KKT Compact-Line cBoxX 30 User manual

Compact-Line
Operating Instructions
cBoxX 30
cBoxX 40
cBoxX 50
cBoxX 60
cBoxX 70
cBoxX 80
cBoxX 90
cBoxX 100
cBoxX 120
cBoxX 160
cBoxX 180
cBoxX 200

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Table 1: Contact details
Manufacturer
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone]
F [phone]
E [email protected]
W www.kkt-chillers.com
Service
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone] *
F [phone]
E [e-mail]
W www.kkt-chillers.com*
Service USA
KKT chillers, Inc.
1280 Landmeier Road
Elk Grove Village
IL 60007
T [phone]
F [phone]
TF [phone] *
E [e-mail] *

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Introduction
These operating instructions have been drawn up 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 refrigerating machine (chiller). It also contains advice on how to prevent
or correct faults.
Please allow yourself sufficient time to read through these instructions carefully and to digest all
the information this document contains. If you have any further questions, please contact the
KKT chillers Service Team using the contact details provided.
If properly used for its intended use and correctly maintained, the chiller ensures sustained, fault-
free operation. The methods and procedures described in these instructions should help you to
detect problems early and to take appropriate countermeasures.
If you keep to the maintenance programme described you ensure the reliability and safety of the
machine. You also keep the operating costs low and at the same time increase 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 purchased from KKT chillers. In this way you ensure the reliability and quality
of the machine.
KKT chillers reserves the right to change technical details without prior notice. The illustrations in
this document are not to scale!
As the Compact-Line units can be adapted to specific projects, this document only contains
information that is generally valid for all units in the series.
All project-specific data is enclosed with the unit in separate summary documentation.
▪Machine configuration
▪Parameter list
▪P&I diagram
▪Pump characteristic curve(s)
▪Circuit diagram
▪All other project specific details
ATTENTION! A black exclamation mark on a yellow background in a triangle indicates
important information and instructions to which you must pay particular attention and
must always follow.

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Contents
Introduction............................................................................................................................................. 3
1. Product description ................................................................................................................... 8
1.1. Intended use ...................................................................................................................... 8
1.2. Elements...........................................................................................................................11
1.3. Explanation of terms........................................................................................................12
2. Function and main components.............................................................................................13
2.1. Compressor ......................................................................................................................13
2.2. Evaporator ........................................................................................................................14
2.3. Condenser ........................................................................................................................14
2.4. Expansion valve ...............................................................................................................14
2.5. Refrigerant........................................................................................................................14
2.6. Oil ......................................................................................................................................15
2.7. Filter dryer ........................................................................................................................15
2.8. Pressure sensors .............................................................................................................15
2.9. Temperature sensors.......................................................................................................15
2.10. Control unit/ main circuit board......................................................................................15
2.11. Display ..............................................................................................................................15
2.12. Control cabinet.................................................................................................................16
2.13. Pump.................................................................................................................................16
2.14. Fan ....................................................................................................................................16
2.15. Cold water cycle ...............................................................................................................16
2.16. Materials used in the water circuit .................................................................................17
2.17. Water quality ....................................................................................................................19
2.18. Permitted cooling media .................................................................................................20
3. Options and accessories.........................................................................................................20
3.1. Version without tank, with pump ....................................................................................20
3.2. Version without tank, without pump...............................................................................20
3.3. Version with water cooled condenser.............................................................................21
3.4. Heater for compressor and control cabinet ...................................................................21
3.5. Insulation of the cold pipes and the pump(s) ................................................................21
3.6. Tank heater with thermostatic pump start.....................................................................22
3.7. Overflow valve for standby mode....................................................................................22
3.8. Higher pressure pump.....................................................................................................22
3.9. Second consumer circuit.................................................................................................23
3.10. Additional evaporator pump............................................................................................23
3.11. Automatic water feed.......................................................................................................23
3.12. Water circuit in non-ferrous metal-free version .............................................................23
3.13. DI package........................................................................................................................23
3.14. Special voltage.................................................................................................................23
3.15. Phase monitoring.............................................................................................................24
3.16. Hot gas bypass for output control <1K...........................................................................24
3.17. High-temperature package..............................................................................................24
3.18. Special paint finish ..........................................................................................................24

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3.19. Air filter mat (accessories)...............................................................................................24
3.20. Levelling feet (accessories).............................................................................................24
3.21. Level package (accessories) ...........................................................................................25
3.22. Filter assembly group coolant circuit (accessories).......................................................25
3.23. Filter assembly group cooling water circuit (accessories).............................................25
3.24. MultiplexX connection group (accessories)....................................................................26
3.25. Refill cartridge R410A (accessories) ..............................................................................26
3.26. Anybus-Gateway (accessories)........................................................................................26
3.27. Remote Control Panel (accessories)...............................................................................27
3.28. Special languages (accessories).....................................................................................27
3.29. Wooden Crate (accessories) ..........................................................................................27
3.30. Seaworthy crate packaging (accessories)......................................................................27
3.31. Water Pump Redundancy................................................................................................27
3.32. Closed Water Loop...........................................................................................................27
4. Safety........................................................................................................................................29
4.1. General information.........................................................................................................29
4.2. Hazard warnings ..............................................................................................................29
4.3. Residual energy................................................................................................................32
4.4. Safety devices, guards and safeguards .........................................................................33
4.4.1. High-pressure limiter................................................................................................33
4.4.2. High-pressure monitoring ........................................................................................34
4.4.3. Low-pressure monitoring .........................................................................................34
4.4.4. Flow monitoring........................................................................................................34
4.4.5. Personal protective equipment when operating the machine ..............................34
4.5. Personal protective equipment for servicing work ........................................................35
4.6. Airborne sound emissions...............................................................................................35
4.7. Notes on reducing noise and vibration...........................................................................36
4.7.1. Noise .........................................................................................................................36
4.7.2. Vibration....................................................................................................................36
4.8. Residual risks...................................................................................................................37
4.8.1. Electrical ...................................................................................................................37
4.8.2. Mechanical ...............................................................................................................37
4.8.3. Chemical ...................................................................................................................37
4.8.4. Other .........................................................................................................................37
4.9. Dangerous substances....................................................................................................37
4.9.1. Refrigerant R410A ...................................................................................................37
4.9.2. Oil POE 160SZ..........................................................................................................39
4.10. Reasonably foreseeable misuse.....................................................................................40
4.11. Information for emergencies...........................................................................................41
5. Handling and storage ..............................................................................................................41
5.1. Dangerous goods .............................................................................................................41
5.2. Transport ..........................................................................................................................41
5.2.1. Forklift truck .............................................................................................................42
42
5.2.2. Crane.........................................................................................................................43

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5.3. Unpacking.........................................................................................................................44
5.4. Storage .............................................................................................................................44
6. Installation ...............................................................................................................................45
6.1. Overview ...........................................................................................................................45
6.2. Installation site.................................................................................................................45
6.2.1. General information .................................................................................................45
6.2.2. Minimum room volume............................................................................................45
6.2.3. Ambient temperature...............................................................................................46
6.2.4. Effect of surrounding air flow ..................................................................................46
6.2.5. Minimum clearances ...............................................................................................46
6.2.6. External attachments...............................................................................................46
6.2.7. Process level.............................................................................................................47
6.2.8. Surface and foundation ...........................................................................................47
6.2.9. Stability .....................................................................................................................48
6.2.10. Levelling....................................................................................................................48
6.2.11. Vibration isolation ....................................................................................................48
6.2.12. Installation................................................................................................................49
6.2.13. Hydraulic installation ...............................................................................................49
6.2.14. Frost protection measures ......................................................................................50
6.2.15. Flushing the cold water circuit ................................................................................50
6.2.16. Filling.........................................................................................................................50
6.2.17. Venting......................................................................................................................52
6.2.18. Electrical installation................................................................................................53
7. Commissioning ........................................................................................................................54
7.1. Installation checklist........................................................................................................54
8. Operation..................................................................................................................................55
8.1. Switching on.....................................................................................................................55
8.2. Selecting the operating mode.........................................................................................55
8.3. External release ...............................................................................................................55
8.4. Control ..............................................................................................................................55
8.5. Control panel....................................................................................................................56
8.5.1. Start screen ..............................................................................................................57
8.5.2. Main menu................................................................................................................58
8.5.3. Information ...............................................................................................................58
8.5.4. Settings.....................................................................................................................60
8.5.5. Alarm menu ..............................................................................................................60
8.6. Parameters.......................................................................................................................61
8.7. Controller description ......................................................................................................62
8.7.1. Electronic level monitoring ......................................................................................62
8.7.2. Switching the chiller On/off .....................................................................................62
8.7.3. Cold water flow temperature control ......................................................................63
8.7.4. Compressor control..................................................................................................64
8.7.5. Fan speed control ....................................................................................................64
8.7.6. Electronic expansion valve control..........................................................................65
8.7.7. Temperature limit monitoring..................................................................................65

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8.7.8. Group fault alarm .....................................................................................................65
8.8. Operating modes..............................................................................................................65
8.8.1. ECO mode .................................................................................................................65
8.8.2. Comfort mode...........................................................................................................65
9. Cleaning ...................................................................................................................................66
9.1. Air filter mat......................................................................................................................66
9.2. Condenser ........................................................................................................................66
9.3. Water filter........................................................................................................................66
9.4. Complete cleaning of the cold water circuit...................................................................66
10. Service......................................................................................................................................67
10.1. Maintenance ....................................................................................................................67
10.2. Fault correction ................................................................................................................67
10.3. Spare parts.......................................................................................................................67
11. Taking out of service ...............................................................................................................68
11.1. Draining ............................................................................................................................68
12. Recycling ..................................................................................................................................69
13. Products, solutions and services............................................................................................69
14. Lists ..........................................................................................................................................70
14.1. List of illustrations............................................................................................................70
14.2. List of tables.....................................................................................................................70
I. Main dimensions .....................................................................................................................72
II. Installation instructions...........................................................................................................76
III. Troubleshooting .......................................................................................................................80
IV. Maintenance intervals in accordance with the VDMA...........................................................85
V. Product Registration................................................................................................................88
VI. EC Declaration of Conformity..................................................................................................89

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1. Product description
Please read all the points in these operating instructions before starting up the machine. You
should pay particular attention to the points on safety, commissioning/startup and operation. If
you have further questions about your machine, please contact the KKT chillers Service Team
(see Table 1: Contact details).
1.1. Intended use
The cBoxX is a factory-tested, fully automatic compressor chiller. The machine is solely for cooling
liquids (fluids) in accordance with EN 378-1. An adequate supply of cooling air must be provided.
Only approved liquids may be used. The cBoxX corresponds to protection class IP 54 (when the
housing is closed) and is suitable for both indoor and outdoor installation (note the options
packages).
The operator is responsible for complying with the specified operating, servicing and maintenance
conditions according to these operating instructions.
The owner of the chiller, not the manufacturer, is responsible and liable for all personal injuries
and damage to property caused by improper use of the unit (misuse).
Table 2 shows the general safety instructions of the chiller. These are attached to the machine in
a clear and readily visible position. A complete description of all hazard warnings is given in
Chapter 4.2 Hazard warnings.
Table 2: Safety instructions
Note and follow the instructions for use!
Before opening the machine it must be disconnected from the power supply!
After disconnecting the machine from the power supply, always wait for at least
5 minutes before opening it.
Danger! High voltage! If the machine is only switched off at its main switch,
dangerous electrical voltage is still present at several terminals in the control
cabinet.

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Technical data
Table 3: Technical data
Compact-Line
-
cBoxX 30
cBoxX 40
cBoxX 50
cBoxX 60
cBoxX 70
cBoxX 80
cBoxX 90
cBoxX 100
Refrigerating capacity @ tw2=20°C / tu=32°C
kW
34
43
55
68
78
87
95
105
Refrigeration circuit hermetically tight
no
Refrigerant
-
R410A
GWP
2088
Refrigerant capacity
kg
6
6
6
7
8
8
8
8
CO2 equivalent
t CO2
12,5
12,5
12,5
14,6
16,7
16,7
16,7
16,7
Cooling medium (liquid/secondary refrigerant)
-
Water or water / glycol
Ambient temperature range
°C
+5 to +45 (optionally -25 to +50°C)
Liquid feed temperature
°C
+8 to +30 (optionally to -10)
Target constancy
K
+/-1
Tank volume
l
300
500
Coolant circulation, nominal (dt = 5K)
m³/h
5.5
7.2
9.2
11.1
12.4
14.3
16.1
18.2
Free pump pressure (standard)
bar
3
Water connection, nominal size
RP
11/2"
2"
Air flow rate (max.)
m³/h
9350
9350
12600
20000
23270
23270
23270
23270
Sound pressure level at 5 m distance
dBA
62
62
55
69
59
59
59
59
Operating voltage (standard)
V/Ph/Hz
400/ 3/ 50
Protection class
-
IP54
Height
mm
2030
2030
Width
mm
830
830
Length
mm
1240
1840
Net weight
kg
540
540
550
620
650
650
700
720
Gross weight
kg
840
840
850
920
1150
1150
1200
1220

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Compact-Line
-
cBoxX 120
cBoxX 160
cBoxX 180
cBoxX 200
Refrigerating capacity @ tw2=20°C / tu=32°C
kW
135
166
194
210
Refrigeration circuit hermetically tight
no
Refrigerant
-
R410A
GWP
2088
Refrigerant capacity
kg
17
17
23,5
23,5
CO2 equivalent
t CO2
35,5
35,5
49,1
49,1
Cooling medium (liquid/secondary refrigerant)
-
Water or water / glycol
Ambient temperature range
°C
+5 to +45 (optionally -25 to +50°C)
Liquid feed temperature
°C
+8 to +30 (optionally to -10)
Target constancy
K
+/-1
Tank volume
l
700
900
Coolant circulation, nominal (dt = 5K)
m³/h
21,5
27,2
32,2
35,4
Free pump pressure (standard)
bar
3
Water connection, nominal size
RP
DN65 PN10 EN1092
Air flow rate (max.)
m³/h
45550
49100
Sound pressure level at 5 m distance
dBA
67
67
67
67
Operating voltage (standard)
V/Ph/Hz
400/ 3/ 50
Protection class
-
IP54
Height
mm
2030
Width
mm
1200
Length
mm
2665
3965
Net weight
kg
1100
1200
1300
1400
Gross weight
kg
1800
1900
2200
2300