KKT cBoxX 30, cBoxX 40, cBoxX 50, cBoxX 70, cBoxX 60 Operating Instructions Manual
...
Compact-Line
Operating Instructions
cBoxX 30
cBoxX 40
cBoxX 50
cBoxX 60
cBoxX 70
cBoxX 80
cBoxX 90
cBoxX 100
cBoxX 120
cBoxX 160
cBoxX 180
cBoxX 200
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Table 1: Contact details
Manufacturer
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T +49 9228 9977 0
F +49 9228 9977 149
E info@kkt-chillers.com
W www.kkt-chillers.com
Service
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T +49 9228 9977 7190 *
F +49 9228 9977 7474
E service@kkt-chillers.com
W www.kkt-chillers.com*
Service USA
KKT chillers, Inc.
1280 Landmeier Road
Elk Grove Village
IL 60007
T +1 847 734 1600
F +1 847 734 1601
TF +1 866 517 6867 *
E support@kkt-chillersusa.com *
3 / 89 83000102.Ki
Introduction
These operating instructions have been drawn up by KKT chillers on the basis of the Machinery
Directive 2006/42/EC. They contain all important information and instructions for the installation
and safe operation of the refrigerating machine (chiller). It also contains advice on how to prevent
or correct faults.
Please allow yourself sufficient time to read through these instructions carefully and to digest all
the information this document contains. If you have any further questions, please contact the
KKT chillers Service Team using the contact details provided.
If properly used for its intended use and correctly maintained, the chiller ensures sustained, faultfree operation. The methods and procedures described in these instructions should help you to
detect problems early and to take appropriate countermeasures.
If you keep to the maintenance programme described you ensure the reliability and safety of the
machine. You also keep the operating costs low and at the same time increase the life of the
components.
To ensure that the performance of your chiller is not impaired, we recommend that you only use
original spare parts purchased from KKT chillers. In this way you ensure the reliability and quality
of the machine.
KKT chillers reserves the right to change technical details without prior notice. The illustrations in
this document are not to scale!
As the Compact-Line units can be adapted to specific projects, this document only contains
information that is generally valid for all units in the series.
All project-specific data is enclosed with the unit in separate summary documentation.
▪ Machine configuration
▪ Parameter list
▪ P&I diagram
▪ Pump characteristic curve(s)
▪ Circuit diagram
▪ All other project specific details
ATTENTION! A black exclamation mark on a yellow background in a triangle indicates
important information and instructions to which you must pay particular attention and
must always follow.
4 / 89 83000102.Ki
Contents
Introduction ............................................................................................................................................. 3
1. Product description ................................................................................................................... 8
1.1. Intended use ...................................................................................................................... 8
1.2. Elements ........................................................................................................................... 11
1.3. Explanation of terms ........................................................................................................ 12
2. Function and main components ............................................................................................. 13
2.1. Compressor ...................................................................................................................... 13
2.2. Evaporator ........................................................................................................................ 14
2.3. Condenser ........................................................................................................................ 14
2.4. Expansion valve ............................................................................................................... 14
2.5. Refrigerant ........................................................................................................................ 14
2.6. Oil ...................................................................................................................................... 15
2.7. Filter dryer ........................................................................................................................ 15
2.8. Pressure sensors ............................................................................................................. 15
2.9. Temperature sensors....................................................................................................... 15
2.10. Control unit/ main circuit board ...................................................................................... 15
2.11. Display .............................................................................................................................. 15
2.12. Control cabinet ................................................................................................................. 16
2.13. Pump ................................................................................................................................. 16
2.14. Fan .................................................................................................................................... 16
2.15. Cold water cycle ............................................................................................................... 16
2.16. Materials used in the water circuit ................................................................................. 17
2.17. Water quality .................................................................................................................... 19
2.18. Permitted cooling media ................................................................................................. 20
3. Options and accessories ......................................................................................................... 20
3.1. Version without tank, with pump .................................................................................... 20
3.2. Version without tank, without pump ............................................................................... 20
3.3. Version with water cooled condenser ............................................................................. 21
3.4. Heater for compressor and control cabinet ................................................................... 21
3.5. Insulation of the cold pipes and the pump(s) ................................................................ 21
3.6. Tank heater with thermostatic pump start ..................................................................... 22
3.7. Overflow valve for standby mode .................................................................................... 22
3.8. Higher pressure pump ..................................................................................................... 22
3.9. Second consumer circuit ................................................................................................. 23
3.10. Additional evaporator pump ............................................................................................ 23
3.11. Automatic water feed ....................................................................................................... 23
3.12. Water circuit in non-ferrous metal-free version ............................................................. 23
3.13. DI package ........................................................................................................................ 23
3.14. Special voltage ................................................................................................................. 23
3.15. Phase monitoring ............................................................................................................. 24
3.16. Hot gas bypass for output control <1K........................................................................... 24
3.17. High-temperature package .............................................................................................. 24
3.18. Special paint finish .......................................................................................................... 24
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3.19. Air filter mat (accessories) ............................................................................................... 24
3.20. Levelling feet (accessories) ............................................................................................. 24
3.21. Level package (accessories) ........................................................................................... 25
3.22. Filter assembly group coolant circuit (accessories) ....................................................... 25
3.23. Filter assembly group cooling water circuit (accessories) ............................................. 25
3.24. MultiplexX connection group (accessories) .................................................................... 26
3.25. Refill cartridge R410A (accessories) .............................................................................. 26
3.26. Anybus-Gateway (accessories) ........................................................................................ 26
3.27. Remote Control Panel (accessories)............................................................................... 27
3.28. Special languages (accessories) ..................................................................................... 27
3.29. Wooden Crate (accessories) .......................................................................................... 27
3.30. Seaworthy crate packaging (accessories) ...................................................................... 27
3.31. Water Pump Redundancy ................................................................................................ 27
3.32. Closed Water Loop ........................................................................................................... 27
4. Safety........................................................................................................................................ 29
4.1. General information ......................................................................................................... 29
4.2. Hazard warnings .............................................................................................................. 29
4.3. Residual energy................................................................................................................ 32
4.4. Safety devices, guards and safeguards ......................................................................... 33
4.4.1. High-pressure limiter ................................................................................................ 33
4.4.2. High-pressure monitoring ........................................................................................ 34
4.4.3. Low-pressure monitoring ......................................................................................... 34
4.4.4. Flow monitoring ........................................................................................................ 34
4.4.5. Personal protective equipment when operating the machine .............................. 34
4.5. Personal protective equipment for servicing work ........................................................ 35
4.6. Airborne sound emissions ............................................................................................... 35
4.7. Notes on reducing noise and vibration ........................................................................... 36
4.7.1. Noise ......................................................................................................................... 36
4.7.2. Vibration .................................................................................................................... 36
4.8. Residual risks ................................................................................................................... 37
4.8.1. Electrical ................................................................................................................... 37
4.8.2. Mechanical ............................................................................................................... 37
4.8.3. Chemical ................................................................................................................... 37
4.8.4. Other ......................................................................................................................... 37
4.9. Dangerous substances .................................................................................................... 37
4.9.1. Refrigerant R410A ................................................................................................... 37
4.9.2. Oil POE 160SZ .......................................................................................................... 39
4.10. Reasonably foreseeable misuse ..................................................................................... 40
4.11. Information for emergencies ........................................................................................... 41
5. Handling and storage .............................................................................................................. 41
5.1. Dangerous goods ............................................................................................................. 41
5.2. Transport .......................................................................................................................... 41
5.2.1. Forklift truck ............................................................................................................. 42
42
5.2.2. Crane ......................................................................................................................... 43
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5.3. Unpacking ......................................................................................................................... 44
5.4. Storage ............................................................................................................................. 44
6. Installation ............................................................................................................................... 45
6.1. Overview ........................................................................................................................... 45
6.2. Installation site ................................................................................................................. 45
6.2.1. General information ................................................................................................. 45
6.2.2. Minimum room volume ............................................................................................ 45
6.2.3. Ambient temperature ............................................................................................... 46
6.2.4. Effect of surrounding air flow .................................................................................. 46
6.2.5. Minimum clearances ............................................................................................... 46
6.2.6. External attachments ............................................................................................... 46
6.2.7. Process level ............................................................................................................. 47
6.2.8. Surface and foundation ........................................................................................... 47
6.2.9. Stability ..................................................................................................................... 48
6.2.10. Levelling .................................................................................................................... 48
6.2.11. Vibration isolation .................................................................................................... 48
6.2.12. Installation ................................................................................................................ 49
6.2.13. Hydraulic installation ............................................................................................... 49
6.2.14. Frost protection measures ...................................................................................... 50
6.2.15. Flushing the cold water circuit ................................................................................ 50
6.2.16. Filling ......................................................................................................................... 50
6.2.17. Venting ...................................................................................................................... 52
6.2.18. Electrical installation ................................................................................................ 53
7. Commissioning ........................................................................................................................ 54
7.1. Installation checklist ........................................................................................................ 54
8. Operation.................................................................................................................................. 55
8.1. Switching on ..................................................................................................................... 55
8.2. Selecting the operating mode ......................................................................................... 55
8.3. External release ............................................................................................................... 55
8.4. Control .............................................................................................................................. 55
8.5. Control panel .................................................................................................................... 56
8.5.1. Start screen .............................................................................................................. 57
8.5.2. Main menu ................................................................................................................ 58
8.5.3. Information ............................................................................................................... 58
8.5.4. Settings ..................................................................................................................... 60
8.5.5. Alarm menu .............................................................................................................. 60
8.6. Parameters ....................................................................................................................... 61
8.7. Controller description ...................................................................................................... 62
8.7.1. Electronic level monitoring ...................................................................................... 62
8.7.2. Switching the chiller On/off ..................................................................................... 62
8.7.3. Cold water flow temperature control ...................................................................... 63
8.7.4. Compressor control .................................................................................................. 64
8.7.5. Fan speed control .................................................................................................... 64
8.7.6. Electronic expansion valve control .......................................................................... 65
8.7.7. Temperature limit monitoring .................................................................................. 65
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8.7.8. Group fault alarm ..................................................................................................... 65
8.8. Operating modes .............................................................................................................. 65
8.8.1. ECO mode ................................................................................................................. 65
8.8.2. Comfort mode ........................................................................................................... 65
9. Cleaning ................................................................................................................................... 66
9.1. Air filter mat ...................................................................................................................... 66
9.2. Condenser ........................................................................................................................ 66
9.3. Water filter ........................................................................................................................ 66
9.4. Complete cleaning of the cold water circuit ................................................................... 66
10. Service ...................................................................................................................................... 67
10.1. Maintenance .................................................................................................................... 67
10.2. Fault correction ................................................................................................................ 67
10.3. Spare parts ....................................................................................................................... 67
11. Taking out of service ............................................................................................................... 68
11.1. Draining ............................................................................................................................ 68
12. Recycling .................................................................................................................................. 69
13. Products, solutions and services ............................................................................................ 69
14. Lists .......................................................................................................................................... 70
14.1. List of illustrations............................................................................................................ 70
14.2. List of tables ..................................................................................................................... 70
I. Main dimensions ..................................................................................................................... 72
II. Installation instructions ........................................................................................................... 76
III. Troubleshooting ....................................................................................................................... 80
IV. Maintenance intervals in accordance with the VDMA ........................................................... 85
V. Product Registration ................................................................................................................ 88
VI. EC Declaration of Conformity .................................................................................................. 89
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1. Product description
Please read all the points in these operating instructions before starting up the machine. You
should pay particular attention to the points on safety, commissioning/startup and operation. If
you have further questions about your machine, please contact the KKT chillers Service Team
(see Table 1: Contact details).
1.1. Intended use
The cBoxX is a factory-tested, fully automatic compressor chiller. The machine is solely for cooling
liquids (fluids) in accordance with EN 378-1. An adequate supply of cooling air must be provided.
Only approved liquids may be used. The cBoxX corresponds to protection class IP 54 (when the
housing is closed) and is suitable for both indoor and outdoor installation (note the options
packages).
The operator is responsible for complying with the specified operating, servicing and maintenance
conditions according to these operating instructions.
The owner of the chiller, not the manufacturer, is responsible and liable for all personal injuries
and damage to property caused by improper use of the unit (misuse).
Table 2 shows the general safety instructions of the chiller. These are attached to the machine in
a clear and readily visible position. A complete description of all hazard warnings is given in
Chapter 4.2 Hazard warnings.
Table 2: Safety instructions
Note and follow the instructions for use!
Before opening the machine it must be disconnected from the power supply!
After disconnecting the machine from the power supply, always wait for at least
5 minutes before opening it.
Danger! High voltage! If the machine is only switched off at its main switch,
dangerous electrical voltage is still present at several terminals in the control
cabinet.
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Technical data
Table 3: Technical data
Compact-Line
-
cBoxX 30
cBoxX 40
cBoxX 50
cBoxX 60
cBoxX 70
cBoxX 80
cBoxX 90
cBoxX 100
Refrigerating capacity @ tw2=20°C / tu=32°C
kW
34
43
55
68
78
87
95
105
Refrigeration circuit hermetically tight
no
Refrigerant
-
R410A
GWP
2088
Refrigerant capacity
kg 6 6 6 7 8 8 8 8
CO2 equivalent
t CO2
12,5
12,5
12,5
14,6
16,7
16,7
16,7
16,7
Cooling medium (liquid/secondary refrigerant)
-
Water or water / glycol
Ambient temperature range
°C
+5 to +45 (optionally -25 to +50°C)
Liquid feed temperature
°C
+8 to +30 (optionally to -10)
Target constancy
K
+/-1
Tank volume
l
300
500
Coolant circulation, nominal (dt = 5K)
m³/h
5.5
7.2
9.2
11.1
12.4
14.3
16.1
18.2
Free pump pressure (standard)
bar
3
Water connection, nominal size
RP
11/2"
2"
Air flow rate (max.)
m³/h
9350
9350
12600
20000
23270
23270
23270
23270
Sound pressure level at 5 m distance
dBA
62
62
55
69
59
59
59
59
Operating voltage (standard)
V/Ph/Hz
400/ 3/ 50
Protection class
-
IP54
Height
mm
2030
2030
Width
mm
830
830
Length
mm
1240
1840
Net weight
kg
540
540
550
620
650
650
700
720
Gross weight
kg
840
840
850
920
1150
1150
1200
1220
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Compact-Line
-
cBoxX 120
cBoxX 160
cBoxX 180
cBoxX 200
Refrigerating capacity @ tw2=20°C / tu=32°C
kW
135
166
194
210
Refrigeration circuit hermetically tight
no
Refrigerant
-
R410A
GWP
2088
Refrigerant capacity
kg
17
17
23,5
23,5
CO2 equivalent
t CO2
35,5
35,5
49,1
49,1
Cooling medium (liquid/secondary refrigerant)
-
Water or water / glycol
Ambient temperature range
°C
+5 to +45 (optionally -25 to +50°C)
Liquid feed temperature
°C
+8 to +30 (optionally to -10)
Target constancy
K
+/-1
Tank volume
l
700
900
Coolant circulation, nominal (dt = 5K)
m³/h
21,5
27,2
32,2
35,4
Free pump pressure (standard)
bar
3
Water connection, nominal size
RP
DN65 PN10 EN1092
Air flow rate (max.)
m³/h
45550
49100
Sound pressure level at 5 m distance
dBA
67
67
67
67
Operating voltage (standard)
V/Ph/Hz
400/ 3/ 50
Protection class
-
IP54
Height
mm
2030
Width
mm
1200
Length
mm
2665
3965
Net weight
kg
1100
1200
1300
1400
Gross weight
kg
1800
1900
2200
2300
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1.2. Elements
1
Metal cladding, top, operator side
a
Safety instructions
2
Metal cladding, bottom, operator side
b
Water connections
3
Metal cladding, top, service side
c
Rating plate
4
Metal cladding, bottom, service side
d
Display
5
Metal cladding, condenser protective grating
e
Main switch
6
Cladding, hydraulics
1 2 3 4 5 6 a b c d e
12 / 89 83000102.Ki
1.3. Explanation of terms
A few important terms which appear in this document are briefly explained here for improved
understanding.
Table 4: Explanation of terms
Term
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
Ambient 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 / 89 83000102.Ki
2. 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). 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 1: C6848 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.
2.1. 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). Sequential changeover ensures that all compressors are loaded uniformly.
Compressor
Condenser and fan
Evaporator
Expansion
valve
Heat
Cold
14 / 89 83000102.Ki
2.2. 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.
2.3. 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 9: 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 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
water cooled condenser)
2.4. 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.
2.5. 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 fluorinated greenhouse gas consisting of the zeotropic mixture of 50% R32 and 50%
R125 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 Table 1: Contact details).
15 / 89 83000102.Ki
2.6. 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 Table 1: Contact details).
2.7. 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 120 – cBoxX 200) must be replaced.
2.8. 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.
2.9. 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.
2.10. Control unit/ 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.
2.11. 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 panel).
16 / 89 83000102.Ki
2.12. Control cabinet
The control cabinet conforms to the requirements of EN 60204 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 2: Demounting the side panel of the switch cabinet
2.13. 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, and Chapter 3.2 Version without tank, without
pump).
2.14. 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 2.
2.15. 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,
with pump, and Chapter 3.2 Version without tank, without pump). In the process circuit the cold
17 / 89 83000102.Ki
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.
2.16. Materials used in the water circuit
The material composition of the standard equipment is shown in Table 5:
Table 5: Materials used - standard version
Component
Material (cBoxX 30 – 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
Grey cast iron and V2A 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
V2A 1.4301
Pressure sensor XSK AC10I-U188
V2A 1.4301
Overflow valve (optional)
Gunmetal
Tank heater (optional)
Nickel-chrome-iron alloy 825
Component
Material (cBoxX 120 – cBoxX 200)
Unit connections
ABS
Piping and fittings
ABS
evaporator
V2A 1.4301 and copper (99,9%)
Tank
Tank ports/connection sockets
V2A 1.4301
V4A 1.4571
Pump
Mechanical seals
Grey cast iron and V2A 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 / 89 83000102.Ki
If equipped with the optional Water circuit in non-ferrous metal-free version the material
composition is as shown in Table 6:
Table 6: Materials used for the non-ferrous metal-free version
Component
Material (cBoxX 30 – cBoxX 100)
Unit connections (rotating parts)
V2A 1.4305
Hose
Synthetic rubber
Evaporator
V2A 1.4301
Tank
Tank ports/connection sockets
V2A 1.4301
V4A 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
Elbow threaded couplings
(level indicator)
PVC and polyoxymethylene (POM)
Hose (level indicator)
PE natural
Temperature sensor PT1000
V2A 1.4301
Pressure sensor XSK AC10I-U188
V2A 1.4301
Overflow valve (optional)
V2A 1.4301
Tank heater (optional)
Nickel-chrome-iron alloy 825
Component
Material (cBoxX 120 – cBoxX 200)
Unit connections
ABS
Piping and fittings
ABS
evaporator
V2A 1.4301
Tank
Tank ports/connection sockets
V2A 1.4301
V4A 1.4571
Pump
Mechanical seals
V2A 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
V2A 1.4301
19 / 89 83000102.Ki
2.17. Water quality
The following limits must be maintained for safe operation of the equipment:
Table 7: Water quality
Property /
components
Unit
Value range
Standard version
Value range
Non-ferrous metal-free version
pH value (20 °C) - 7-9
6-9
Saturation index
-
-0.2 < 0 < +0.2
-0.2 < 0 < +0.2
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
< 250
< 250
Glycol fraction (AFN)
% by vol
20-40
20-40
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
<0.2
<0.2
Free carbonic acid
mg/l
<20
<20
Manganese
mg/l
<0.1
<0.1
Ammonia
mg/l
<2
<2
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.
20 / 89 83000102.Ki
2.18. Permitted cooling media
Water and mixtures of water / Antifrogen N (AFN) or water / Antifrogen L (AFL) according to the
details given in Chapter 2.17 Water 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 8: AFN and AFL mix ratios (or equivalent)
Setting
Frost-free at
t-environment to
AFN mix ratio
AFL mix ratio
Glycol 20 - 25 %
-10°C
20-25 %
25-30 %
Glycol 30 - 35 %
-15°C
30-35 %
32-37 %
Glycol 40 %
-25 °C
40 %
42 %
3. 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 Contact details).
Details of your machine's equipment are given in the separate summary documentation.
3.1. 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)
3.2. 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
reactions and silting up.
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3.3. Version with water cooled condenser
Whereas the basic versions of the Compact-Line is specified with an air cooled condenser, the
units are also available with an water cooled condenser.
Thereby the condenser is a plate heat exchanger with copper brazed stainless steel plates. The
3way valve is mounted in the cooling water outlet and is adjusted by an actuator depending on
the condensing pressure. The operation mode can be switched from the 3way operation to a
2way operation by closing the pre mounted bypass valve. The cooling water temperature is
measured by an additional temperature sensor in the cooling water inlet and is shown at the
controller display.
The project specific data as well as the adapted hydraulic scheme and the dimension sketch can
be found in the additional short documentation.
3.4. Heater for compressor and control cabinet
The oil sump heater prevents refrigerant from becoming deposited in the oil of the compressor at
low ambient temperatures. When the compressor is started up this refrigerant would be liberated
from the oil as gas and make the oil foam up. Under these basic conditions the lubrication of
components in the compressor 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 ambient air drawn in condensing on the electrical and electronic
components of the cabinet thereby damaging them.
For both heaters to be active, the chiller must not be disconnected from the power supply (8.2
Selecting the operating mode).
3.5. Insulation of the cold pipes and the pump(s)
To prevent condensation on cold chiller pipes, where high temperature differences exist between
the surroundings and cold water flow and taking into account the relative humidity the option of
insulation of the cold pipes must be specified.
The water quality shown in Table 7: Water quality has to be guaranteed imperatively –
the manufacturer does not assume liability for damages caused by other water
qualities.
22 / 89 83000102.Ki
3.6. Tank heater with thermostatic pump start
The tank heater maintains a minimum temperature in the tank. The pump circulates the cold
water, while the tank heater controls the temperature in the system. We recommend a hydraulic
installation as shown in Figure 3. Any bypass valves must therefore always be installed frost-free.
For the heater to be active, the chiller must not be disconnected from the power supply. Even if
the external release (8.3 External release) is deactivated, the pump remains active.
Figure 3: C6856 thermostatic pump start with overflow valve (recommended installation)
3.7. Overflow valve for standby mode
The optional overflow valve should be installed if it is possible for the flow of the cold water to
reduce sharply or be completely prevented while the unit is running. The internal overflow valve
ensures the minimum volumetric flow through the chiller and therefore prevents the pump from
switching off. Figure 4 shows the position of the internal overflow valve.
Figure 4: C6863 overflow valve for standby mode
3.8. Higher pressure pump
The standard Compact-Line units have a 3 bar pump, which is designed for the nominal
volumetric flow of the respective unit. Optionally the units can also be built with higher pressure
pumps, within the limits of the minimum or maximum volumetric flow (1.2 Technical data). The
pump characteristic curve of the pump(s) used in your unit is enclosed with the unit.
cBoxX
Frost-free area
Application
Application
cBoxX
23 / 89 83000102.Ki
3.9. Second consumer circuit
The standard Compact-Line units have a 3 bar pump, which is designed for the nominal
volumetric flow of the respective unit. If several consumers with different water specifications are
to be cooled with one unit, the unit can also be supplied with an optional second cold water
circuit. Ask your KKT chillers contact.
3.10. Additional evaporator pump
The evaporator is optimised for the nominal volumetric flow rate of cold water. The nominal
volumetric flow rate is given in Table 3 Technical data.
If the operating volumetric 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 temperature. A second pump supplies the process circuit with cold water.
3.11. Automatic water feed
Any leaks and evaporation can cause the quantity of cold water available for the chiller function to
reduce during the course of operation of the chiller. The Automatic water feed option provides the
possibility of topping up the cold water circuit automatically. The tank contents are monitored
continuously and if necessary topped up until it has again reached the optimum level. In this case
the operator only has to connect the chiller to the building's water system via the feed connection
(see Figure 5). The inlet pressure must lie between 1 bar and 10 bar.
Figure 5: Top-up connection
If you operate your chiller with a mixture of water / glycol and top up only with pure water, you
must check the glycol content of the circuit water at regular intervals and if necessary adjust it.
3.12. Water circuit in non-ferrous metal-free version
If your machine is a non-ferrous metal-free version, all parts of the chiller's cold water circuit in
contact with the media are free from non-ferrous metals. Certain components such as the
evaporator and pump are suitably modified. The materials used in the water circuit are listed in
Table 6.
3.13. DI package
The DI package contains the non-ferrous metal-free option for the water circuit (see chapter,
3.12) and a replaceable DI cartridge with conductivity monitoring and control.
3.14. Special voltage
The special voltage option describes the use of the aggregate outside the voltage supply of 400V
(±10%)/3phases/50Hz. Here alternative components (e.g. compressors, pumps or fans) as well
as an autotransformer (integrated or unattached) can be used.
24 / 89 83000102.Ki
For chillers with an integrated autotransformer sizes cBoxX 30 to cBoxX100, the transformer is
located in an additional flanged-mounted housing; for sizes cBoxX 120 to cBoxX 200 it is located
in the existing housing. For exact specifications, please refer to the circuit diagram. Please get in
touch with your KKT chillers contact person for further information on implementing this option.
3.15. Phase monitoring
The Compact-Line units can be equipped with optional phase monitoring. This monitors the phase
sequence, phase failure, undervoltage and asymmetry and covers a voltage range of 200-690V. If
the respective predefined limits are exceeded the system switches off and protects the electrical
components installed in the unit.
3.16. Hot gas bypass for output control <1K
If a more precise target constant than ±1 Kelvin is required, the chiller can be equipped with an
output control. In this case the output of the refrigeration circuit is adjusted to the cooling
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. High-temperature package
In principle, the units must be operated within the given ambient temperature range (see
Table 3). If the high-temperature package is selected, the unit can be operated at an ambient
temperature of up to 50 °C without high-pressure faults.
3.18. Special paint finish
While the condenser's protective grille is always painted in RAL 7015 anthracite black, the
cladding panels (1.3 Elements) can also be optionally finished in special colours.
3.19. Air filter mat (accessories)
If the chiller is operated in surroundings with dust or oil vapour the condenser should be
protected with the air filter mat. The filter is fixed using the Velcro tapes attached in the
condenser protective grille. The filter is cleaned by removing it and washing it with water or a
slightly alkaline solution. Heavily-contaminated filters must be replaced by new ones. Please
contact the KKT chillers Service Team (see Table 1 Contact details).
3.20. Levelling feet (accessories)
The levelling feet are used for vibration isolation and for height adjustment. They consist of a
threaded rod and a grey cast iron shell with an elastic element attached. The threaded rod
enables the height to be adjusted and compensates for floors sloping by up to 5°. The elastic
element has a slip-resistant covering. Figure 6 and Figure 7 show the installed machine foot – the
technical drawing is given in the appendix.
25 / 89 83000102.Ki
Figure 6: Machine base (foot) – outside view
Figure 7: Machine base (foot) - mounting on the baseplate
3.21. Level package (accessories)
The level package is used if the application is to be installed more than 500 mm above or below
the chiller (see also Chapter 6.2.7 Process level). This option is delivered uninstalled and consists
of an electronically controlled valve and a non-return valve. The electronically controlled valve
must be installed at the unit inlet, the non-return valve at the unit outlet. The electronically
controlled valve is installed electrically in the control cabinet as shown in the circuit diagram.
3.22. Filter assembly group coolant circuit (accessories)
The water filter protects the coolant circuit against dirt. The set, consisting of a filter, fitting and
two shut off valves, is enclosed with the chiller in a separate pack and must be fitted onto the
cold water inlet of the chiller from the outside when the chiller is installed.
3.23. Filter assembly group cooling water circuit (accessories)
The water filter protects the cooling water circuit against dirt. The set, consisting of a filter, fitting,
two shut off valves and two pressure gauges for displaying the cooling water inlet- and outlet
pressure is enclosed with the chiller in a separate pack. The installation can be either mounted
for shutting of the filter group or for shutting of the complete cooling water circuit.
26 / 89 83000102.Ki
3.24. MultiplexX connection group (accessories)
If the refrigerating capacity of a chiller is not sufficient, several units of the same type can be
combined in the version with tank and pump. A MultiplexX connection group can be ordered for
this purpose and consists of the level package (3.21 Level package) and a corresponding
connection kit for the flow balance between the tanks. The refrigerating capacity of the individual
units can then be added together. Please contact your KKT chillers contact to arrange the
appropriate project planning for this option.
3.25. Refill cartridge R410A (accessories)
Chillers with refrigerant capacity >12kg must be declared as dangerous goods in accordance with
UN2857 (5.1 Dangerous goods). The optional R410A refill cartridge is available for units with
refrigerant capacities >12kg (cBoxX 120- CBoxX 200) so that you do not incur any additional
logistics costs. Following the performance check in the factory, a quantity of refrigerant is filled in
a certified refrigerant cylinder so that the 12kg limit is kept to in the unit. The refill cartridge is
then delivered together with the unit. The refrigerant quantity drained for transport can be
returned to the system as part of the commissioning using the summary description provided with
the refill cartridge.
3.26. Anybus-Gateway (accessories)
The Anybus-Gateway is ready mounted in the switch cabinet and can be used as an interface for
processing all chiller signals. Therefore the following processing protocols are available
depending on the customer specification:
▪ Modbus
▪ Profibus
▪ CANopen
▪ Profinet
▪ Devicenet
▪ EtherNet
▪ EtherCAT
▪ ControlNet
▪ CC-Link
A Modbus TCP communication is already included on the display pcb as a standard feature. An
Anybus gateway is not required.
27 / 89 83000102.Ki
3.27. Remote Control Panel (accessories)
For the case that the chiller shall be operated not from the machine itself but from a different
operating place the chiller can be delivered with a remote control panel. Thereby the same display
is mounted together with the operating voltage supply in one miniature housing. The remote
control panel is connected to the chiller with clips and takes over the complete function of the
controller in the main device. By switching the accordant bridge integrated in the control cabinet,
the required operating place can be chosen.
(in = internally installed control / out = outward leading control)
3.28. Special languages (accessories)
These instruction manuals are provided in German, English, French and Spanish. Other languages
are available on request.
3.29. Wooden Crate (accessories)
Whereas the chillers of the Compact-Line are delivered on a wooden palette with Styrofoam
corners stretched in the foil as a standard, the chillers can be also ordered in a wooden crate.
There the chillers are protected additionally by a wooden crate with IPPC-Label according ISPM
15.
3.30. Seaworthy crate packaging (accessories)
Seaworthy crates for the Compact-Line are produced according to International Standards for
Phytosanitary Measures with packaging made of solid wood (ISPM 15). This means that the
crates are made of heat-treated solid wood which has been stripped of its bark. Only wood-based
materials, such as OSB boards, are used. In addition, all crates are marked with the IPPC logo
and registration number. The units are fixed in the crate with the help of coach bolts, ring nuts
and polyester straps and are packed in a sea air consistent foil with desiccant. The components
used to pack the units can be dismantled using a cross-head screwdriver.
3.31. Water Pump Redundancy
Depending on the optional configuration, the cboxX (water chiller) can be equipped with a dual
water pump for redundancy and increased life time of the pump itself. The operating hours of the
pumps are programmable and can be shared by both pumps (f. e. 24h switch on/off between
both pumps). In case of a pump defect, an automatic switch to the pump redundant, ensures the
continuation of the water chiller and the operation of the end customers application.
3.32. Closed Water Loop
The water chiller is designed as a closed water loop system with an expansion tank. The
expansion tank is pressurized in accordance with the volume of the entire system volume
(including installation). The expansion tank balances temperature swings and related system
pressure of the water loop. In case the coolant temperature rises the expansion tank takes in the
expanded volume of the coolant and if the coolant temperature falls the stored volume will be
released back into the loop again.
Advantages of a closed water loop system are:
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