KKT KSC Series User manual

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
page 1von138
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Manufacturer
ait-deutschland GmbH T [phone]
Industriestraße 3 F [phone]
95359 Kasendorf E [e-mail]
Germany W www.kkt-chillers.com
Representative in the US and Service Center
KKT chillers, Inc. T 847 734 1600
1 80 Landmeier Road F 847 734 1601
Elk Grove Village, IL 60007 TF 866 517 6867
USA E [e-mail]
YOUR LOCAL SERVICE CONTRACTOR IS:
COMPANY NAME:
PHONE NUMBER: FAX NUMBER:

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
page von138
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Contents page
1 General Remarks, Safety Warnings ...............................................................................................................................4
1.1 Industrial cooler Type KPC 1 -L-U/S ......................................................................................................................4
1. Maintenance ..........................................................................................................................................................4
1.3 Warranty.................................................................................................................................................................4
1.4 Safety Warnings: .....................................................................................................................................................5
General description ......................................................................................................................................................6
.1 Functional description .............................................................................................................................................8
.1.1 High-/Low- pressure control...........................................................................................................................9
.1. Electronic controls.......................................................................................................................................10
3 Brief operating instructions .........................................................................................................................................11
3.1 Installing, maintenance and repair.........................................................................................................................11
3. Linking to power supply.........................................................................................................................................11
3.3 EMC Compatibility and Grounding..........................................................................................................................11
3.3 Filling the unit with water-ethylene glycol-mixture ...................................................................................................12
3.4 Draining air from the unit ......................................................................................................................................12
3.5 Setting the clock in the SPS (Siemens S73) ...........................................................................................................14
3.6 Connecting the Data Cable ....................................................................................................................................17
4 Technical Specifications..............................................................................................................................................18
4.1 Data sheet............................................................................................................................................................18
4. Dimensional drawing Type KSC 15-L- U/S ............................................................................................................19
5 4. 3 Water chiller control scheme ...............................................................................................................................19
5 Transport ...................................................................................................................................................................21
6 Installing the chiller ....................................................................................................................................................22
7 Notes on the water connections ..................................................................................................................................24
8 Power supply ..............................................................................................................................................................25
9 TROUBLE SHOOTING...................................................................................................................................................26
9.1 Typical Failures .....................................................................................................................................................28
9. Explanations about the automatic restart of the Chiller KSC 15-L-….......................................................................32
9. .1 Main switch: On => Off => On ......................................................................................................................32
9. . Mains supply: ok => power failure => power returns.....................................................................................32
10 Preventive Maintenance: Weekly Check, Two times a year Check .................................................................................33
ELECTRIC CONTROL PANEL MSR.......................................................................................................................................34
11 Description of the individual parts ...............................................................................................................................35
11.1 Evaporator............................................................................................................................................................35
11. Compressor ..........................................................................................................................................................36
11.3 Condenser ............................................................................................................................................................59
11.4 Fans .....................................................................................................................................................................60
11.5 Frequency Inverter ................................................................................................................................................66
11.6 Programmable Logic Controller PLC .......................................................................................................................71
11.7 High -Pressure limiter............................................................................................................................................72
11.8 Sight glass ............................................................................................................................................................73
11.9 Filter drier.............................................................................................................................................................75
11.10 Liquid receiver ......................................................................................................................................................90
11.11 Primary water pump..............................................................................................................................................91
11.11.1 Motor of pump ..........................................................................................................................................110
11.1 Air vent ...............................................................................................................................................................123
11.13 Safety valve ........................................................................................................................................................126

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
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11.14 Expansion vessel ................................................................................................................................................127
11.15 Manometers .......................................................................................................................................................128
11.16 Flow switch .........................................................................................................................................................129
11.17 Flow control valve ...............................................................................................................................................130
11.18 Overflow valve.....................................................................................................................................................131
11.19 Dirt trap ..............................................................................................................................................................134
11.19.1 Collective alarm.........................................................................................................................................135
11. 0 Switch cabinet ....................................................................................................................................................136
1 Safety notes .............................................................................................................................................................136
1 .1 Notes for refrigerant............................................................................................................................................136
1 . Instructions regarding machine oil .......................................................................................................................137
13 Circuit diagram .........................................................................................................................................................138

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
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1General Remarks, Safety Warnings
Industrial cooler Type KSC 15-L- U/S
1.1 Industrial cooler Type KPC 1 -L-U/S
Manufacturer: ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T [phone]
F [phone]
After-sales: ait-deutschland GmbH
After sales dept.
Industriestraße 3
95359 Kasendorf
Germany
T [phone]
F [phone]
Refrigerant R134a
Total filling weight outdoor model x 1 ,0 kg
Permitted working pressure: 19 bar
1. Maintenance
The cooling block must be serviced at least twice a year by a Chiller company.
1.3 Warranty
The unit is supplied finished, tested and ready to work. The unit warranty will be void if any modification to the
unit is carried out without written agreement of KKT.
For warranty purposes, the following conditions must be satisfied:
•The initial start of the unit must be carried out by trained personnel from an Authorized KKT Service
Partner.
•Maintenance must be carried out by properly trained personnel.
•Only genuine KKT spare parts must be used.
•For KSC 15-L-U/S: Ethylene glycol must be added to the rate of min. 35vol% to max. 38vol%.
•The manual (this document) must not remove from the chiller.
•All the scheduled maintenance operations detailed in this manual must be performed at the specified
times. Please use a higher amount of services if the local conditions require it.
•The “Warranty Registration” has to be send return to KKT chillers.
Failure to satisfy any of these conditions will automatically void the
warranty.

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
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1.4 Safety Warnings:
-Cooling water circuit is pressurized.
-Switch off the Chiller and depressurize before servicing the cooling water circuit.
-Drain water from pipes and spare parts before shipment.
-Do not operate the Chiller without ethylene glycol! The cooling water must contain min. 35% to max. 38%
ethylene glycol.
-Nominal static filling pressure when Chiller has been switched off: 1,5bar.
-Don`t handle valves while the Chiller is running
-Ethylene glycol be added at the rate of min. 35% to max. 38% of the volume of water anytime otherwise
warranty void.
-The rate depends not on the local ambient temperature.
-Don’t use automotive antifreeze.
-Voltage continuous to be present at the terminals, even after the MR system has been switched off.
-Parts in the refrigerant circuit are hot, even the Chiller has been switched off.
-WEAR SAFETY GLOVES AND GLASSES WHEN WORKING ON UNIT TO AVOID INJURY!
-WEAR LONG SLEEVE SHIRT AND PANTS WHEN WORKING ON UNIT!
-NO LOOSE CLOTHING ITEMS ALLOWED TO AVOID INJURY!
-PLEASE READ THE MANUAL!
Additional see the safety notes for refrigerant and oil page 113.
OBSERVE THE SAFETY RULES
Before commencing work on the unit, switch the plant to voltage-free
IN CASES OF EMERGENCY TURN OFF THE AGGREGATE BY THE MASTER SWITCH !
Caution!
Work on electric and refrigerant circuits should only be performed by qualified operatives
Observe the safety rules!
Warranty void if manual removed from chiller.
Do not remove the Secure Digital Memory card from the CPU before the chiller is switched off!!!!!!

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
page 6von138
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General description
The chiller KSC 15-L-U/S are fully assembled, factory inspected and tested, and suitable for fully-automated
operation. The water ethylene glycol mixture that undergoes cooling is constantly circulated by the pump in a
closed system which is monitored by an flow switch and an expansion tank. The temperature is controlled by
an Siemens SPS. The settings on the governor is kept automatically within the limits that are possible for the
given degree of temperature exactitude.
The process heat is transmitted from the water in the in-built heat exchanger (evaporator) to the refrigerant
circuit (R 134a). The compressor raises the refrigerant to a higher temperature and pressure so that the
warmth can be released via the condenser to the surrounding air. Consequently good air supply and escape
are vital for the proper running of the plant. The condenser-pressure is controlled by a Frequency inverter for
the condenser fan speed.
The chiller KSC 15-L-U/S are fitted with low-pressure sensor as protection against freezing and excess
temperature. With this, it is possible to set leaving water temperatures from +19°C to + °C.
Ethylene glycol must be added at the rate of min. 35vol.% to max. 38vol.% and it depends not on the
ambient temperature!
Do not use automotive ethylene glycol!!!
Changes in the settings should only be made by qualified operatives.
Cooling block Type KSC 15-L- U/S
Air-cooled design for outdoor use, consisting mainly of:
The housing with stable welded, galvanized framework-construction , lateral cover-plates with drawer-edges
made of galvanized steel plate with ventilating nozzles worked into the top plate.
Framework-construction and top-plates, powder-coated on the inside and outside, RAL 1013 -pearl white. All
outer fastening screws rust-proof, inspection-caps at the front easily removable for maintenance using
casement-fastener caps.
Compressors, cooling and cold-water/ethylene-glycol mountings, additionally sound and rain-proofed using a
galvanized cover-plate.
Condenser axial-fans controlled by frequency inverter depends of the condenser pressure. Ventilators equipped
with protective-grating on the delivery side
Laterally mounted capacitor heat-exchanger made of Cu-AL with covering galvanized framework, enameled fully
in black.
Cooling-unit for fluid cooling, consisting of:

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
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Stable base-frame construction made of steel-profiles, powder-coated. SCROLL-motor compressor, of fully
hermetic construction with suction-gas cooled design complete with special shut-off valves placed at the
pressure and suction side. Vibration-absorbing-mounted compressors. Cooling circulation with coolant-
collectors, coolant shut-off mounting, filter-dryer, inspection glass and moisture indicator, fluid solenoid-valve,
service-valves as well as the complete internal cooling pipe work made of Cu-pipe with coolant and special oil
filling.
High-capacity plate-vaporizer of plumbed design. Heat-exchanger plates with optimized profile for safety
coolant and built in expansion-valve.
Vaporizer and suction-side pipe work, diffusion-seal insulated.

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
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Safety pack for the cooling circuit, consisting of:
Crankcase heater, high pressure pressostat as well as protective motor relay.
Shut-off ball valve at the cold water / ethylene-glycol entry, dirt absorber, expansion tank, feeder and safety
valve. High-pressure centrifugal-pump adjusted to the overall system, filling and drainage valve with automatic,
ventilation, manometer in forward and reverse flow. Quantity balancing-valve, overflow valve with connection
piece for computer terminal in cold water / AFN exit.
Temperature control as hot gas by-pass control with one regulating solenoid valves for each circuit.
The supply temperature of the water circuit is controlled by a Siemens SPS.
Additionally there is an connections to the MR for signals “run” and several faults
Condenser pressure control via pressure transmitter in the cooling circuit and frequency inverter, overload relay
for system safety.
Internal cold water / ethylene-glycol (AFN) piping made of Cu-pipe, brazed, with diffusion sealer, surrounded by
armaflex insulation.
All necessary block and clip angles used for cooling and cold water / ethylene-glycol(AFN) construction are
made of rust-proof and powder-coated material.
Switch-cabinet integrated in cooling block, system of protection IP 54, wired according to VDE-regulations with
a main switch, supply-check indicator lamp, phase monitoring relay and Siemens components such as,
overload release, sliding-panel, motor safety-switch, control-switch and indicator lamps.
A pump post-relay for the safety of the vaporizer as well as pot. proof contacts for "supply-control" and
"collective fault messages".
The switch cabinet of the outdoor version contains a switch cabinet heater and a mechanical switch cabinet
ventilator.
All parts described above are assembled into a ready-to-connect unit.
.1 Functional description
The cold water pump starts as soon as the master switch 5Q1 have been turned from “OFF” to “ON”.
The pump main switch should only to be turned to “On” when the aqueous medium circuit has been completely
filled and all air has been removed.
The flow switch protecting of the refrigerating compressors is cut off during start-up.
The pressure on the delivery side of the pump rises directly with the system pressure.
Should this fail to be in case the plant has either a leak or insufficient water. A flow switch acts to prevent
freezing of the evaporator when water volumes drop. The refrigerating machines switch on as soon as the
safety sequence, flow switch and control motor-protection pump is in order.

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
page 9von138
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A lag in connection time has been allowed for in the refrigeration compressors to avoid surges in the current.
The refrigeration compressors keep running as long as cold is required and the reference value for the water
temperature has not been reached.
The water pump remains in constant operation.
Apart from which, the refrigerating machines are only ever switched off during circulation in cases of low or
high pressure in the refrigeration cycle.
When switched off in the normal way, a restart delay provides overload protection to the compressor.
The refrigerant circuits which starts first is changed after 4hours when the difference between the water
return and supply is smaller than 0,7K for a dedicated time .
.1.1 High-/Low- pressure control
The high-pressure sensor shut off the compressor via SPS if the pressure rises up to 18,9bar.
In series the second compressor will run.
If the sensory high pressure control is not in function a high pressure pressostat is installed.
The high-pressure pressostat reacts to excess pressure of the magnitude of 19, bar
by shutting off the compressor.
Causes of this include
- failure of condenser fans,
- high outdoor temperatures,
- a dirty condenser.
The compressor can only be put back in operation when the reset switch is activated on the HP-pressure
control and the pressure has dropped.
An automatic start has not been provided for.
The low-pressure sensor also switches off the compressor when the pressure sinks to 0,5 bar. The sensor is
by-passed during start-up for 30 s.
Causes of this include
- defective Expansion valve,
- low outdoor temperatures,
- low level of refrigerant.
If the pressure rises to 1,0 bar, the compressor will switch on again automatically.

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
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.1. Electronic controls
The control system consists of a Siemens SPS. The reference value is set at the works at 0°C for the outlet
temperature. The sensor for the SPS is installed on the outlet side.
Regulating refrigerating capacity
The exact regulation of the leaving temperature is achieved by means of controller and hot gas by-pass
solenoid valve. The setting is based on steady capacity regulating.
Condenser pressure regulation
the condenser-pressure is regulated with help of the Frequency Inverter.
– see captions 4.5 “Frequency Inverter Settings” and 11.5 “Frequency Inverter”

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Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
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3Brief operating instructions
See also chapter 5 – 10 in this operating instruction
3.1 Installing, maintenance and repair
Only qualified operatives with the requisite knowledge, equipment and facilities should maintenance and
repair the KKT chiller.
If its necessary to change the filling weight of the refrigerant circuit, please note:
Fill only with the refrigerants listed on the manufacturer name plate, and only up to the indicated filling
weight.
See also the enclosed Installing instruction
3. Linking to power supply
The size of the connection cable had to be conform to the local regulations. For current values and power
input see wiring diagram page .
The industrial coolers of the KSC series are generally designed for a main supply of 480V 3Ph 60 Hz.
The connection L1, L , L3, PE is performed via the terminal block X1 (power supply) in the switch cabinet.
The cooling block is switched on via the main switch 5Q1.
3.3 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.

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The width of the grounding wire must be min. 16mm² (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 (X1) in the switch
cabinet. The ground resistance must be less than 10 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 KPC108-L-U/S stands near an Avanto-Chiller KSC 15-L-U/S)
3.3 Filling the unit with water-ethylene glycol-mixture
Water to be used (de-ionized water / destilled water / VE water / bartly de-ionized water)
This type of water has to be purchased and provided locally
Mix it with Ethylene-glycol at the rate of min. 35% to max. 38%.
Use ethylene-glycol of only one manufacturer.
(e.g.: DOWTHERM SR1-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.1,5 bar via the feed cock when the pump is off.
After filling, check all connections for leakage.
Don’t use propylene-glycol or automotive antifreeze
See also the enclosed Installing instruction
3.4 Draining air from the unit
The KSC 15 includes a closed water system.
If air get out of the system the water pressure drops down. If that happens you had to check the water
pressure and if its to low you have to refill the water circuit.
The procedure should be repeated until no more air is in the system
After all these steps, turn the main switch in position "1". If all the prerequisites for operation have been met,
the chiller will start at the latest 1 minute.
In case of malfunctions: search for faults, take note of Chapter 9, TROUBLE SHOOTING, in this manual.

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
page 13von138
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See also the enclosed Installing instruction

Operating Instruction
Healthcare chiller of the KSC Series
Version „Revision 09“ Type KSC 15-L-U/S
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3.5 Setting the clock in the SPS (Siemens S73)
See also Installations Instructions cap. VIII SPS Settings
Setting the clock on the operation panel OP73
Remark: The function of the button F1, F . F3 and F4 will shown above the buttons at the screen.
The following steps are to be used:
1. Switch on the main switch 5Q1
. Now the chiller is running in autarc.
3. If the date and time displayed are incorrect, change them using the following steps.
4. If the display shows any failure please press back till the display looks like figure
Abbildung 1 figure
5. Than press „F4“.

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6. Than press „F “
7. Press “Enter” and the “left arrow” and “right arrow” to set the cursor for change the values with the “up
arrow”, “down arrow”. Close with “Enter”.
8. Than change the cursor with up arrow to the date.
With left arrow” and “right arrow” change the possition of the cursor wihtin the date and with the “up
arrow”, “down arrow” change the values. Close with “Enter”
9. Press F for setting.The black sign show that the time will be set in the opertion panel.
daymonth

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10.With “Back” you go to System
11.With another “Back” you will go to the first picture.

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3.6 Connecting the Data Cable

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4Technical Specifications
4.1 Data sheet
Model Outdoor
Dimensions Depth 940 mm
Breadth 3040 mm
Height 1850 mm
Weight without refrigerant load ca. 1070 kg
Weight with load ca. 1100 kg
Shipping weight ca. 1600 kg
Weight total refrigerant load 4,0 kg
CO equivalent 34,4 t CO
Number of fans 4
Quantity of air x 18000 m³/h
Refrigerant R134a
GWP 1430
Required quantity of refrigerant See name plate
High-pressure switch 19, bar
Water connection inlet “ G" female
Water connection outlet “ G" female
Cold water temperature outlet min. 19 °C
Cold water temperature outlet max. °C
Tolerance ±0,5 K
Primary water pump type CR 10- 05
Rated water capacity min. 7,8 m³/h
Rated water pressure 7,5 bar
Ambient temperature min. - 0 °C
max. +48 °C
Cooling capacity 60,0 kW
Rated cold water outlet temperature 0 °C
Temperature of surroundings 48 °C
Main supply 480 V / 3Ph / 60 Hz
Control voltage 4 VDC
Fluctuations in main voltage max. -14/+10 %
Fluctuations in Frequency max. ±1 Hz
Power input max. 9 kW
Loudness at 10 m 61 db(A)

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4. Dimensional drawing Type KSC 15-L- U/S
5

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Version „Revision 09“ Type KSC 15-L-U/S
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4. 3 Water chiller control scheme