KKT chillers vBoxX 6 Operational manual

1 / 88 83000602Km
Vario Line
vBoxX 6
vBoxX 8
vBoxX 10
vBoxX 12
vBoxX 15
vBoxX 18
vBoxX 24
vBoxX 28
Translation of the original operating manual
EN

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Table 1: Contact details
Manufacturer
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone]
F [phone]
E [e-mail]
W www.kkt-chillers.com
Service
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone]
F [phone]
E [e-mail]
W www.kkt-chillers.com
Service USA
KKT chillers, Inc.
765 Dillon Drive
Wood Dale
IL 60191
T [phone]
F [phone]
TF [phone]
E [e-mail]
W www.kkt-chillers.com

3 / 88 83000602Km
Introduction
This instruction manual (operating instructions) has been prepared by KKT chillers on the basis of the
Machinery Directive 2006/42/EC. 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.
Allow yourself sufficient time to read through this manual carefully and to take in all the information it
contains. If you have any further questions you can contact the KKT chillers service team; refer to the
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 status and to initiate corresponding countermeasures.
By complying with the servicing and maintenance programme described you ensure that the machine's
reliability and safety are maintained. In addition, you keep the operating costs low and at the same time
lengthen the 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. In this way you ensure the reliability and quality of the machine.
WARNING! A black exclamation mark on a yellow background in a triangle indicates
important information, which you must pay particular attention to and must always
note and follow.
KKT chillers reserves the right to change technical specifications without prior announcement. The figures
in this document are not to scale!
As the Vario Line units can be adapted to a specific project, this document contains only information that
is of general relevance for all units in the series.
All project-specific data is enclosed with the unit in a separate quick start guide.
Machine configuration
Parameter list
PI flow chart
Pump characteristic curve(s)
Circuit diagram
All other project-specific details

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Contents
Vario Line............................................................................................................................................1
Introduction.............................................................................................................................................3
1. Product description....................................................................................................................8
1.1. Intended use ......................................................................................................................8
1.2. Elements...........................................................................................................................10
1.3. Explanation of terms........................................................................................................11
2. Function and main components.............................................................................................12
2.1. Compressor ......................................................................................................................12
2.2. Evaporator ........................................................................................................................13
2.3. Condenser ........................................................................................................................13
2.4. Expansion valve................................................................................................................13
2.5. Refrigerant........................................................................................................................13
2.6. Oil ......................................................................................................................................14
2.7. Filter dryer.........................................................................................................................14
2.8. Pressure sensors .............................................................................................................14
2.9. Temperature sensors.......................................................................................................14
2.10. Control unit.......................................................................................................................14
2.11. Display ..............................................................................................................................14
2.12. Control cabinet.................................................................................................................14
2.13. Pump.................................................................................................................................15
2.14. Ventilator ..........................................................................................................................15
2.15. Cold water circuit .............................................................................................................15
2.16. Materials used in the water circuit .................................................................................16
2.17. Water quality ....................................................................................................................17
2.18. Permitted coolant media .................................................................................................18
3. Options and accessories .........................................................................................................19
3.1. Version without tank, with pump ....................................................................................19
3.2. Version without tank, without pump...............................................................................19
3.3. Version with water-cooled condenser.............................................................................19
3.4. Control cabinet heating ...................................................................................................20
3.5. Insulation of cold lines and pump(s) ..............................................................................20
3.6. Tank heater with thermostatic pump start.....................................................................21
3.7. Overflow valve for standby operation .............................................................................21
3.8. Higher pressure pump .....................................................................................................22
3.9. Speed-controlled pump ...................................................................................................22
3.10. Additional evaporator pump............................................................................................22
3.11. Second consumer pump..................................................................................................22
3.12. Second temperature level ...............................................................................................22
3.13. Second medium ...............................................................................................................23
3.14. Automatic water feed.......................................................................................................23
3.15. Flow control switch...........................................................................................................23

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3.16. Water circuit in non-ferrous metal version .....................................................................23
3.17. DI package........................................................................................................................24
3.18. Conductivity monitoring...................................................................................................24
3.19. Conductivity control .........................................................................................................24
3.20. Special voltage .................................................................................................................24
3.21. Phase monitoring.............................................................................................................24
3.22. UL version.........................................................................................................................24
3.23. Special paint finish ..........................................................................................................24
3.24. Air filter mat (accessories)...............................................................................................25
3.25. Vario Foot (accessories) ..................................................................................................25
3.26. Level package (accessories) ...........................................................................................25
3.27. Filter assembly, coolant circuit (accessories) ................................................................25
3.28. Filter assembly, cooling water circuit (accessories) ......................................................25
3.29. Gateway (accessories).....................................................................................................25
3.30. Remote control panel (accessories) ...............................................................................26
3.31. Special languages (accessories).....................................................................................26
3.32. Wooden crate (accessories)............................................................................................26
3.33. Seaworthy crate packaging (accessories)......................................................................26
4. Safety........................................................................................................................................26
4.1. General information.........................................................................................................26
4.2. Hazard warnings ..............................................................................................................26
4.3. Residual energy................................................................................................................29
4.4. Safety devices, guards and safeguards..........................................................................30
4.4.1. High pressure limiter................................................................................................30
4.4.2. High-pressure monitoring via sensor ......................................................................30
4.4.3. Low-pressure monitoring .........................................................................................30
4.4.4. Flow monitoring........................................................................................................30
4.4.5. Oil temperature monitor ..........................................................................................31
4.4.6. Personal protective equipment when operating the machine ..............................31
4.5. Personal protective equipment for servicing work.........................................................31
4.6. Airborne sound emissions ...............................................................................................31
4.7. Notes on reducing noise and vibration...........................................................................33
4.7.1. Noise .........................................................................................................................33
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 .........................................................................................................................34
4.9. Hazardous substances ....................................................................................................34
4.9.1. Refrigerant R410A ...................................................................................................34
4.9.2. Oil ..............................................................................................................................35
4.10. Reasonably foreseeable misuse.....................................................................................36

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4.11. Information for emergencies...........................................................................................37
5. Handling and storage ..............................................................................................................38
5.1. Dangerous goods .............................................................................................................38
5.2. Transport ..........................................................................................................................38
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. Process level.............................................................................................................42
6.2.7. Surface and foundation ...........................................................................................42
6.2.8. Stability .....................................................................................................................42
6.2.9. Levelling....................................................................................................................42
6.2.10. Vibration isolation.....................................................................................................42
6.2.11. Installation ................................................................................................................43
6.2.12. Hydraulic installation................................................................................................44
6.2.13. Frost protection measures.......................................................................................44
6.2.14. Flushing the cold water circuit.................................................................................44
6.2.15. Filling.........................................................................................................................45
6.2.16. Venting ......................................................................................................................46
6.2.17. Electrical installation................................................................................................46
7. Initial startup............................................................................................................................48
7.1. Installation checklist........................................................................................................48
8. Operation..................................................................................................................................49
8.1. Switching on .....................................................................................................................49
8.2. Selecting the operating mode .........................................................................................49
8.3. External release ...............................................................................................................49
8.4. Control ..............................................................................................................................49
8.5. Control panel ....................................................................................................................50
8.5.1. Start screen ..............................................................................................................51
8.5.2. Change of operating mode ......................................................................................52
8.5.3. Navigating to the menu levels.................................................................................53
8.6. Parameter.........................................................................................................................54
8.7. Controller description ......................................................................................................54
8.7.1. Electronic level monitoring ......................................................................................54
8.7.2. Switching the chiller on/off......................................................................................54
8.7.3. Cold water feed temperature control......................................................................55

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8.7.4. Compressor control..................................................................................................56
8.7.5. Fan speed control.....................................................................................................56
8.7.6. Electronic expansion valve control..........................................................................56
8.7.7. Temperature limit monitoring..................................................................................56
8.7.8. Group fault message + warning message..............................................................57
9. Cleaning....................................................................................................................................58
9.1. Air filter mat......................................................................................................................58
9.2. Condenser ........................................................................................................................58
9.3. Water filters......................................................................................................................58
9.4. Complete cleaning of the cold water circuit...................................................................58
10. Service......................................................................................................................................59
10.1. Servicing/maintenance ...................................................................................................59
10.2. Fault clearance.................................................................................................................59
10.3. Spare parts.......................................................................................................................60
11. Withdrawing from service........................................................................................................61
11.1. Draining ............................................................................................................................61
12. Recycling ..................................................................................................................................62
13. Products, solutions and services............................................................................................62
I. Overview of the menu levels ...................................................................................................63
II. Troubleshooting .......................................................................................................................72
III. Maintenance intervals in accordance with the VDMA...........................................................86
IV. Product registration .................................................................................................................88

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1. Product description
Please read through all the points of this instruction manual 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 Table
1: Contact details ).
1.1. Intended use
The vBoxX is a factory-tested, fully automatic compression 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 vBoxX is suitable for both indoor and outdoor installation (note options
packages).
The user (owner) is obliged to comply with the conditions specified by the manufacturer with regard to
operation, servicing and maintenance according to this instruction manual.
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 are attached to the outside of the
machine in a clearly 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!
The machine must be safely disconnected from the power supply before it is
opened! Then wait for at least 2 minutes before opening the machine.
Warning! Electric shock! If the machine is only switched off at its main switch,
dangerous electrical voltage is still applied at several terminals in the control
cabinet.

9 / 88 83000602Km Table 3: Technical data
Vario Line
-
vBoxX 6
vBoxX 8
vBoxX 10
vBoxX 12
vBoxX 15
vBoxX 18
vBoxX 24
vBoxX 28
Cooling capacity @ tw2=20°C / tu=32°C
kW
6.2
8.2
10.2
12.4
15.3
18.3
24.5
28.5
Refrigeration circuit hermetically sealed
yes
Refrigerant
-
R410A
GWP
2088
Refrigerant capacity
kg
1.6
1.6
1.8
1.8
2.5
3.2
3.4
3.4
CO2 equivalent
t CO2
3.3
3.3
3.8
3.8
5.2
6.7
7.1
7.1
Coolant
-
Water or water / glycol
Ambient temperature range
°C
-25 to +50°C
Refrigerant supply temperature
°C
-10 to +30°C
+5 to +30
Setpoint consistency (basic features)
K
+/-0.5
Tank volume
l
100
160
Tank volume (max)
l
88
151
Refrigerant circulating flow volume nom
(dt = 5K) m³/h 1.1 1.4 1.8 2.1 2.6 3.1 4.8 4.8
free pump pressure (basic features)
bar
3
Water connection nominal diameter
RP
1"
1 ½”
Air flow rate (max.)
m³/h
4.400
4.400
4.400
4.400
8.200
8.200
8.200
8.200
Sound pressure level at 5m distance
dBA
54
54
54
54
59
59
59
59
Operating voltage (basic features)
V/Ph/Hz
400/ 3/ 50 or 480 V/3 Ph/60 Hz or 400 V/3 Ph/60 Hz
Protection class
-
IP44
Height
mm
1385
1500
Width
mm
800
800
Length
mm
800
1000
Net weight
kg
265
265
265
265
340
340
340
340
Gross weight
kg
365
365
365
365
500
500
500
500
The data listed here apply to the units with basic features. Differences can occur, as the units are adapted to the respective customer specification from project to project. The exact, project-specific data can be found in the enclosed quick start guide.

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1.2. Elements
1
Operating side
a
Safety instructions
2
Cover
b
Water connections
3
Tank, service side
c
Nameplate
4
Compressor, service side
d
Display
5
Condenser protection grille
e
Main switch
f
Tank fill

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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.

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2. Function and main components
The chiller consists of the main compressor, condenser, expansion valve and evaporator
components, which are arranged in a circuit (
Figure 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 Refrigerating circuit diagram
In addition, diverse pressure and temperature sensors, a control unit, a high-pressure switch, one
or more pumps and a fan are also installed for control and operation of the chiller.
2.1. Compressor
The compressor generates the pressure difference necessary for evaporation and condensation
between the heat sink and heat source in the refrigerant circuit. Refrigerant vapour coming from
the evaporator is drawn in and compressed in the compressor to the condensing pressure.
The compressors used for the Vario-Line are speed-controlled and thus automatically adapt to the
required load profile – the chiller therefore always operates with maximum energy efficiency.
Compressor
Condenser and fan
Evaporator
Expansion
valve
Heat
Coolant

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2.2. Evaporator
The evaporator is a plate heat exchanger that transfers 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 status 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 status 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
vapour, use the optionally available air filter (see
Chapter 3.24 Air filter mat ).
If a cooling water system is available and the warm exhaust air of the chiller is to be avoided, the
chiller can also be equipped with a water-cooled condenser (see
Chapter 3.3 Version with water-
cooled condenser ).
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.
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 status in doing so.
R410A is a fluorinated greenhouse gas consisting of the zeotropic mixture of 50% each of R32
and R125 with virtually negligible temperature glide. R410A has a very high volumetric cooling
capacity and has no ozone depletion potential (ODP=0). A corresponding safety data sheet can be
requested from our KKT chillers Service Team (
see Table 1: Contact details ).

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2.6. Oil
The compressor components subject to friction are lubricated by oil that is added in the factory
by the compressor manufacturer. Polyolester (POE) oil FV505 is used for this purpose. The oil is
soluble in the refrigerant and distributes itself with it throughout the entire refrigeration circuit.
A corresponding safety data sheet can be requested from our KKT chillers Service Team
(
see Table 1: 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 carried out on the
refrigeration circuit, for which it is opened, the filter dryer must be replaced.
2.8. Pressure sensors
The pressure sensors used are compact pressure transmitters with piezoresistive measurement
cell. The sensors continuously record the system pressure at various locations in the refrigerant
and cold water circuits. The values are used to regulate the system and for visualisation on the
controller display.
2.9. Temperature sensors
The temperature sensors employed are equipped with a platinum measurement cell. The sensors
continuously record the temperature at various locations in the refrigerant and cold water circuits.
The values are used to control the system.
2.10. Control unit
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. To open the control cabinet, undo the screws in
the front panel first (hex socket head, 4mm). The tilt the front panel slightly towards the front and
lift it out from above (see figure below). Now open the control cabinet door with the corresponding
control cabinet key.

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Figure 2: Opening the control cabinet
2.13. Pump
The pump of the chiller provides for the necessary circulation of the cold water. This is drawn out
of the chiller’s internal tank and is pumped through the process circuit. Optionally, the units can
also be supplied as circulating coolers without tank, with pump or without tank, without pump
(see
Chapter 3.1 Version without tank, with pump and Chapter 3.2 Version without tank, without
pump ).
2.14. Ventilator
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 wire guards on the discharge side. 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.
2.15. Cold water circuit
The cold water is drawn in from the chiller’s internal tank by the internal pump and is then
pumped through the process circuit. Optionally, the units can also be supplied as circulating
coolers without tank with pump or without tank, without pump (see
Chapter 3.1 Version without
tank, with pump and Chapter 3.2 Version without tank, without 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 cold water goes back to
the tank. Then the cycle starts again.

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2.16. Materials used in the water circuit
The basic features result from the material composition shown in Table 5:
Table 5: Materials used, basic configuration
Component
Material
Unit connections
V2A 1.4305
Evaporator
V2A 1.4301 and copper (99.9%)
Tank
Tank nozzle
V2A 1.4301
V4A 1.4305
Pump
Mechanical seal
V2A 1.4301
EPDM
Sealing plugs yellow
Polyamide PA 6
Sealing plugs black
Polyoxymethylene (POM)
Filling and drain valve
Brass, nickel-plated
Bends, tees, couplings
Gun metal CC499K, brass
Temperature sensor
V2A 1.4401 – AISI316
Pressure sensor
V2A 1.4301
Overflow valve (optional)
Gunmetal
Tank heater (optional)
Nickel chromium iron alloy, alloy 825
Water circuit
John Guest pipping made of polybutylene,
Hose made of synthetic rubber
Push-fit fitting
Acetal copolymer, nitrile (NBR), V2A
Table 6: Materials used, non-ferrous metal free version
Component
Material
Unit connections
V2A 1.4305
Evaporator
V2A 1.4301
Tank
Tank nozzle
V2A 1.4301
V4A 1.4305
Pump
Mechanical seal
V2A 1.4301
EPDM
Sealing plugs yellow
Polyamide PA 6
Sealing plugs black
Polyoxymethylene (POM)
Filling and drain valve
V2A 1.4301
Bends, tees, couplings
V2A 1.4301
Temperature sensor
V2A 1.4401 – AISI316
Pressure sensor
V2A 1.4301
Overflow valve (optional)
V2A 1.4301 / plastic
Tank heater (optional)
Nickel chromium iron alloy, alloy 825
Water circuit
John Guest piping made of polybutylene (BGI)
Hose made of synthetic rubber (BGII)
Push-fit fitting
Acetal copolymer, nitrile (NBR), V2A

17 / 88 83000602Km
2.17. Water quality
The following limit values must be complied with to ensure safe operation of the units:
Table 7: Water quality
Property / component
parts
Unit
Value range
Standard configuration
Value range
Non-ferrous metal-free
version
pH-value (20°C)
-
7.5 - 9
6-10
Saturation index
-
-0.2 < 0 < +0.2
-
Conductivity
µS/cm
30-500
3-2000
Water hardness
°dH
4.5 - 8.5
<8.5
Total bacterial count
K/ml
<10,000
<10,000
Particle size
µm
< 250
< 250
Glycol fraction (AFN)
% by vol
0, 20-40
0, 20-40
Oil fraction
% by vol
0
0
Chloride (Cl-)
mg/L
<200
<200
Sulphate
mg/L
<70
<300
Nitrate
mg/L
<100
<100
Copper
mg/L
<0.1
<0.1
Iron
mg/L
<0.2
<0.2
Free carbon dioxide
mg/L
<5
<20
Manganese
mg/L
<0.5
<0.1
Ammonia
mg/L
<0.5
<20
Free chlorine
mg/L
<0.5
<0.5
Sulphide SO3
mg/L
<1
<1
Hydrogen carbonate
(alkalis) HCO3
mg/L
70-200
-
Hydrogen sulphide
(H2S)
mg/L
<0.05
<0.05
Filterable substances
mg/L
<30
<30
The specified limit values must always be complied with in order to avoid blockaging of the plate
heat exchanger.
Furthermore, slime-forming bacteria must be prevented in the cooling water. If this is not
possible, KKT chillers can recommend or provide an appropriate inhibitor to remove the slime
forming agents on the basis of a biological water analysis carried out in advance.

18 / 88 83000602Km
2.18. Permitted coolant media
Water and mixtures of water / Antifrogen N (AFN) or water / Antifrogen L (AFL) as defined in
Chapter 2.17 Water quality are allowed. The following table shows the requirements for the mix
ration of water with antifreezes AFN and AFL. These values must be kept to as accurately as
possible in order to maintain your machine's efficiency and prevent damage to components.
WARNING! Do not use mixtures of different anti-freezes. This can cause unwanted
chemical reactions and silting-up.
Table 8: AFN and AFL mix ratios (or equivalent)
Setting
Frost-free at t-ambient
up to
AFN mixing ratio
AFL mix ratio
Glycol 20 - 25 %
-10°C
20-25 %
25-30 %
Glycol 30 - 35 %
-15°C
30-35 %
32-37 %
Glycol 40 %
-25°C
40 %
42 %

19 / 88 83000602Km
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 unit, 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
Table 1: Contact details ).
Information on your machine’s features can be found in the separately enclosed quick start
guide.
3.1. Version without tank, with pump
The Vario-Line units are optionally also available as circulating coolers. In this case, the units are
delivered without an internal tank. The temperature sensor is then located in the return line of the
cooler. If a tank open to the atmosphere (atmospheric tank) is integrated on site, it must be
ensured that the tank is not installed at a lower geodetic level than the cooler. Additional
pressure losses between the on-site tank and integrated pump must be avoided (dpmax=0.3bar)
3.2. Version without tank, without pump
The Vario-Line units are optionally also available as circulating coolers. In this case, the units are
delivered without an internal tank and without a pump. The temperature sensor is then located in
the return line of the cooler. Circulation of the cold water via the evaporator then takes place via a
pump to be installed on site. This must at least be designed for the pressure loss of the overall
system.
3.3. Version with water-cooled condenser
While the basic variant of the Vario-Line has an air-cooled condenser, it is possible to purchase
the individual units of this series with water-cooled condensers too.
Figure 3: C6848 Refrigerating circuit diagram
The condenser used is a plate heat exchanger whose stainless steel plates are copper soldered.
The 3-way valve is located in the cooling water outlet and is controlled via an actuator according
to the condensation pressure. Switching from 3-way to 2-way control can be achieved by closing
the additionally provided bypass valve.

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The cooling water temperature is registered by an additional temperature sensor in the cooling
water inlet and is displayed on the controller display.
The water quality listed under Table 7: Water quality must be complied with – the
manufacturer does not accept any liability for any damage caused by a different
water specification!
The project-specific data and the adjusted PI flowchart and dimensioned diagram can be found in
the enclosed quick guide.
3.4. Control cabinet heating
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.
The control cabinet can only be active if the chiller is not de-energised (Main switch ON) (see
Chapter 8.1 Switching on ).
3.5. Insulation of cold lines and pump(s)
To prevent condensation on cold chiller pipes, where high temperature differences exist between
the surroundings and cold water flow and taking into account the relative humidity the option of
insulation of the cold pipes must be specified.