KKT Compact-Line cBoxX Series User manual

Compact
CompactCompact
Compact-
--
-Line
LineLine
Line
Operating Instructions
cBoxX 30
cBoxX 40
cBoxX 50
cBoxX 60
cBoxX 70
cBoxX 80
cBoxX 90
cBoxX 100
cBoxX 1 0
cBoxX 160
cBoxX 180
cBoxX 00

Table
Table Table
Table 1
11
1:
::
: Contact details
Contact detailsContact details
Contact details
Manufacturer
Service
Service USA
/ 77
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone]
F [phone]
E [email protected]
W www.kkt-chillers.com
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone] *
F [phone]
E [e-mail]
W www.kkt-chillers.com
KKT chillers, Inc.
765 Dillon Drive
Wood Dale, IL 60191
T [phone]
F [phone]
TF [phone] *
E [email protected]
8300010 .Kf
*
*

3 / 77 8300010 .Kf
Introduction
IntroductionIntroduction
Introduction
These operating instructions have been drawn up by KKT chillers on the basis of the Machinery
Directive 006/4 /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
ATTENTION! A black exclamation markATTENTION! A black exclamation mark
ATTENTION! A black exclamation mark on a yellow background in a triangle indicates
on a yellow background in a triangle indicates on a yellow background in a triangle indicates
on a yellow background in a triangle indicates
important information and instructions to which you must pay particular attention and
important information and instructions to which you must pay particular attention and important information and instructions to which you must pay particular attention and
important information and instructions to which you must pay particular attention and
must always follow.
must always follow.must always follow.
must always follow.

4 / 77 8300010 .Kf
Contents
Introduction ............................................................................................................................................. 3
1. Product description ................................................................................................................... 8
1.1. Intended use ...................................................................................................................... 8
1. . Technical data .................................................................................................................... 9
1.3. Elements ........................................................................................................................... 11
1.4. Explanation of terms ........................................................................................................ 1
. Function and main components ............................................................................................. 13
.1. Compressor ...................................................................................................................... 13
. . Evaporator ........................................................................................................................ 14
.3. Condenser ........................................................................................................................ 14
.4. Expansion valve ............................................................................................................... 14
.5. Refrigerant ........................................................................................................................ 14
.6. Oil ...................................................................................................................................... 15
.7. Filter dryer ........................................................................................................................ 15
.8. Pressure sensors ............................................................................................................. 15
.9. Temperature sensors....................................................................................................... 15
.10. Control unit/ main circuit board ...................................................................................... 15
.11. Display .............................................................................................................................. 15
.1 . Control cabinet ................................................................................................................. 16
.13. Pump ................................................................................................................................. 16
.14. Fan .................................................................................................................................... 16
.15. Cold water cycle ............................................................................................................... 16
.16. Materials used in the water circuit ................................................................................. 17
.17. Water quality .................................................................................................................... 19
.18. Permitted cooling media ................................................................................................. 0
3. Options and accessories ......................................................................................................... 0
3.1. Version without tank, with pump .................................................................................... 0
3. . Version without tank, without pump ............................................................................... 0
3.3. Version with water cooled condenser ............................................................................. 1
3.4. Heater for compressor and control cabinet ................................................................... 1
3.5. Insulation of the cold pipes and the pump(s) ................................................................ 1
3.6. Tank heater with thermostatic pump start .....................................................................
3.7. Overflow valve for standby mode ....................................................................................
3.8. Higher pressure pump .....................................................................................................
3.9. Second consumer circuit ................................................................................................. 3
3.10. Additional evaporator pump ............................................................................................ 3
3.11. Automatic water feed ....................................................................................................... 3
3.1 . Water circuit in non-ferrous metal-free version ............................................................. 3
3.13. DI package ........................................................................................................................ 4
3.14. Special voltage ................................................................................................................. 4
3.15. Phase monitoring ............................................................................................................. 4
3.16. Hot gas bypass for output control <1K........................................................................... 4
3.17. High-temperature package .............................................................................................. 4

5 / 77 8300010 .Kf
3.18. Special paint finish .......................................................................................................... 4
3.19. Air filter mat (accessories) ............................................................................................... 4
3. 0. Levelling feet (accessories) ............................................................................................. 5
3. 1. Level package (accessories) ........................................................................................... 5
3. . Filter assembly group coolant circuit (accessories) ....................................................... 5
3. 3. Filter assembly group cooling water circuit (accessories) ............................................. 6
3. 4. MultiplexX connection group (accessories) .................................................................... 6
3. 5. Refill cartridge R410A (accessories) .............................................................................. 6
3. 6. Anybus-Gateway (accessories) ........................................................................................ 6
3. 7. Remote Control Panel (accessories).............................................................................. 7
3. 8. Special languages (accessories) ..................................................................................... 7
3. 9. Wooden Crate (accessories) .......................................................................................... 7
3.30. Seaworthy crate packaging (accessories) ...................................................................... 7
3.31. Water Pump Redundancy ................................................................................................ 7
3.3 . Closed Water Loop ........................................................................................................... 8
4. Safety........................................................................................................................................ 8
4.1. General information ......................................................................................................... 8
4. . Hazard warnings .............................................................................................................. 8
4.3. Residual energy................................................................................................................ 30
4.4. Safety devices, guards and safeguards ......................................................................... 31
4.4.1. High-pressure limiter ................................................................................................ 31
4.4. . High-pressure monitoring ........................................................................................ 3
4.4.3. Low-pressure monitoring ......................................................................................... 3
4.4.4. Flow monitoring ........................................................................................................ 3
4.4.5. Personal protective equipment when operating the machine .............................. 3
4.5. Personal protective equipment for servicing work ........................................................ 3
4.6. Airborne sound emissions ............................................................................................... 33
4.7. Notes on reducing noise and vibration ........................................................................... 34
4.7.1. Noise ......................................................................................................................... 34
4.7. . Vibration .................................................................................................................... 34
4.8. Residual risks ................................................................................................................... 34
4.8.1. Electrical ................................................................................................................... 34
4.8. . Mechanical ............................................................................................................... 34
4.8.3. Chemical ................................................................................................................... 34
4.8.4. Other ......................................................................................................................... 35
4.9. Dangerous substances .................................................................................................... 35
4.9.1. Refrigerant R410A ................................................................................................... 35
4.9. . Oil POE 160SZ .......................................................................................................... 36
4.10. Reasonably foreseeable misuse ..................................................................................... 37
4.11. Information for emergencies ........................................................................................... 38
5. Handling and storage .............................................................................................................. 38
5.1. Dangerous goods ............................................................................................................. 38
5. . Transport .......................................................................................................................... 38
5. .1. Forklift truck ............................................................................................................. 39
5. . . Crane ......................................................................................................................... 40

6 / 77 8300010 .Kf
5.3. Unpacking ......................................................................................................................... 41
5.4. Storage ............................................................................................................................. 41
6. Installation ............................................................................................................................... 4
6.1. Overview ........................................................................................................................... 4
6. . Installation site ................................................................................................................. 4
6. .1. General information ................................................................................................. 4
6. . . Minimum room volume ............................................................................................ 4
6. .3. Ambient temperature ............................................................................................... 43
6. .4. Effect of surrounding air flow .................................................................................. 43
6. .5. Minimum clearances ............................................................................................... 43
6. .6. External attachments ............................................................................................... 43
6. .7. Process level ............................................................................................................. 44
6. .8. Surface and foundation ........................................................................................... 44
6. .9. Stability ..................................................................................................................... 45
6. .10. Levelling .................................................................................................................... 45
6. .11. Vibration isolation .................................................................................................... 45
6. .1 . Installation ................................................................................................................ 46
6. .13. Hydraulic installation ............................................................................................... 46
6. .14. Frost protection measures ...................................................................................... 47
6. .15. Flushing the cold water circuit ................................................................................ 47
6. .16. Filling ......................................................................................................................... 47
6. .17. Venting ...................................................................................................................... 49
6. .18. Electrical installation ................................................................................................ 50
7. Commissioning ........................................................................................................................ 51
7.1. Installation checklist ........................................................................................................ 51
8. Operation.................................................................................................................................. 5
8.1. Switching on ..................................................................................................................... 5
8. . Selecting the operating mode ......................................................................................... 5
8.3. External release ............................................................................................................... 5
8.4. Control .............................................................................................................................. 5
8.5. Control panel .................................................................................................................... 53
8.5.1. Start screen .............................................................................................................. 54
8.5. . Main menu ................................................................................................................ 55
8.5.3. Information ............................................................................................................... 55
8.5.4. Settings ..................................................................................................................... 57
8.5.5. Alarm menu .............................................................................................................. 58
8.6. Parameters ....................................................................................................................... 58
8.7. Controller description ...................................................................................................... 59
8.7.1. Electronic level monitoring ...................................................................................... 59
8.7. . Switching the chiller On/off ..................................................................................... 59
8.7.3. Cold water flow temperature control ...................................................................... 60
8.7.4. Compressor control .................................................................................................. 61
8.7.5. Fan speed control .................................................................................................... 6
8.7.6. Electronic expansion valve control .......................................................................... 6
8.7.7. Temperature limit monitoring .................................................................................. 6

7 / 77 8300010 .Kf
8.7.8. Group fault alarm ..................................................................................................... 6
8.8. Operating modes .............................................................................................................. 6
8.8.1. ECO mode ................................................................................................................. 6
8.8. . Comfort mode ........................................................................................................... 63
9. Cleaning ................................................................................................................................... 63
9.1. Air filter mat ...................................................................................................................... 63
9. . Condenser ........................................................................................................................ 63
9.3. Water filter ........................................................................................................................ 63
9.4. Complete cleaning of the cold water circuit ................................................................... 63
10. Service ...................................................................................................................................... 64
10.1. Maintenance .................................................................................................................... 64
10. . Fault correction ................................................................................................................ 64
10.3. Spare parts ....................................................................................................................... 64
11. Taking out of service ............................................................................................................... 65
11.1. Draining ............................................................................................................................ 65
1 . Recycling .................................................................................................................................. 66
13. Products, solutions and services ............................................................................................ 66
14. Lists .......................................................................................................................................... 67
14.1. List of illustrations............................................................................................................ 67
14. . List of tables ..................................................................................................................... 68
I. Troubleshooting ....................................................................................................................... 69
II. Maintenance intervals in accordance with the VDMA ........................................................... 73
III. Product Registration ................................................................................................................ 76
IV. EC Declaration of Conformity .................................................................................................. 77

1.
1.1.
1. Product description
Product descriptionProduct description
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,
you have further questions about your machine, please contact the KKT
(see
see see
see Table 1
Table 1Table 1
Table 1:
: :
: Contact
ContactContact
Contact details
detailsdetails
details).
1.1.
1.1.1.1.
1.1. Intended use
Intended useIntended use
Intended use
The cBoxX is a factory-
tested, fully automatic compressor chiller. The machine
liquids (fluids) in accordance with EN
Only approved liquids may be used. The cBoxX corresponds to protection class IP
housing is closed) and is suitable for both
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
and damage to property caused by improper use of the unit (misuse).
Table shows the general safety instructions of the chiller. These are attached to the machine in
a clear and readily vi
sible position. A complete description of all hazard warnings is given in
Chapter 4.2 Hazard
HazardHazard
Hazard warnings
warningswarnings
warnings.
..
.
Table
TableTable
Table : Safety instructions
: Safety instructions: Safety instructions
: Safety instructions
Note and follow the instructions for use!
Note and follow the instructions for use!Note and follow the instructions for use!
Note and follow the instructions for use!
Before opening the machine
Before opening the machineBefore opening the machine
Before opening the machine
After disconnecting the machine from the power supply, always wait for at least
After disconnecting the machine from the power supply, always wait for at least After disconnecting the machine from the power supply, always wait for at least
After disconnecting the machine from the power supply, always wait for at least
minutes before opening it.
minutes before opening it. minutes before opening it.
minutes before opening it.
Danger! High voltage! If the machine is only switched off at its main switch,
Danger! High voltage! If the machine is only switched off at its main switch, Danger! High voltage! If the machine is only switched off at its main switch,
Danger! High voltage! If the machine is only switched off at its main switch,
dangerous electric
dangerous electricdangerous electric
dangerous electric
cabinet.
cabinet.cabinet.
cabinet.
8 / 77
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
tested, fully automatic compressor chiller. The machine
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
housing is closed) and is suitable for both
indoor and outdoor installation (note the options
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 shows the general safety instructions of the chiller. These are attached to the machine in
sible position. A complete description of all hazard warnings is given in
Note and follow the instructions for use!
Note and follow the instructions for use!Note and follow the instructions for use!
Note and follow the instructions for use!
Before opening the machine
Before opening the machineBefore opening the machine
Before opening the machine
it must be disconnected from the power supply!
it must be disconnected from the power supply! it must be disconnected from the power supply!
it must be disconnected from the power supply!
After disconnecting the machine from the power supply, always wait for at least
After disconnecting the machine from the power supply, always wait for at least After disconnecting the machine from the power supply, always wait for at least
After disconnecting the machine from the power supply, always wait for at least
minutes before opening it.
minutes before opening it. minutes before opening it.
minutes before opening it.
Danger! High voltage! If the machine is only switched off at its main switch,
Danger! High voltage! If the machine is only switched off at its main switch, Danger! High voltage! If the machine is only switched off at its main switch,
Danger! High voltage! If the machine is only switched off at its main switch,
dangerous electric
dangerous electricdangerous electric
dangerous electric
al voltage is still present at several terminals in the control
al voltage is still present at several terminals in the control al voltage is still present at several terminals in the control
al voltage is still present at several terminals in the control
8300010 .Kf
Please read all the points in these operating instructions before starting up the machine. You
commissioning/startup and operation. If
chillers
Service Team
tested, fully automatic compressor chiller. The machine
is solely for cooling
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
indoor and outdoor installation (note the options
The operator is responsible for complying with the specified operating, servicing and maintenance
manufacturer, is responsible and liable for all personal injuries
Table shows the general safety instructions of the chiller. These are attached to the machine in
sible position. A complete description of all hazard warnings is given in
it must be disconnected from the power supply!
it must be disconnected from the power supply! it must be disconnected from the power supply!
it must be disconnected from the power supply!
After disconnecting the machine from the power supply, always wait for at least
After disconnecting the machine from the power supply, always wait for at least After disconnecting the machine from the power supply, always wait for at least
After disconnecting the machine from the power supply, always wait for at least
Danger! High voltage! If the machine is only switched off at its main switch,
Danger! High voltage! If the machine is only switched off at its main switch, Danger! High voltage! If the machine is only switched off at its main switch,
Danger! High voltage! If the machine is only switched off at its main switch,
al voltage is still present at several terminals in the control
al voltage is still present at several terminals in the control al voltage is still present at several terminals in the control
al voltage is still present at several terminals in the control

9 / 77 8300010 .Kf
1. .
1. .1. .
1. . Technical data
Technical dataTechnical data
Technical data
Table
TableTable
Table 3
33
3: Technical data
: Technical data: Technical data
: Technical data
Compact
-
Line
-
cBoxX 30
cBoxX 40
cBoxX 50
cBoxX 60
cBoxX 70
cBoxX 80
cBoxX 90
cBoxX 100
Refrigerating capacity @ tw = 0°C /
tu=3 °C kW 34 43 55 68 78 87 95 105
Refrigerant
-
R410A
Refrigerant capacity
kg
6
6
6
7
8
8
8
8
Cooling medium (liquid/secondary
refrigerant) - Water or water / glycol
Ambient temperature range
°C
+5 to +45 (optionally
-
5 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.
9.
11.1
1 .4
14.3
16.1
18.
Free pump pressure (standard)
bar
3
Water connection, nominal size
RP
11/ "
"
Air flow rate (max.)
m³/h
9350
9350
1 600
0000
3 70
3 70
3 70
3 70
Sound pressure level at 5 m distance
dBA
6
6
55
69
59
59
59
59
Operating
voltage (standard)
V/Ph/Hz
400/ 3/ 50
Protection class
-
IP54
Height
mm
030
030
Width
mm
830
830
Length
mm
1 40
1840
Net weight
kg
540
540
550
6 0
650
650
700
7 0
Gross weight
kg
840
840
850
9 0
1150
1150
1 00
1 0

10 / 77 8300010 .Kf
Compact
-
Line
-
cBoxX 1 0
cBoxX 160
cBoxX 180
cBoxX 00
Refrigerating capacity @ tw = 0°C /
tu=3 °C kW 135 166 194 10
Refrigerant
-
R410A
Refrigerant capacity
kg
17
17
3,5
3,5
Cooling medium (liquid/secondary
refrigerant) - Wasser oder Wasser / Glykol
Ambient
temperature range
°C
+5 bis +45 (optional
-
5 bis +50°C)
Liquid feed temperature
°C
+8 bis +30 (optional bis
-
10)
Target constancy
K
+/
-
1
Tank volume
l
700
900
Coolant circulation, nominal (dt = 5K)
m³/h
1,5
7,
3 ,
35,4
Free pump pressure
(standard)
bar
3
Water connection, nominal size
RP
DN65 PN10 EN109
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
030
Width
mm
1 00
Length
mm
665
3965
Net weight
kg
1100
1 00
1300
1400
Gross weight
kg
1800
1900
00
300

11 / 77 8300010 .Kf
1.3.
1.3.1.3.
1.3. Elements
ElementsElements
Elements
1
11
1
Metal cladding, top, operator side
a
aa
a
Safety instructions
Metal cladding, bottom, operator side
b
bb
b
Water connections
3
33
3
Metal cladding, top, service side
c
cc
c
Rating plate
4
44
4
Metal cladding, bottom, service side
d
dd
d
Display
5
55
5
Metal cladding, condenser protective grating
e
ee
e
Main switch
6
66
6
Cladding, hydraulics
1
3
4
5
6
a
b
c
d
e

1 / 77 8300010 .Kf
1.4.
1.4.1.4.
1.4. Explanation of terms
Explanation of termsExplanation of terms
Explanation of terms
A few important terms which appear in this document are briefly explained here for improved
understanding.
Table
TableTable
Table 4
44
4: Explanation of terms
: Explanation of terms: Explanation of terms
: Explanation of terms
Term
TermTerm
Term
Explanation
ExplanationExplanation
Explanation
Application
The heat source connected hydraulically with the chiller.
Process circuit
Application and piping to the chiller.
Cold water cycle
The process circuit and chiller in hydraulic piping.
Cold water
Cooling medium in the cold water circuit.
Cooling air
Ambi
ent air drawn through the machine, which absorbs the heat.
Net weight
Ready to operate machine without cold water.
Gross weight
Ready to operate machine including cold water.

13 / 77 8300010 .Kf
.
..
. Function and main components
Function and main componentsFunction and main components
Function and main components
The chiller consists of the main components: compressor, condenser, expansion valve and
evaporator, which are arranged in a circuit (Figure 1
Figure 1Figure 1
Figure 1). Refrigerant circulates in this circuit (cycle).
It absorbs heat from the cold water in the evaporator and gives it up to the ambient air in the
condenser.
Figure
Figure Figure
Figure 1
11
1: C6848
: C6848: C6848
: C6848 refrigeration diagram
refrigeration diagramrefrigeration diagram
refrigeration diagram
In addition, diverse pressure and temperature sensors, a control unit, a high-pressure switch, one
or more pumps and one or more fans are also installed for control and operation of the chiller.
.1.
.1..1.
.1. Compressor
CompressorCompressor
Compressor
The compressor generates the pressure difference between the heat sink and heat source in the
refrigerant circuit needed for evaporation and condensing. Coolant vapor from the evaporator is
drawn in and compressed to the condensing pressure in the compressor.
The compressors used operate according to the scroll principle. Scroll compressors are
maintenance-free, quiet and have a very high efficiency.
The flow temperature is controlled by switching on or off one or more compressors (see 8.7.4
Compressor control
Compressor controlCompressor control
Compressor control). Sequential changeover ensures that all compressors are loaded uniformly.
Compressor
Condenser and fan
Evaporator
Expansion
valve
Heat
Cold

14 / 77 8300010 .Kf
. .
. .. .
. . Evaporator
EvaporatorEvaporator
Evaporator
The evaporator is a plate heat exchanger which transfers heat from the cold water to the
refrigerant. In order for the heat transfer to take place, the refrigerant in the evaporator has a
lower temperature than the cold water and when it absorbs heat it changes its physical state from
liquid to gaseous.
If the cold water is contaminated, deposits can form on the transfer surfaces of the evaporator.
These impair the heat transfer to the refrigerant and reduce the refrigerating capacity of the
machine. For this reason, always ensure the specified water quality and do not use any other
additives than those specified.
.3.
.3..3.
.3. Condenser
CondenserCondenser
Condenser
The condenser is a microchannel heat exchanger which transfers heat from the refrigerant to the
ambient air. In order for the heat transfer to take place, the refrigerant in the condenser has a
higher temperature than the ambient air drawn in and when it gives off heat its physical state
changes from gaseous to liquid.
Contaminated cooling air can cause deposits to form on the surface of the condenser over time.
This impairs heat transfer to the refrigerant which restricts the operating limit of the machine and
reduces the machine's refrigerating capacity. Please refer to Chapter
Chapter Chapter
Chapter 9: Cleaning
CleaningCleaning
Cleaning for a description
of how to clean the condenser. If you operate your chiller in an environment containing dust or oil
vapour, use the optionally available air filter mat (see 3.19 Air
Air Air
Air filter mat
filter matfilter mat
filter mat).
).).
).
In case that there already is an existing house water system and the warm condensing air has to
be avoided, the chiller can also be specified with a water cooled condenser (see 3.3 Version with
Version with Version with
Version with
water cooled condenser
water cooled condenserwater cooled condenser
water cooled condenser)
.4.
.4..4.
.4. Expansion valve
Expansion valveExpansion valve
Expansion valve
The expansion valve controls the admission of liquid refrigerant to the evaporator and at the
same time restricts the pressure of the refrigerant before it enters the evaporator. With this
restriction the refrigerant cools to the evaporation temperature.
The expansion valve used in your machine is controlled electronically. The electronic control
ensures that the evaporator is always optimally supplied with refrigerant. This improves the COP
(Coefficient of Performance) and reduces pressure fluctuations in the refrigeration circuit.
.5.
.5..5.
.5. Refrigerant
RefrigerantRefrigerant
Refrigerant
The refrigerant R410A circulates in the refrigeration circuit. It conveys heat from the evaporator to
the condenser and at the same time continuously changes its physical state.
R410A is a zeotropic mixture of 50% each R3 and R1 5 with virtually negligible temperature
glide. R410A has a very high volumetric refrigerating capacity and has no ozone depletion
potential (ODP=0). A corresponding safety data sheet can be obtained from our KKT chillers
Service Team (see
see see
see Tab
TabTab
Table 1
le 1le 1
le 1:
: :
: Contact
ContactContact
Contact details
detailsdetails
details).

15 / 77 8300010 .Kf
.6.
.6..6.
.6. Oil
OilOil
Oil
The components of the compressor subject to friction are lubricated by oil, which is added to the
refrigerant in the factory. The polyolester-160SZ is used for this. The oil is soluble in the
refrigerant and is distributed with it throughout the refrigeration circuit. The total oil quantity of
the respective unit is given in the technical data. A corresponding safety data sheet can be
obtained from our KKT chillers Service Team (see
see see
see Table 1
Table 1Table 1
Table 1:
: :
: Contact
ContactContact
Contact details
detailsdetails
details).
.7.
.7..7.
.7. Filter dryer
Filter dryerFilter dryer
Filter dryer
The task of the filter dryer is to absorb any contamination or moisture from the refrigerant circuit.
Both refrigerant and oil are hygroscopic. When the refrigeration circuit is installed the oil can
absorb moisture. This moisture can cause corrosion and has a negative effect on 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 requiring it to be opened, the filter dryer (cBoxX 30 –
cBoxX100) respectively the filter cartridge (cBoxX 1 0 – cBoxX 00) must be replaced.
.8.
.8..8.
.8. Pressure sensors
Pressure sensorsPressure sensors
Pressure sensors
The pressure sensors used are compact pressure transmitters with piezoresistive measuring cell.
The sensors register the system pressure continuously in different places within the refrigerant
and cold water circuit. The values are used to control the system and for visualisation at the
controller display.
.9.
.9..9.
.9. Temperature sensors
Temperature sensorsTemperature sensors
Temperature sensors
The temperature sensors used are equipped with a platinum measuring cell. The sensors register
the temperature continuously in different places within the refrigerant and cold water circuit. The
values are used to control the system.
.10.
.10..10.
.10. Control unit/
Control unit/Control unit/
Control unit/ main circuit board
main circuit boardmain circuit board
main circuit board
The control unit is programmed in the factory. All system readings and information come together
on it. In addition, the electrical components are controlled via algorithms.
.11.
.11..11.
.11. Display
DisplayDisplay
Display
The display is used to visualise the information required by the operator and the system
processes. It is also possible to make entries at it. The display communicates with the control
unit. Further information on operation is given in Chapter 8.5 Control
ControlControl
Control panel
panelpanel
panel)
))
).

16 / 77 8300010 .Kf
.1 .
.1 ..1 .
.1 . Control cabinet
Control cabinetControl cabinet
Control cabinet
The control cabinet conforms to the requirements of EN 60 04 and contains the electrical and
electronic components for controlling the chiller. After removing the operator control panel the
control cabinet is accessible and can be opened using a standard two-way key. In order to avoid a
damage of the main switch while demounting the side panel, the side panel has to be tipped
10cm on the bottom side. A circuit diagram is supplied with the unit.
Figure
Figure Figure
Figure : Demounting the side panel of the swit
: Demounting the side panel of the swit: Demounting the side panel of the swit
: Demounting the side panel of the switch cabinet
ch cabinetch cabinet
ch cabinet
.13.
.13..13.
.13. Pump
PumpPump
Pump
The chiller's pump ensures the necessary circulation of the cold water. The water is drawn out of
the chiller's internal tank and is pumped through the process circuit. Optionally, the units can also
be designed as a continuous flow cooler without tank, with pump or without tank, without pump
(see Chapter 3.1 Version without tank with pump
Version without tank with pumpVersion without tank with pump
Version without tank with pump and Chapter
and Chapter and Chapter
and Chapter 3.2 Version without tank without
Version without tank without Version without tank without
Version without tank without
pump
pumppump
pump).
.14.
.14..14.
.14. Fan
FanFan
Fan
The fan draws the cooling air from the surroundings through the condenser and blows out the
heated air upwards out of the chiller. To prevent injuries, the fan is protected against accidental
contact by protective grilles. The fan's speed is variable and is controlled by the main printed
board. The speed of the fan is essentially controlled by the condensing pressure. The fan is
protected against thermal overload. In units with two fans the speed of fan 1 is always the same
as the speed of fan .
.15.
.15..15.
.15. Cold water cycle
Cold water cycleCold water cycle
Cold water cycle
The cold water is drawn out of the chiller's internal tank by the internal pump and is pumped
through the process circuit. Optionally, the units can also be designed as a continuous flow cooler
without tank, with pump or without tank, without pump (see Chapter 3.1 Version without tank
Version without tank Version without tank
Version without tank

17 / 77 8300010 .Kf
with pump
with pumpwith pump
with pump an
an an
and Chapter
d Chapter d Chapter
d Chapter 3.2 Version without tank without pump
Version without tank without pumpVersion without tank without pump
Version without tank without pump). In the process circuit the cold
water absorbs heat. The circuit closes when the cold water is pumped back into the chiller. It
flows through the evaporator, in which it gives off heat. The cold water then passes back into the
tank. The cycle begins again.
.16.
.16..16.
.16. Materials used in the water circuit
Materials used in the water circuitMaterials used in the water circuit
Materials used in the water circuit
The material composition of the standard equipment is shown in Table 5
Table 5Table 5
Table 5:
Table
TableTable
Table 5
55
5: Materials used
: Materials used : Materials used
: Materials used -
--
- standard version
standard versionstandard version
standard version
Component
ComponentComponent
Component
Material
MaterialMaterial
Material
(cBoxX 30
(cBoxX 30 (cBoxX 30
(cBoxX 30
–
––
–
cBoxX 100)
cBoxX 100)cBoxX 100)
cBoxX 100)
Unit conn
ections
V A
1.4305
Hose
Synthetic rubber
Evaporator
V A 1.4301 and copper (99.9%)
Tank
Tank ports/connection sockets
V A
1.4301
V4A 1.4571
Pump
Mechanical seal
Grey cast iron and V A
1.4301
EPDM
Sealing plugs, yellow
Polyamide PA
6
Sealing plugs,
black
Polyoxymethylene (POM)
Filling and drain cock
Nickel
-
plated brass
Bends, tees, couplings
Gunmetal CC499K
Fittings
V4A
1.4408
Hose nozzles
Nickel
-
plated brass
Swivelling elbow threaded coupling
(level indicator)
PVC and nickel
-
plated brass
Temperature sensor PT1000
V A 1.4301
Pressure sensor XSK AC10I
-
U188
V A 1.4301
Overflow valve (optional)
Gunmetal
Tank heater (optional)
Nickel
-
chrome
-
iron alloy 8 5
Component
ComponentComponent
Component
Material (cBoxX 1 0
Material (cBoxX 1 0 Material (cBoxX 1 0
Material (cBoxX 1 0
–
––
–
cBoxX 00)
cBoxX 00)cBoxX 00)
cBoxX 00)
Unit connections
ABS
Piping and fittings
ABS
evaporator
V A 1.4301
and copper
(99,9%)
Tank
Tank ports/connection sockets
V A
1.4301
V4A 1.4571
Pump
Mechanical seals
Grey cast iron and V A
1.4301
EPDM
Sealing plugs, yellow
Polyamide PA
6
Sealing plugs, black
Polyoxymethylene (POM)
Filling
and drain cock
Nickel
-
plated brass
Swivelling elbow threaded coupling
(level indicator)
PVC and nickel
-
plated brass

18 / 77 8300010 .Kf
If equipped with the optional Water circuit in non
Water circuit in nonWater circuit in non
Water circuit in non-
--
-ferrous metal
ferrous metalferrous metal
ferrous metal-
--
-free version
free versionfree version
free version the material
composition is as shown in Table
TableTable
Table 6
66
6:
Table
TableTable
Table 6
66
6: Materials used for the non
: Materials used for the non: Materials used for the non
: Materials used for the non-
--
-ferrous metal
ferrous metalferrous metal
ferrous metal-
--
-free version
free versionfree version
free version
Component
ComponentComponent
Component
Material
MaterialMaterial
Material
(cBoxX 30
(cBoxX 30 (cBoxX 30
(cBoxX 30
–
––
–
cBoxX 100)
cBoxX 100)cBoxX 100)
cBoxX 100)
Unit connections (rotating parts)
V A
1.4305
Hose
Synthetic rubber
Evaporator
V A 1.4301
Tank
Tank ports/connection sockets
V A
1.4301
V4A 1.4571
Pump
Mechanical seal
V A
1.4301
EPDM
Sealing plugs, yellow
Polyamide PA 6
Sealing plugs, black
Polyoxymethylene (POM)
Filling and drain cock
V4A 1.4401
Fittings
V4A
1.4408
Hose nozzles
V4A
1.4408
Elbow threaded couplings
(level indicator)
PVC and
polyoxymethylene (POM)
Hose (level indicator)
PE natural
Temperature sensor PT1000
V A 1.4301
Pressure sensor XSK AC10I
-
U188
V A 1.4301
Overflow valve (optional)
V A
1.4301
Tank heater (optional)
Nickel
-
chrome
-
iron alloy 8 5
Component
ComponentComponent
Component
Material (cBoxX
Material (cBoxXMaterial (cBoxX
Material (cBoxX
1 0
1 0 1 0
1 0
–
––
–
cBoxX 00)
cBoxX 00)cBoxX 00)
cBoxX 00)
Unit connections
ABS
Piping and fittings
ABS
evaporator
V A 1.4301
Tank
Tank ports/connection sockets
V A
1.4301
V4A 1.4571
Pump
Mechanical seals
V A
1.4301
EPDM
Sealing plugs, yellow
Polyamide PA 6
Sealing plugs, black
Polyoxymethylene (POM)
Filling and drain cock
V4A 1.4401
Swivelling elbow threaded coupling
(level indicator)
PVC und polyoxymethylen (POM)
Hose for level indicator
PE nature
Temperature sensor PT1000
V A 1.4301

19 / 77 8300010 .Kf
.17.
.17..17.
.17. Water quality
Water qualityWater quality
Water quality
The following limits must be maintained for safe operation of the equipment:
Table
Table Table
Table 7
77
7: Water quality
: Water quality: Water quality
: Water quality
Property /
Property / Property /
Property /
components
componentscomponents
components
Unit
UnitUnit
Unit
Value range
Value rangeValue range
Value range
Standard version
Standard versionStandard version
Standard version
Value range
Value rangeValue range
Value range
Non
NonNon
Non-
--
-ferrous metal
ferrous metalferrous metal
ferrous metal-
--
-free version
free versionfree version
free version
pH value ( 0 °C)
-
7
-
9
6
-
9
Saturation index
-
-
0. < 0 < +0.
-
0. < 0 <
+0.
Conductivity
µS/cm
80
-
500
5
-
500
Water hardness
°dH
<5.6
<5.6
Carbonate hardness
mol/m³
<0.5
<0.5
Total plate count
K/ml
<10,000
<10,000
Grain size
µm
< 50
< 50
Glycol fraction (AFN)
% by vol
0
-
40
0
-
40
Oil fraction
% by vol
0
0
Chloride (Cl
-
)
mg/l
<50
<50
Sulphate
mg/l
<50
<50
Nitrate
mg/l
<100
<100
Copper
mg/l
<0.1
<0.1
Iron
mg/l
<0.
<0.
Free carbonic acid
mg/l
< 0
< 0
Manganese
mg/l
<0.1
<0.1
Ammonia
mg/l
<
<
Free chloride
mg/l
<0.5
<0.5
Sulphide
mg/l
<0.03
<0.03
In order to avoid a restriction of the plate heat exchanger the above listed limit values have to be
guaranteed imperatively.
Furthermore mucilage bacteria are not allowed in the cooling water. If that is not possible, KKT
chillers can recommend an accordant inhibitor based on a biologic water analysis.

0 / 77 8300010 .Kf
.18.
.18..18.
.18. Permitted cooling media
Permitted cooling mediaPermitted cooling media
Permitted cooling media
Water and mixtures of water / Antifrogen N (AFN) or water / Antifrogen L (AFL) according to the
details given in Chapter
ChapterChapter
Chapter 2.17 Water
WaterWater
Water quality
qualityquality
quality.
..
. The following table shows the requirements for the
mix ratio of water with the antifreezes AFN or AFL. To maintain the performance of your machine
and prevent damage to components, these values must be maintained as precisely as possible.
Table
TableTable
Table 8
88
8: AFN and AFL mix ratios (or equivalent)
: AFN and AFL mix ratios (or equivalent): AFN and AFL mix ratios (or equivalent)
: AFN and AFL mix ratios (or equivalent)
Setting
SettingSetting
Setting
Frost
FrostFrost
Frost
-
--
-
free to
free tofree to
free to
AFN mix ratio
AFN mix ratioAFN mix ratio
AFN mix ratio
AFL mix ratio
AFL mix ratioAFL mix ratio
AFL mix ratio
Glycol 0
-
5 %
-
10°C
0
-
5
%
5
-
30
%
Glycol 30
-
35 %
-
15°C
30
-
35
%
3
-
37
%
Glycol 40 %
-
5 °C
40
%
4
%
3.
3.3.
3. Options and accessories
Options and accessoriesOptions and accessories
Options and accessories
The chiller can be equipped in the factory with the options described in the following.
The items marked "accessories" are enclosed with the unit, unattached, and can be reordered at
any time using the appropriate product number. The installer of the machine is responsible for
installing the accessories. You can also ask our KKT chillers Service Team to arrange for this
installation (see Table 1
Table 1Table 1
Table 1 Contact
ContactContact
Contact details
detailsdetails
details).
Details of your machine's equipment are given in the separate summary documentation.
3.1.
3.1.3.1.
3.1. Version without tank, with pump
Version without tank, with pump Version without tank, with pump
Version without tank, with pump
The Compact-Line units are also optionally available as continuous flow chillers. In this case the
units are delivered without an internal tank. The temperature sensor is then located in the
chiller's return line. If a tank open to the atmosphere is integrated on site, it is necessary to
ensure that the tank is not installed at a lower level than the chiller. Additional pressure losses
between the tank on site and integrated pump must be avoided (dp
max
=0.3bar)
3. .
3. .3. .
3. . Version without tank, without pump
Version without tank, without pump Version without tank, without pump
Version without tank, without pump
The Compact-Line units are also optionally available as continuous flow chillers. In this case the
units are delivered without an internal tank and without pump. The temperature sensor is then
located in the chiller's return line. The cold water is then circulated via the evaporator by a pump
to be installed on site. This must at least be designed to the pressure loss of the overall system.
ATTENTION! Do not mix different antifreezes. This can cause unwanted chemical
ATTENTION! Do not mix different antifreezes. This can cause unwanted chemical ATTENTION! Do not mix different antifreezes. This can cause unwanted chemical
ATTENTION! Do not mix different antifreezes. This can cause unwanted chemical
reactions and silting up.
reactions and silting up.reactions and silting up.
reactions and silting up.