KKT Compact-Line cBoxX 100, Operating Instructions Manual

Page 1: ...Compact Compact Compact Compact Line Line Line Line Operating Instructions cBoxX 30 cBoxX 40 cBoxX 50 cBoxX 60 cBoxX 70 cBoxX 80 cBoxX 90 cBoxX 100 cBoxX 120 cBoxX 160 cBoxX 180 cBoxX 200...

Page 2: ...ermany T 49 9228 9977 0 F 49 9228 9977 149 E info kkt chillers com W www kkt chillers com ait deutschland GmbH Industriestra e 3 95359 Kasendorf Germany T 49 9228 9977 7190 F 49 9228 9977 7474 E servi...

Page 3: ...ly 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 noti...

Page 4: ...rcuit 17 2 17 Water quality 19 2 18 Permitted cooling media 20 3 Options and accessories 20 3 1 Version without tank with pump 20 3 2 Version without tank without pump 20 3 3 Version with water cooled...

Page 5: ...4 1 General information 28 4 2 Hazard warnings 28 4 3 Residual energy 30 4 4 Safety devices guards and safeguards 31 4 4 1 High pressure limiter 31 4 4 2 High pressure monitoring 32 4 4 3 Low pressure...

Page 6: ...es 47 6 2 15 Flushing the cold water circuit 47 6 2 16 Filling 47 6 2 17 Venting 49 6 2 18 Electrical installation 50 7 Commissioning 51 7 1 Installation checklist 51 8 Operation 52 8 1 Switching on 5...

Page 7: ...e cold water circuit 63 10 Service 64 10 1 Maintenance 64 10 2 Fault correction 64 10 3 Spare parts 64 11 Taking out of service 65 11 1 Draining 65 12 Recycling 66 13 Products solutions and services 6...

Page 8: ...mproper use of the unit misuse Table 2 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 i...

Page 9: ...col Ambient temperature range C 5 to 45 optionally 25 to 50 C Liquid feed temperature C 8 to 30 optionally to 10 Target constancy K 1 Tank volume l 300 500 Coolant circulation nominal dt 5K m h 5 5 7...

Page 10: ...0 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 m h 21 5 27 2 32 2 35 4 Free pump pressure standard bar 3 Water conn...

Page 11: ...instructions 2 2 2 2 Metal cladding bottom operator side b b b b Water connections 3 3 3 3 Metal cladding top service side c c c c Rating plate 4 4 4 4 Metal cladding bottom service side d d d d Disp...

Page 12: ...Explanation of terms Term Term Term Term Explanation Explanation Explanation Explanation Application The heat source connected hydraulically with the chiller Process circuit Application and piping to...

Page 13: ...pressure switch one or more pumps and one or more fans are also installed for control and operation of the chiller 2 1 2 1 2 1 2 1 Compressor Compressor Compressor Compressor The compressor generates...

Page 14: ...t or oil vapour use the optionally available air filter mat see 3 19 Air Air Air Air filter mat filter mat filter mat filter mat In case that there already is an existing house water system and the wa...

Page 15: ...t be replaced 2 8 2 8 2 8 2 8 Pressure sensors Pressure sensors Pressure sensors Pressure sensors The pressure sensors used are compact pressure transmitters with piezoresistive measuring cell The sen...

Page 16: ...ut pump see Chapter 3 1 Version without tank with pump Version without tank with pump Version without tank with pump Version without tank with pump and Chapter and Chapter and Chapter and Chapter 3 2...

Page 17: ...00 cBoxX 100 cBoxX 100 cBoxX 100 Unit connections V2A 1 4305 Hose Synthetic rubber Evaporator V2A 1 4301 and copper 99 9 Tank Tank ports connection sockets V2A 1 4301 V4A 1 4571 Pump Mechanical seal G...

Page 18: ...A 1 4571 Pump Mechanical seal V2A 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...

Page 19: ...free version free version pH value 20 C 7 9 6 9 Saturation index 0 2 0 0 2 0 2 0 0 2 Conductivity S cm 80 500 5 500 Water hardness dH 5 6 5 6 Carbonate hardness mol m 0 5 0 5 Total plate count K ml 10...

Page 20: ...le 1 Table 1 Table 1 Table 1 Contact Contact Contact Contact details details details details Details of your machine s equipment are given in the separate summary documentation 3 1 3 1 3 1 3 1 Version...

Page 21: ...pressor subject to friction would be poor and the compressor could be damaged The control cabinet heating is controlled thermostatically and at low ambient temperatures it prevents moisture from the a...

Page 22: ...3 7 3 7 3 7 Overflow valve Overflow valve Overflow valve Overflow valve for standby mode for standby mode for standby mode for standby mode The optional overflow valve should be installed if it is po...

Page 23: ...lumetric flow rate of the cold water is more than 50 smaller an evaporation pump must be installed The evaporator pump circulates the cold water internally and keeps the storage water at feed temperat...

Page 24: ...ng demand by an electronically controlled valve Unlike the standard control by switching compressors on or off a higher target constant is achieved by the continuous regulation of the valve 3 17 3 17...

Page 25: ...e baseplate 3 21 3 21 3 21 3 21 Level package accessories Level package accessories Level package accessories Level package accessories The level package is used if the application is to be installed...

Page 26: ...then be added together Please contact your KKT chillers contact to arrange the appropriate project planning for this option 3 25 3 25 3 25 3 25 Refill cartridge R410A accessories Refill cartridge R410...

Page 27: ...wooden crate There the chillers are protected additionally by a wooden crate with IPPC Label according ISPM 15 3 30 3 30 3 30 3 30 Seaworthy crate packaging Seaworthy crate packaging Seaworthy crate p...

Page 28: ...uired of the tank Reduces weight of the chiller 4 4 4 4 Safety Safety Safety Safety Provided it is used as intended the chiller is designed to operate safely provided also that the instructions concer...

Page 29: ...After disconnecting the machine from the power supply always wait for at After disconnecting the machine from the power supply always wait for at After disconnecting the machine from the power supply...

Page 30: ...faces of pipes and components of the refrigerant and cold water circuit and elect circuit and elect circuit and elect circuit and electrical equipment can be very cold during operation and even rical...

Page 31: ...afeguards Safety devices guards and safeguards Safety devices guards and safeguards Safety devices guards and safeguards pressure limiter pressure limiter pressure limiter pressure limiter pressure li...

Page 32: ...ructions in the Troubleshooting Troubleshooting Troubleshooting Troubleshooting chapter see Appendix chapter see Appendix chapter see Appendix chapter see Appendix 0 4 4 4 Flow monitoring Flow monitor...

Page 33: ...arried out on the chiller the protective equipment described in Table Table Table Table equipment for servicing work equipment for servicing work equipment for servicing work equipment for servicing w...

Page 34: ...e effect of vibration still further it is possible to install the chiller with optionally available levelling feet 3 20 Levelling feet Levelling feet Levelling feet Levelling feet These are fitted wit...

Page 35: ...ther information The effect of fire can cause bursting or explosion of the container Ignitable gas air mixtures possible under certain conditions Measures in case of accidental release Environmental p...

Page 36: ...mfortable position Get medical attention Following skin contact remove soiled soaked clothing Wash skin with water If symptoms develop get medical advice Following eye contact rinse the eyes with clea...

Page 37: ...contact Avoid inhaling high concentrations of vapour or fumes Storage suitable material for containers mild steel Tightly close unused containers to prevent the penetration of moisture Store away from...

Page 38: ...BoxX 100 chillers have been specified so that they contain 12 kg refrigerant The cBoxX 120 cBoxX 200 chillers basically have a refrigerant filling 12kg In order to avoid the declaration as dangerous g...

Page 39: ...centre of gravity cBoxX 0 centre of gravity cBoxX 30 30 30 30 60 60 60 60 Figure Figure Figure Figure 11 11 11 11 C6846 C6846 C6846 C6846 0 0 0 0 centre of gravity centre of gravity centre of gravity...

Page 40: ...ure Figure Figure Figure 14 14 14 14 C6841 C6841 C6841 C6841 0 crane transport cBoxX 0 crane transport cBoxX 0 crane transport cBoxX 0 crane transport cBoxX 30 30 30 30 100 100 100 100 Table Table Tab...

Page 41: ...of the packaging materials used Materials in the packaging Materials in the packaging Materials in the packaging Materials in the packaging is stored for more than one month it should remain in the tr...

Page 42: ...ration capacity The air flow rate required for your machine is given in Table Table Table Table 3 3 3 3 Technical Technical Technical Technical data data data data When choosing the installation site...

Page 43: ...the surrounding area the machine also draws in cooling air The machine controls the quantity of cooling air automatically via the speed of the fan Air currents surrounding the machine such as the win...

Page 44: ...l package Level package must be installed 6 2 8 Surface and foundation Surface and foundation Surface and foundation Surface and foundation The surface on which the machine is installed must be flat a...

Page 45: ...on the machine can also be bolted to the ground Holes are provided in the machine baseplate for precisely this purpose These are shown in Appendix Appendix Appendix Appendix III III III III The system...

Page 46: ...ers equipped with an internal tank the cold water cycle must be h Filling and feed topping up Draining Unit outlet cold water circuit 1 supply line Unit outlet cold water circuit 1 return line Unit ou...

Page 47: ...lically with the cold water circuit this must be flushed several times If there are dirt traps in the cold water circuit they must be cleaned after the flushing 6 2 16 Filling Filling Filling Filling...

Page 48: ...tivating the first fill always ensure that the cold water circuit is free of leaks The control adds fresh water until the operating All filling and feed connections are identified with the following p...

Page 49: ...ped from the pump body see Figure 17 Figure 17 Figure 17 Figure 17 Figure Figure Figure Figure 17 17 17 17 Position of the pump vent vertical type Position of the pump vent vertical type Position of t...

Page 50: ...ic components must have become acclimatised ATTENTION The electrical installation testing and commissioning may only be ATTENTION The electrical installation testing and commissioning may only be ATTE...

Page 51: ...installed for at least 12 hours at 5 C so that the compressor oil can heat up and the refrigerant can be liberated from the oil If your machine is equipped with oil sump heating and the machine has be...

Page 52: ...ly automatic operation only starts in this mode if the external release has been installed beforehand as described in Chapter 8 3 External release External release External release External release ON...

Page 53: ...er Number Function Function Function Function 1 UP button 2 OK button 3 DOWN button 4 Display with plain text 5 Main switch Use the UP and DOWN buttons to select the required menu item The selected me...

Page 54: ...r is displayed on the Start screen Active alarm Top left hand side Number of pumps running Left hand middle Number of compressors running Bottom left hand side Number of fans running Middle Actual val...

Page 55: ...Information Information Information In the Information menu you can move into various submenus to obtain an overview of the state of the chiller Figure Figure Figure Figure 2 2 2 23 3 3 3 Information...

Page 56: ...urs counter gives information on the operating hours of the individual components and cannot be reset Figure Figure Figure Figure 26 26 26 26 Operating hours counter Operating hours counter Operating...

Page 57: ...g inputs Analog inputs Analog inputs The analog outputs show the signal upstream of the digital analog converter The value 10000 corresponds to an output voltage of 10 volts Figure Figure Figure Figur...

Page 58: ...ened Alarms that are preceded by the abbreviation DI refer directly to the digital input All digital inputs must be closed in a fault free state The abbreviation AI indicates a sensor error of an anal...

Page 59: ...switched off the chiller does not start to ensure that no cooling process is initiated that may not be able to be ended 8 7 2 Switching the chiller On off Switching the chiller On off Switching the c...

Page 60: ...3 Cold water flow temperature control Cold water flow temperature control Cold water flow temperature control Cold water flow temperature control In the normal case the sensor in the tank system with...

Page 61: ...he E EPROM and the factory setting is accepted as the new number of compressors The compressors are requested depending on the controller output signal The compressor with the least number of operatin...

Page 62: ...l ntrol ntrol ntrol An electronic expansion valve with PI controller is used to keep the overheating constant To prevent the maximum operating pressure MOP from being exceeded a P controller is used w...

Page 63: ...rille panels 3 and 5 see Chapter 1 3 Elements Elements Elements Elements First of all remove coarse dirt particles from the outside using a standard vacuum cleaner Then flush the microchannel heat exc...

Page 64: ...ntire system can be guaranteed by proper The purpose of the maintenance is ensure that the machine operates reliably and without unexpected failures work in order to minimise downtimes An overview of...

Page 65: ...f frost suitable measures must be taken to protect the liquid from frost The complete cold water circuit must be fully drained before a stoppage of the unit Do this as follows Drain the tank via the d...

Page 66: ...chillers also offers other products solutions and services which are not described in this document For more information visit our homepage http www kkt http www kkt http www kkt http www kkt chillers...

Page 67: ...y cBoxX 70 100 39 Figure 12 C6846 0 centre of gravity cBoxX 120 160 39 Figure 13 C6846 0 centre of gravity cBoxX 180 200 39 Figure 14 C6841 0 crane transport cBoxX 30 100 40 Figure 15 Exhaust air duct...

Page 68: ...rrous metal free version 18 Table 7 Water quality 19 Table 8 AFN and AFL mix ratios or equivalent 20 Table 9 Definition of the safety symbols 29 Table 10 Hazard warnings 30 Table 11 Personal protectiv...

Page 69: ...ensor AI ESS outlet Sensor break AI ESS outlet Testing the supply cable connector sensor AI air flow Sensor break AI air flow Testing the supply cable connector sensor AI conductivity Sensor break AI...

Page 70: ...tside the permitted range Check fan 1 Check supply cable Fan blocked Current measurement of individual phases Load contactor is not working correctly DI fault fan 1 Internal monitoring of the fan has...

Page 71: ...se pressure loss downstream of pump 1 Pump pressure 1 max STOP Pressure at the pump outlet 1 is too high Reduce pressure loss downstream of pump 1 Gate valves in the external piping may need opening o...

Page 72: ...e See also High pressure stop High pressure STOP The high pressure of the refrigeration circuit lies within the critical range Are all metal cladding panels in place Check condenser for external conta...

Page 73: ...est x 8 Oil change x 9 Check that the crankcase heater is working x 10 Check that the output control is working x 11 Check the refrigerant side for leaks x 12 Check high low pressure switching equipme...

Page 74: ...Replace filter dryer X If com ponents in the refrig eration circuit are replaced 45 Check all pipes carrying refrigerant for corrosion and damage x Fans Fans Fans Fans 50 Optical check for dirt damag...

Page 75: ...hts and error messages x 94 Check the temperature and pressure sensors are functioning properly x 95 Check the function of the motor protection switches x 96 Check 24 VDC and supply voltage x x 97 Che...

Page 76: ...76 77 83000102 Kf III III III III Product Registration Product Registration Product Registration Product Registration PDF download http www kkt chillers com en downloads product registration...

Page 77: ...77 77 83000102 Kf IV IV IV IV EC Declaration of Conformity EC Declaration of Conformity EC Declaration of Conformity EC Declaration of Conformity...