 Louvered grille for air inlet
4 Louvered grille for air outlet
5 Ca le entry
6 Cooling medium inlet
7 Tank drain nozzle for maintenance, transportation and disposal of the cooling medium
8 Cooling medium return
Fig. 2 nBoxX3.0 and nBoxX4.5 View from front (left) and from rear (right)

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Fig. 3 nBoxX6.0 View from front (left) and from rear (right)
Key to figures 2 and 3
Key to figures 2 and 3Key to figures 2 and 3
Key to figures 2 and 3
1 Louvered grille for air outlet (two-part)
2 Display
3 Liquid level display of cooling medium
4 Tank filling nozzle for cooling medium
5 Rating plate
6 Louvered grille for air inlet (two-part)
7 Tank drain nozzle for maintenance, transportation and disposal of the cooling medium
8 Ca le entry
9 Cooling medium inlet/outlet
10 Cooling medium return/inlet
For the closed cooling units, we recommend the installation of a pressure manometer, 0 – 6 ar, in
the cooling medium circuit.

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3.1
3.13.1
3.1 General functional description
General functional descriptionGeneral functional description
General functional description
Fig. 4 Refrigerant ir uit (s hemati diagram: example, units with open refrigerant ir uit)
The cooling system comprises the four main components: evaporator (12
1212
12), compressor (13
1313
13), con-
denser (1
11
1) with fan (2
22
2) as well as the control or expansion valve (4
44
4), which are connected together y
pipes. A pressure switch (14
1414
14) limits the maximum pressure in the refrigerant circuit. The R134a
(CH
2
FCF
3
) refrigerant is free from chlorine. Its Ozone Depletion Potential (ODP) is 0.
A filter dryer (3
33
3) which is integrated into the hermetically sealed refrigerant circuit provides effective
protection against moisture, acid, dirt particles, and foreign odies. A temperature control with tem-
perature pro e (6
66
6) ensures that the cooling medium is maintained at a preset set-point temperature.
In the evaporator (12
1212
12), the liquid refrigerant is converted to a gaseous state. The heat necessary for
this purpose is taken from the cooling medium in the plate heat exchanger, which has the effect of
cooling the cooling medium. The refrigerant is heavily compressed in the compressor (13
1313
13). As a re-
sult the refrigerant has a higher temperature than the am ient air. This heat is dissipated to the am-
ient air over the surface of the condenser (1
11
1), resulting in the refrigerant liquefying again.
The refrigerant is injected into the evaporator (12
1212
12) using a thermostatic expansion valve (4
44
4), as a
result it is expanded and is therefore a le to a sor the heat from the cooling medium (water, water-
glycol mixture).
The cooling medium is pumped to the equipment in a closed circuit using a pump (9
99
9) and cooling
medium tank (10
1010
10). The flow switch (11
1111
11) ensures the evaporator (12
1212
12) is protected against freezing if
the flow rate is too low. The level switch (5,
5, 5,
5, optional) protects the pump (9
99
9) against dry running. The
cooling medium (water or water-glycol mixture) feed temperature is regulated using the temperature
pro e (6
66
6) in the tank.
P
S
11
3
12
5
6
7
8
9
10
4
12
13
14

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3.1.1
3.1.13.1.1
3.1.1 Controller
ControllerController
Controller
The cooling units are fitted with a controller for setting the functions of the cooling unit. Operating
states are displayed using a display unit and parameters can e set using uttons.
3.1.2
3.1.23.1.2
3.1.2 Safety devices
Safety devicesSafety devices
Safety devices
The cooling unit has a pressure switch in accordance with EN 12263, tested at component level, in
the refrigerant circuit; this device is set to the maximum permissi le pressure (PS). An automatic
reset device ensures that the system continues to work after the pressure drops (auto-reset).
Temperature monitoring prevents the evaporator coil from icing over. If there is a risk of icing, the
compressor switches itself off and automatically switches itself ack on again at higher tempera-
tures.
The refrigerant compressor motor and the fan motors are equipped with thermal winding protection
switches against excess current and excess temperatures.
To ensure that the compressor runs relia ly and without pro lems (for example after reaching the
set-point temperature or after a fault), the compressor automatically switches ack on after a delay
of 180 seconds.
The cooling unit has two integrated floating fault signal contacts (see circuit diagram of the relevant
unit type, sections 13.4 and 13.5). Individual fault messages can e interrogated via an integrated
Su -D socket using an external PLC controller.
3.2
3.23.2
3.2 Proper us
Proper usProper us
Proper use
ee
e
The Nano-Line has een developed and designed in accordance with the state of the art and the
recognised rules governing safety. Nevertheless, if used improperly, they may pose a threat to life
and lim or cause damage to property. The Nano-Line units descri ed in these instructions must only
e used for cooling water or a water-glycol mixture. If using other fluids (e.g. de-ionised water),
please refer to the technical specifications contained in the appendix, or contact the manufacturer.
Under no circumstances should the limit values specified in the technical specifications e ex-
ceeded.
Explosion hazard!
Explosion hazard!Explosion hazard!
Explosion hazard!
The use of the cooling unit for cooling inflamma le or explosive su stances is prohi ited.
The use of the cooling unit for cooling inflamma le or explosive su stances is prohi ited.The use of the cooling unit for cooling inflamma le or explosive su stances is prohi ited.
The use of the cooling unit for cooling inflamma le or explosive su stances is prohi ited.

11 / 48 83000902.Ka
4
44
4Transportation
TransportationTransportation
Transportation
If the cooling system is stored or transported at temperatures elow freezing, you must completely
drain the cooling medium circuit and flush it with a water-glycol mixture to prevent frost damage. This
instruction also applies to the external condenser circuit for a water-cooled condenser (option).
Only transport the cooling unit in its original packaging material efore commissioning for the first
time. In case of damage, inform the manufacturer without delay. When transporting the cooling unit,
the weight specified on the rating plate must e taken into consideration. Use lifting gear with an
appropriate minimum load capacity. To prevent transport damage to the unit, proceed as follows:
Only transport the unit in an upright position.
•
Fig. 5 Eyebolt for transportation (nBoxX 1.5 shown here as an example)
Only transport the unit on the pallet supplied with the unit or with the eye olt provided (1).
Prevent excessive vi ration. If it is necessary to move the unit in the factory, you must disconnect all
connections on the unit. Before transporting, empty the water circuit and tank (if applica le)
1

12 / 48 83000902.Ka
5
55
5Assem ly and connection
Assem ly and connectionAssem ly and connection
Assem ly and connection
5.1
5.15.1
5.1 I
II
Installation site requirements
nstallation site requirementsnstallation site requirements
nstallation site requirements
The site must e free from excessive dirt and moisture. The am ient temperature must not exceed
43°C. Install the cooling unit close to the equipment eing cooled to avoid long distances and re-
lated performance losses. Performance losses arise in particular due to:
Pressure drops in the refrigerant piping system caused y resistance in the pipes and individual
components such as shut-off valves and pipe ends. Heat transfer in not insulated pipes.
Select the installation site such that: Easy access is possi le at any time. This situation will ease
maintenance and repair. The condenser fan does not operate in a "short-circuit", where y the warm
exhaust air from the condenser is drawn in again y the condenser's fan.
An "air short-circuit" will result in a loss of performance of the cooling unit. Maintain the following
minimum distances (in mm) from the wall:
Fig. 6 Spa e requirements
Note!
Note!Note!
Note!
For units of the type nBoxX1.5, the airflow passes through the unit from front to ack.
For units of the type nBoxX1.5, the airflow passes through the unit from front to ack.For units of the type nBoxX1.5, the airflow passes through the unit from front to ack.
For units of the type nBoxX1.5, the airflow passes through the unit from front to ack.
With unit of the types nBoxX3.0, nBoxX4.5 and nBoxX
With unit of the types nBoxX3.0, nBoxX4.5 and nBoxXWith unit of the types nBoxX3.0, nBoxX4.5 and nBoxX
With unit of the types nBoxX3.0, nBoxX4.5 and nBoxX 6.0 the airflow passes through
6.0 the airflow passes through 6.0 the airflow passes through
6.0 the airflow passes through
the unit from ack to front.
the unit from ack to front.the unit from ack to front.
the unit from ack to front.
Ensure the room is adequately ventilated y installing the cooling unit such that the heat dissipated
y the unit does not heat the room excessively.
The am ient temperature will increase due to the heat dissipated. This temperature increase may
cause a loss of performance of the cooling unit.
In case of installation in a "small" room, it is imperative that you provide forced ventilation, as other-
wise the heat dissipated will uild up.

13 / 48 83000902.Ka
The connection of ducts for fresh and exhaust air to our devices is not suita le, as these units are
equipped with axial fans and these cannot uild up the necessary additional air pressure.
To prevent performance losses, do not install the cooling unit near any form of heating.
Outdoor siting: Cooling units must e installed such that they cannot ecome damaged y internal
traffic and transport operations.
5.2
5.25.2
5.2 Installing the cooling unit
Installing the cooling unitInstalling the cooling unit
Installing the cooling unit
Install the cooling unit on an even, firm surface. The maximum permissi le deviation from the verti-
cal is 2°. Avoid the production of noise due to vi ration (vi ration dampers, sheets of foam ru er)
5.3
5.35.3
5.3 Making the hydraulic connection
Making the hydraulic connectionMaking the hydraulic connection
Making the hydraulic connection
Caution!
Caution! Caution!
Caution!
Risk of damage to the circulation pump due to soiling in the cool
Risk of damage to the circulation pump due to soiling in the coolRisk of damage to the circulation pump due to soiling in the cool
Risk of damage to the circulation pump due to soiling in the cooling medium circuit!
ing medium circuit! ing medium circuit!
ing medium circuit!
Flush the cooling medium circuit prior to connecting to the cooling unit.
Flush the cooling medium circuit prior to connecting to the cooling unit.Flush the cooling medium circuit prior to connecting to the cooling unit.
Flush the cooling medium circuit prior to connecting to the cooling unit.
The cooling medium outlet on the cooling unit (must e connected to the cooling medium inlet on
the equipment to e cooled. The cooling medium inlet on the cooling unit must e connected to the
cooling medium outlet on the equipment to e cooled.
Use only insulated pipes and/or hoses to connect the equipment to the cooling unit.
The nominal size of the piping must e at least the same as the nominal size of the medium connec-
tions on the unit, and on pressure-sealed units must e approved for the maximum pressure ex-
pected, see chapter 11.
Note!
Note!Note!
Note!
The use of steel pipes or galvanised steel pipes is inadmissi le.
The use of steel pipes or galvanised steel pipes is inadmissi le.The use of steel pipes or galvanised steel pipes is inadmissi le.
The use of steel pipes or galvanised steel pipes is inadmissi le.
For pressure-sealed units (nBoxX1.5)
Install a pressure manometer, 0 to 6 ar, in the cooling medium circuit.
Prior to commissioning, it is imperative that the cooling medium pump is filled with cooling medium
and led, see chapter 6.
Caution!
Caution! Caution!
Caution!
Risk of damage for the unit!
Risk of damage for the unit!Risk of damage for the unit!
Risk of damage for the unit!
Insufficient pressure (on pressure
Insufficient pressure (on pressureInsufficient pressure (on pressure
Insufficient pressure (on pressure-
--
-sealed units) and an excessively low flow rate will
sealed units) and an excessively low flow rate will sealed units) and an excessively low flow rate will
sealed units) and an excessively low flow rate will
trigger the safety devices in the unit.
trigger the safety devices in the unit. trigger the safety devices in the unit.
trigger the safety devices in the unit. Pay attention to the required minimum pressure
Pay attention to the required minimum pressure Pay attention to the required minimum pressure
Pay attention to the required minimum pressure
and the minimum flow rate, see chapter 11.
and the minimum flow rate, see chapter 11.and the minimum flow rate, see chapter 11.
and the minimum flow rate, see chapter 11.
If the cooler on the equipment to e cooled is higher than the cooling unit, we recommend installing
a non-return valve in the feed as well as a solenoid valve in the cooling medium circuit return to pre-
vent the tank from overflowing.

14 / 48 83000902.Ka
Caution!
Caution! Caution!
Caution!
Risk of damage for the cooling medium pump due to dry running! If it is possi le to
Risk of damage for the cooling medium pump due to dry running! If it is possi le to Risk of damage for the cooling medium pump due to dry running! If it is possi le to
Risk of damage for the cooling medium pump due to dry running! If it is possi le to
shut off the circuit to the equipment to e cooled, you must inst
shut off the circuit to the equipment to e cooled, you must instshut off the circuit to the equipment to e cooled, you must inst
shut off the circuit to the equipment to e cooled, you must install a ypass valve (can
all a ypass valve (can all a ypass valve (can
all a ypass valve (can
e ordered as an option) etween the feed and return to protect the cooling medium
e ordered as an option) etween the feed and return to protect the cooling medium e ordered as an option) etween the feed and return to protect the cooling medium
e ordered as an option) etween the feed and return to protect the cooling medium
pump.
pump.pump.
pump.
5.4
5.45.4
5.4 Making electrical connection
Making electrical connectionMaking electrical connection
Making electrical connection
It is imperative that you follow the instructions given elow:
It is imperative that you follow the instructions given elow:It is imperative that you follow the instructions given elow:
It is imperative that you follow the instructions given elow:
When carrying out the electrical installation, o serve all applica le national and regional regulations
as well as the regulations from the responsi le utility company. Electrical installation must only e
carried out y a qualified electrician who is responsi le for compliance with the existing standards
and regulations. The voltage and frequency of the connection must correspond to the values stated
on the rating plate.
The cooling unit must e connected to the mains via an all-pole isolating device. No additional tem-
perature control is allowed to e connected upstream of the cooling system on the supply side. In-
stall the pre-fuse cited on the rating plate (miniature circuit- reaker "K" characteristic or slow fuse) to
protect the ca le and equipment from short-circuits. The mains connection must ensure low-noise
potential equalisation. Cooling units must always e integrated into the uilding's equi potential
onding system. The conductor cross-sections of the power ca le must e selected according to the
rated current (see rating plate).
The cooling unit does not have its own overvoltage protection. Measures must e taken y the op-
erator at the supply end to ensure effective lightning and overvoltage protection. The mains voltage
must not exceed the tolerance of +6/-10 %. On three-phase units: The connection must e made
with the field rotating clockwise. The direction of rotation of the field can e measured at the connec-
tion terminals L1, L2 and L3. Connection with a clockwise rotating field ensures that all three-phase
motors rotate in the correct direction. In case of an integrated transformer (optional): Ensure correct
voltage connection on the primary side.
If you want to evaluate the fault codes for fault signals from the cooling unit using the alarm relay,
you must also connect an appropriate low-voltage ca le to terminals 3 – 8, see circuit diagram for
the relevant unit type. If the cooling system requires remote switching, terminals 1 and 2 can e
used for this purpose (see the circuit diagram for the relevant unit type) together with the appropri-
ate programming (parameter 18)
5.4.1
5.4.15.4.1
5.4.1 Connecting the power supply
Connecting the power supplyConnecting the power supply
Connecting the power supply
The units are prewired ready for connection in the factory and equipped with a twelve-wire connec-
tion ca le (length 2,5 m).
Make the electrical connection as per the electrical circuit diagram (see circuit diagram for the rele-
vant unit type).

15 / 48 83000902.Ka
5.4.2
5.4.25.4.2
5.4.2 Connecting the alarm relay interrogation device
Connecting the alarm relay interrogation deviceConnecting the alarm relay interrogation device
Connecting the alarm relay interrogation device
You can also query fault messages with two floating contacts on a separate connection clamp of the
cooling unit. The necessary wires are already present in the connection ca le and are connected in
the device. Connect the correspondingly la elled wires of the connection ca le to the controller as
shown in the electrical circuit diagram (see circuit diagram for the relevant unit type).
5.4.3
5.4.35.4.3
5.4.3 External activati
External activatiExternal activati
External activation
onon
on
The unit has een prepared with the option for control via an external signal. To implement this, the
customer must connect 24 V DC to contacts 1 and 2 (note polarity; see circuit diagram according to
unit type) and set parameter 18 to 1 (see description of the controller).
5.4.4
5.4.45.4.4
5.4.4 Connecting the cooling unit to the PLC
Connecting the cooling unit to the PLCConnecting the cooling unit to the PLC
Connecting the cooling unit to the PLC
To evaluate individual fault messages, the unit can e connected to a programma le logic controller
(PLC). The connection is made with a 15-pole Su -D socket. Use a suita le line to connect the PLC to
the 15-pole Su -D socket
For type nBoxX1.5:
For type nBoxX1.5: For type nBoxX1.5:
For type nBoxX1.5:
Fig. 7 PLC onne tion for nBoxX1.5
•Remove the louvered grille (2
22
2) on the rear of the cooling unit.
•Remove the housing (1
11
1).
•Guide a suita le connection ca le into the unit via the additional ca le gland provided
•Connect the ca le to the 15-pole Su -D socket

16 / 48 83000902.Ka
For types nBoxX3.0, nBoxX4.5 and nBoxX6.0
For types nBoxX3.0, nBoxX4.5 and nBoxX6.0For types nBoxX3.0, nBoxX4.5 and nBoxX6.0
For types nBoxX3.0, nBoxX4.5 and nBoxX6.0
Fig. 8 PLC onne tion for types nBoxX3.0 and nBoxX4.5
•Remove the louvered grille (3
33
3) on the rear of the cooling unit.
•Remove the filter mat, if applica le (2
22
2).
Fig. 9 PLC onne tion for type nBoxX6.0
•Guide a suita le connection ca le into the unit via the additional ca le gland provided
•Connect the ca le to the 15-pole Su -D socket
24V DC ext.
SPS 1
CTS
RTS
RXD
TXD
NC
GND
1
2
3
4
5
6
7
9
10
11
12
13
14
15
8
SPS 8

17 / 48 83000902.Ka
Fig. 10 Assignment of PLC onta ts
6
66
6Commissioning
CommissioningCommissioning
Commissioning
The cooling unit does not have its own main switch to switch the cooling unit on and off. It must e
switched on and off y the higher-level controller.
6.1
6.16.1
6.1 Antifreeze
AntifreezeAntifreeze
Antifreeze
As standard, the units are not suita le for operation elow the specified minimum temperature (see
chapter 11). The units are always to e used with a water-glycol mixture for the coolant with a maxi-
mum glycol content of etween 20 and 30% y volume. The recommended antifreeze is Antifrogen
N. Other types of antifreeze are possi le in specific cases, however only in consultation with the
manufacturer.
Note!
Note!Note!
Note!
Only use distilled or de
Only use distilled or deOnly use distilled or de
Only use distilled or de-
--
-ionised water in cooling units specified for such use
ionised water in cooling units specified for such useionised water in cooling units specified for such use
ionised water in cooling units specified for such use
Caution!
Caution! Caution!
Caution!
Risk of damage for pipes and seals!
Risk of damage for pipes and seals!Risk of damage for pipes and seals!
Risk of damage for pipes and seals!
Other additives may damage the pipes
Other additives may damage the pipes Other additives may damage the pipes
Other additives may damage the pipes and the seal on the cooling medium pump
and the seal on the cooling medium pump and the seal on the cooling medium pump
and the seal on the cooling medium pump
and are therefore not allowed.
and are therefore not allowed.and are therefore not allowed.
and are therefore not allowed.
6.2
6.26.2
6.2 Filling the cooling system with cooling medium
Filling the cooling system with cooling mediumFilling the cooling system with cooling medium
Filling the cooling system with cooling medium
For commissioning, proceed as follows:
Ensure that any shut-off valves installed in the cooling medium circuit are open.
Fill the unit with cooling medium via the fill nozzle (1
11
1) up to the full mark in the tank.
Switch on the power supply to the cooling unit via the higher-level controller. The indicators on the
controller illuminate and indicate the actual feed temperature of the cooling medium.
Check the direction of rotation of the motors (see direction of rotation arrows on the cooling medium
pump and on the condenser fan)
If necessary, lower the set-point temperature momentarily
Note!
Note!Note!
Note!
If the compressor and condenser fan do not start to operate, the temperature of the
cooling medium added is lower than the set-point temperature set.

18 / 48 83000902.Ka
6.3
6.36.3
6.3 Bleeding the cooling medium pump
Bleeding the cooling medium pumpBleeding the cooling medium pump
Bleeding the cooling medium pump
Bleed the pipes and top-up the cooling medium.
For types nBoxX1.5 only:
For types nBoxX1.5 only:For types nBoxX1.5 only:
For types nBoxX1.5 only:
The cooling medium pump fills y itself and does not need to e led.
For types nBoxX3.0, nBoxX4.5, nBoxX6.0
For types nBoxX3.0, nBoxX4.5, nBoxX6.0For types nBoxX3.0, nBoxX4.5, nBoxX6.0
For types nBoxX3.0, nBoxX4.5, nBoxX6.0
Fig. 11 Bleeding the ooling medium pump (types nBoxX3.0, nBoxX4.5 and nBoxX6.0)
Bleed the cooling medium pump y loosening the leed screw a little. As soon as cooling medium
escapes, re-tighten the screw.
During commissioning: Check the connecting pipes and pipe connections for leaks.

19 / 48 83000902.Ka
7
77
7Operation
OperationOperation
Operation
The cooling unit is switched on and off y the higher-level control. It operates automatically, i.e. the
cooling medium is pumped continuously and heat extracted from it during this process. A controller
provides automatic control ased on the hysteresis set. The controller has a display for the indication
of temperature values and uttons for setting operating parameters.
7.1
7.17.1
7.1 Controls
ControlsControls
Controls
Fig. 12 Controls – controller
The units have a 3-digit 7-segment display to indicate operating states and control keys to set oper-
ating parameters. After the power supply is switched on, the display "E0" appears initially for approx.
20 seconds to indicate that the unit is operational ( oot phase controller). After the oot phase, the
chiller will start to work.
During operation, the inlet temperature (to the equipment) of the cooling medium circuit is displayed
via the indicators, alternating with any error messages that are present in the form of error codes;
see section 7.5.
Two LEDs °C and °F are used as indicators for the temperature unit °C (Celsius) or °F (Fahrenheit).
You can perform the following activities via indicators and control keys:
•Reading temperature values
•Reading from error memory
•Acknowledging error messages
•Resetting the pump
•Reading and setting parameters for the controller
The measurement range for temperature measurements is:
•Celsius: –40°C to 70°C
•Fahrenheit: –40°F to 158°F
Temperatures are shown with a resolution of 0.1° in the following ranges:
•Celsius: –9.9°C to 70.0°C
•Fahrenheit: –9.9°F to 99.9°F
Key
KeyKey
Key
1 7-segment display
2 Temperature unit LEDs
3 Control keys

20 / 48 83000902.Ka
7.2
7.27.2
7.2 Key functions
Key functionsKey functions
Key functions
You can use the control keys to change control parameters within the assigned ranges (min. to max.
value). Ta . 1 in section 7.4 shows the parameters that may e set. The function of the control
changes depending on which control level you are on.
7.2.1
7.2.17.2.1
7.2.1 Key functions during operation
Key functions during operationKey functions during operation
Key functions during operation
The keys have the following functions during operation:
key:
Display of software version: Press and hold
Delete error memory when error memory is activated
activatedactivated
activated: Press and hold 10 seconds
key:
Display of temperature values from sensors 1 to 5, one after the other: Press repeatedly
Sensor 1: Cooling medium temperature (displayed continuously or after 30 sec. menu
timeout)
Sensor 2: Icing of evaporator unit
Sensor 3: Condenser, external
Sensor 4: Condenser, internal
Sensor 5: Room temperature (if com ined control active, see section 7.3)
key:
Manual alarm reset:
Parameter adjustment is interrupted if no key is pressed for approx. 30 seconds (or 10
seconds if an alarm is outstanding). If this is not done, the value will not e saved!
The display shows the preset values again.
+
keys:
Jump to the parameterisation level, see section 7.2.2: Press oth keys and hold for
a out 5 seconds.
To exit the parameterisation level, press oth keys again and hold for a out 5 seconds.