KKT KSC Series Instruction Manual

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
Version „Revision 0
Version „Revision 0Version „Revision 0
Version „Revision 05
55
5”
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” Type KSC 2 5
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Manufacturer
ManufacturerManufacturer
Manufacturer
ait-deutschland GmbH T [phone]
Industriestraße 3 F [phone]
95359 Kasendorf E [email protected]
Germany W www.kkt-chillers.com
Representative in the US and Service Center
Representative in the US and Service CenterRepresentative in the US and Service Center
Representative in the US and Service Center
KKT chillers, Inc. T 847 734 600
280 Landmeier Road F 847 734 60
Elk Grove TF 866 5 7 6867
IL 60007 E [email protected]
YOUR LOCAL S
YOUR LOCAL SYOUR LOCAL S
YOUR LOCAL SERVICE CONTRACTOR IS:
ERVICE CONTRACTOR IS:ERVICE CONTRACTOR IS:
ERVICE CONTRACTOR IS:
COMPANY NAME:
PHONE NUMBER: FAX NUMBER:

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
Version „Revision 0
Version „Revision 0Version „Revision 0
Version „Revision 05
55
5”
” ”
” Type KSC 2 5
Type KSC 2 5Type KSC 2 5
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Contents
ContentsContents
Contents
I Technical Data ..................................................................................................................... 4
I. Basics .................................................................................................................................. 5
II. Installation site .................................................................................................................. 7
a) Ambient temperatures ................................................................................................. 7
b) Clearance ...................................................................................................................... 7
c) Servicing and repair access ......................................................................................... 7
d) Air flow .......................................................................................................................... 7
e) Load capacity of the base............................................................................................ 7
III. Transport route/transport ............................................................................................. 0
a) Transport measurements ......................................................................................... 0
b) Transport weight ....................................................................................................... 0
c) Transport safety locks ............................................................................................... 0
d) Crane transport ......................................................................................................... 0
e) Dimensions in inch .................................................................................................... 2
f) Dimensions in mm ..................................................................................................... 3
g) Weights ...................................................................................................................... 4
IV. Power supply/electrical connection ............................................................................ 4
a) Follow local regulations ............................................................................................ 4
b) Voltage, frequency, tolerances ................................................................................. 4
c) Type of cable .............................................................................................................. 4
d) Length and cable width ............................................................................................ 4
e) Strain relief ................................................................................................................ 4
f) Clamps ........................................................................................................................ 5
g) Fuse ............................................................................................................................ 6
h) Phase sequence ........................................................................................................ 6
i) EMC Compatibility and Grounding ............................................................................ 7
j) Data cable ................................................................................................................... 8
V. Interface filter panel (IFP) .............................................................................................. 20
Scope of IFP supply: ...................................................................................................... 2
Installation of IFP ........................................................................................................... 2
VI. Water connection .......................................................................................................... 22
a) Pipe material ............................................................................................................. 22
b) Relation of pipe diameter to distance between chiller and IFP ............................. 22
c) Dimensions of the connections ................................................................................ 22
d) Inflow and outflow ..................................................................................................... 22
e) Water quality ............................................................................................................. 22
f) Glycol........................................................................................................................... 23
g) Filling .......................................................................................................................... 23
h) Vents and air chambers............................................................................................ 23
VII. Initial start-up ............................................................................................................... 27
VIII. SPS Settings ............................................................................................................... 28
IX. Control ............................................................................................................................ 3
a) Pump .......................................................................................................................... 3

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
Version „Revision 0
Version „Revision 0Version „Revision 0
Version „Revision 05
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b) Water pressures ........................................................................................................ 3
c) Compressor ................................................................................................................ 3
d) Vents .......................................................................................................................... 3
e) Refrigerant pressures ............................................................................................... 3
f) Temperatures ............................................................................................................. 3
X Overview water chiller and IFP ....................................................................................... 32
XI Trouble Shooting ............................................................................................................ 33
XII. Maintenance ................................................................................................................ 38
XIII. Warranty ...................................................................................................................... 38
XIV. Safety Warnings ......................................................................................................... 38

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
Version „Revision 0
Version „Revision 0Version „Revision 0
Version „Revision 05
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I
I I
I Technical Data
Technical DataTechnical Data
Technical Data
Model Outdoor
Dimensions Depth 940 mm
Width 3040 mm
Height 850 mm
Weight without refrigerant load ca. 066 kg
Weight with load ca. 090 kg
Shipping weight ca. 600 kg
Weight total refrigerant load 24.0 kg
Quantity of air 2x 8000 m³/h
Number of fans 4
Refrigerant R 34a
Required quantity of refrigerant 2x 2kg
High-pressure switch 9 bar
Water connection inlet internal 2“ G" female thread
Water connection outlet internal 2“ G" femalethread
Cold water temperature outlet min. 9-22 °C ±0.5 K
Cold water temperature inlet max. 30 °C
Primary water pump type 60Hz CR 0 - 05
Primary water pump type 50Hz CR 0 - 07
Rated water capacity min. 7.8 m³/h
Rated water pressure 6.5 bar
Ambient temperature min.-20 °C
max.+48 °C
Cooling capacity 60.0 kW
Rated cold water outlet temperature 20 °C
Temperature of surroundings 48 °C
Main supply 380-480 V / 3Ph / 50-60 Hz
Control voltage 24 VDc
Fluctuations in main voltage max. - 4+ 0 %
Fluctuations in frequency max. ± Hz
Power input max. 29 kW
Noise level at 5 m max.68 db(A)
at max cooling capacity and max. ambient temperature

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
Version „Revision 0
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Version „Revision 05
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I. Basics
I. BasicsI. Basics
I. Basics
Scope of Chiller supply:
-KSC2 5-L-…
-Installing Instruction inside the switch cabinet
-Manual inside the switch cabinet
-Data transfere cable 50m ( 64feet) in a box near the pump
-Short data transfere cable in a box near the pump
-Grounding in a box near the pump
-Overvoltage protection in a box near the pump
-Spare parts in a box near the pump
-Brass fittings for the connection Chiller inlet/outlet and piping (on the pump)
-Stainless steel fittings for the connetion piping and IFP (on the pump)
Carefully read the operating instructions located in the control cabinet before beginning
installation.
Check the equipment for damage on arrival and report any defects immediately.
Claims submitted later cannot be honored.
Please observe the following notes and warnings.
. Removing the operating instructions from the cooling block voids the warranty!
2. The volume of the water circulation system of the cooling block is approx. 7 liters
(~4.5 gal) Please consider this by filling the water system with water ethylene
glycol mixture.
3. Always operate the water circulation system at a volume of 35-38% ethylene
glycol.
This is regardless of the ambient temperature.
Non-compliance voids the warranty.
Use of automobile anti-freeze and propylene glycol is prohibited.
Fill with clean water (potable water quality) with Ethylene-glycol at the rate of min.
35% to max. 38%.
Use ethylene-glycol of only one manufacturer.
(e.g.: DOWTHERM SR -Dow Chemical, Safeflow EG-Clariant)
Do not mix two ore more different manufacturer for one water-ethylene-glycol
circuit.
Open front panel and fill to a pressure of min. ,5 bar via the feed cock when the
pump is off.

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
Version „Revision 0
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After filling, check all connections for leakage.
4. With the pump turned off, fill the system to a static water pressure of .5 bar
(2 .75 psi) by Avanto an Chiller at the same level. (Also see Table page24)
(Also see Table page24) (Also see Table page24)
(Also see Table page24)
5. The cooling block operates completely independently of the MR system.
6. Voltage is still present in the KSC control cabinet when the MR system is turned
off. Risk of death!
Risk of death!Risk of death!
Risk of death!
7. Even with the cooling block turned off, high surface temperatures can cause
burns. Risk of death!
Risk of death!Risk of death!
Risk of death!
Only trained and qualified personnel are permitted to install, start up, and repair the
cooling block.

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
Version „Revision 0
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II. Installation site
II. Installation siteII. Installation site
II. Installation site
a) Ambient temperatures
a) Ambient temperaturesa) Ambient temperatures
a) Ambient temperatures
The chiller is designed to operate at ambient temperatures between –20°C (-4°F)
minimum and +48°C (+ 8.4°F) maximum.
Malfunctions can occur outside these specifications.
If the chiller is used at high ambient temperatures (higher than 40°C = 04°F) the the
If the chiller is used at high ambient temperatures (higher than 40°C = 04°F) the the If the chiller is used at high ambient temperatures (higher than 40°C = 04°F) the the
If the chiller is used at high ambient temperatures (higher than 40°C = 04°F) the the
chiller should be installed that the
chiller should be installed that the chiller should be installed that the
chiller should be installed that the switch cabinet is not fully exposed to the sun
switch cabinet is not fully exposed to the sun switch cabinet is not fully exposed to the sun
switch cabinet is not fully exposed to the sun
radiation when the maximum ambient temperature is prevent. If th
radiation when the maximum ambient temperature is prevent. If thradiation when the maximum ambient temperature is prevent. If th
radiation when the maximum ambient temperature is prevent. If this is not possible
is is not possible is is not possible
is is not possible
please install a sun protection!!
please install a sun protection!! please install a sun protection!!
please install a sun protection!!
Support from KKT
Support from KKTSupport from KKT
Support from KKT chillers
chillerschillers
chillers could be requested.
could be requested.could be requested.
could be requested.
b) Clearance
b) Clearanceb) Clearance
b) Clearance
Maintain at least 00 cm (39.4 in.) around all four sides of the chiller for air intake and
servicing/repair.
Under no circumstances install a roof above the chiller.
c) Servicing and repair access
c) Servicing and repair accessc) Servicing and repair access
c) Servicing and repair access
See Clearance
d) Air flow
d) Air flowd) Air flow
d) Air flow
Never obstruct the air intake to the condensers on the upper third of the chiller.
The diameter of the tubes may not be smaller than the size specified.
e) Load capacity
e) Load capacitye) Load capacity
e) Load capacity of the base
of the baseof the base
of the base
Verify that the installation surface has sufficient load capacity.
A concrete foundation or sectional steel construction is recommended.
A concrete foundation needs to be 200 mm (7.8 in.) wider and 200 mm (7.8 in.) longer
than the cooling block. Final dimensions: approx. 3,200 mm ( 0.5 feet) long by , 00
mm (3.6 ft) wide.
The operating weight of the chiller is approx. , 00 kg (2,425 lbs.).
The operating weight of the chiller is approx. , 00 kg (2,425 lbs.).The operating weight of the chiller is approx. , 00 kg (2,425 lbs.).
The operating weight of the chiller is approx. , 00 kg (2,425 lbs.).
It is important that the cooling block be installed on a level surface.

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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III. Transport r
III. Transport rIII. Transport r
III. Transport route/transport
oute/transportoute/transport
oute/transport
a) Transport measurements
a) Transport measurementsa) Transport measurements
a) Transport measurements
Length: approx. 3,200 mm ( 26 inches)
Width: approx. , 00mm (43.3 inches)
Height: approx. 2, 50mm (approx. 84.65 inches)
You also need to add the height of the transport equipment, such as pallets, lift truck,
transport rollers, etc.
b) Transport weight
b) Transport weightb) Transport weight
b) Transport weight
Weight: approx. ,600 kg (approx. 3,528 lbs.)
c) Transport safety locks
c) Transport safety locksc) Transport safety locks
c) Transport safety locks
There are no transport safety locks to remove.
d) Crane transport
d) Crane transportd) Crane transport
d) Crane transport
If a crane will be used to transport the chiller, note the following:
Lift the chiller only from its base. Insert two steel rods through the holes in the base.
The rods must be specifically designed for this purpose and able to support the weight
( , 00 kg./2,425 lbs.).
Secure the rods with locking pins to prevent shifting.
Use only straps or rope for lifting from the rods.
The straps or ropes must be held in place with a frame to keep them from pressing into
the side walls, gutters, and condenser body. (Refer to the following graphic).

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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e)
e) e)
e) Dimensions in inch
Dimensions in inchDimensions in inch
Dimensions in inch

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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f)
f) f)
f) Dimensions in mm
Dimensions in mmDimensions in mm
Dimensions in mm

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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g) Weights
g) Weightsg) Weights
g) Weights
Net weight: ,060 kg. (2,337 lbs.)
Operating weight: approx. , 00 kg. (2,425 lbs.)
Transport weight: approx. ,600 kg (3,527.4 lbs.)
Refrigerant: approx. 2 X 2 kg. (26.45 lbs.) R 34a
IV. Power supply/ele
IV. Power supply/eleIV. Power supply/ele
IV. Power supply/electrical connection
ctrical connectionctrical connection
ctrical connection
a) Follow local regulations
a) Follow local regulationsa) Follow local regulations
a) Follow local regulations
Strictly adhere to the regulations of the local power company and authorities. Only
trained, authorized persons are permitted to connect the power.
b) Voltage, frequency, tolerances
b) Voltage, frequency, tolerancesb) Voltage, frequency, tolerances
b) Voltage, frequency, tolerances
Voltage range: 380 - 480 Volt – 4%+ 0%
Frequency range: 50 – 60Hz +/- Hz
c) Type of cable
c) Type of cablec) Type of cable
c) Type of cable
Make sure to use appropriately designed and approved cables when routing.
d) Length and cable width
d) Length and cable widthd) Length and cable width
d) Length and cable width
A cable width of at least 6mm² per phase is required for cables up to 50 meters ( 64
ft.) in length.
Therefore, a 5 x 6mm² cable is required.
e) Strain relief
e) Strain reliefe) Strain relief
e) Strain relief
The input cable must be fitted on both sides with a strain relief.

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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f) Clamps
f) Clampsf) Clamps
f) Clamps
Insert the input cable through the cable feed-through (see photograph) next to the
water connections. Route it into the control cabinet through the cable channel installed
on the back of the control cabinet.
Use the clamps to secure the routed cable (see photograph).
Attention!!
Do not pass the power supply line across the switch cabinet!!
Use cable opening in the lower right hand side of cabinet!!
Drilling holes into and running cables into the cabinet can cause interferences with the
regulation electronics!!

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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g) Fuse
g) Fuseg) Fuse
g) Fuse
Maximum 60 A slow-blowing fuse for pre-fusing.
Maximum overcurrent of 200 A for 50 msec.
h) Phase sequence
h) Phase sequenceh) Phase sequence
h) Phase sequence
Observe the correct phase sequence when routing the wires, otherwise the cooling
block will not start. A phase sequence relay (5A ) is installed for this purpose.
The monitoring relay has ist own power supply, measured voltage = supply voltage.
The relay monitors the phase sequence an the phase failureof one of the three phases
in a 3-phase network. No settings are necessary.
When the line voltage is switched on, the green LED lights up. IF the correct phase
sequence is applied to the terminals L -L2-L3, the output relay picks up.
If the wrong phase sequence is applied, the red LED blinks an the output relay does not
pick up. If a phase failure occurs, the red LED lights up an the output relay drops out.
Attention: The red LED is an error diagnosis indicator an does not show the current
state of the relay.

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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i) EMC Compatibility and Grounding
i) EMC Compatibility and Groundingi) EMC Compatibility and Grounding
i) EMC Compatibility and Grounding
This comments are compiled to help the field electrician to install the grounding of the
power supply and to get a EMC Compatibility.
All electrical equipment produces radio and line-borne interference at various
frequencies. The cables pass this on to the environment like an aerial.
The basic countermeasures are isolation of the wiring of control and power components,
proper grounding and shielding of cables.
A large contact area is necessary for low-impedance grounding of HF interference. The
use of grounding straps instead of cables is therefore definitely advisable.
Moreover, cable shields must be
connected with purpose-made ground
clips.
The grounding surface must be highly
conductive bare metal. Remove any
coats of varnish and paint.
The width of the grounding wire must be min. 6mm² (AWG 6) or of the same width of the
power supply.
The grounding must be an isolated ground and must connected on the ground terminal
(X ) in the switch cabinet. The ground resistance must be less than 0 Ohm.
Metal cable conduits are not allowed for grounding.
The piping of the chiller (supply and return) have to be grounded too.
Do not share the ground wire with other devices.
Always use a ground wire that complies with technical standards on electrical equipment
and minimize the length of the ground wire.
When using more than one Inverter, be careful not to loop the ground wire.
(e.g. a CT-Chiller KPC 08-L-U/S stands near an Avanto-Chiller KSC2 5-L-U/S)

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
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j) Data cable
j) Data cablej) Data cable
j) Data cable
Attach the “X8 Chiller” end of the 6-pin data cable (included) to the green connector
(see photograph) at the top right of the control cabinet.
Power plug
A separate feed-through for the power plug is located on the right wall of the control
cabinet (see photograph).

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
Version „Revision 0
Version „Revision 0Version „Revision 0
Version „Revision 05
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Feed-through
•Run the cable from the chiller to the MR electronic cabinets.
•Connect the lightning arrester with the 64 ft / 50 m data cable.
•Connect the short data cable with the lightning arrester.
•Attach the other end of the short data cable on the electronics cabinet ACC X8 of
the MR system.
•Connect the grounding wire.

Installing Instruction
Installing InstructionInstalling Instruction
Installing Instruction
Healthcare chiller of the KSC Series
Healthcare chiller of the KSC SeriesHealthcare chiller of the KSC Series
Healthcare chiller of the KSC Series
Version „Revision 0
Version „Revision 0Version „Revision 0
Version „Revision 05
55
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Type KSC 2 5Type KSC 2 5
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.