KKT KPC 108-L-U/S Operating Instruction

83003702.K Operating Instruction

Type KPC 108-L-U/S

page 1

Manufacturer

ait-deutschland GmbH
Industriestraße 3

95359 Kasendorf
Germany

T [phone]
F [phone]
E [e-mail]
W www.kkt-chillers.com

Representative in the US and Service Center

KKT chillers, Inc.
1280 Landmeier Road
Elk Grove Village
IL 60007

T [phone]
F [phone]
TF [phone]

YOUR LOCAL SERVICE CONTRACTOR IS:

COMPANY NAME:

PHONE NUMBER: FAX NUMBER:

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83003702.K Operating Instruction

Type KPC 108-L-U/S

page 2

Contents

1 General Remarks ................................................................................................................................................... 4

1.1 Warranty .................................................................................................................................................5

1.2 Safety Warnings ......................................................................................................................................5

2 General Description ............................................................................................................................................... 6

2.1 Drawings ...............................................................................................................................................10

2.1.1 KPC 108-L-U/S Outdoor Model .................................................................................................................... 10

3 Brief operating instructions .................................................................................................................................. 11

3.1 Installing, maintenance and repair .........................................................................................................11

3.2 Linking to power supply .........................................................................................................................11

3.3 Filling the unit with cooling medium .......................................................................................................11

3.4 EMC Compatibility and Grounding ..........................................................................................................11

3.5 Draining air from the unit .......................................................................................................................13

3.6 Switch settings of main chiller functions (exfactory settings) ...................................................................13

4 Technical Specifications ...................................................................................................................................... 15

4.1 Data sheet ............................................................................................................................................15

5 Transport ............................................................................................................................................................. 16

6 Installing the industrial cooler .............................................................................................................................. 17

7 Notes on the cooling medium connections ........................................................................................................... 21

8 Power supply ....................................................................................................................................................... 24

9 Operating instructions .......................................................................................................................................... 25

9.1 Switching ON the Industrial Cooler .........................................................................................................25

9.2 High/low pressure control ......................................................................................................................25

9.3 Electronic controls .................................................................................................................................26

9.4 Regulating refrigerating capacity ............................................................................................................26

9.5 Condenser pressure regulation ..............................................................................................................26

9.6 Safety functions to protect components of cooling water circuit ..............................................................26

9.7 Collective alarm .....................................................................................................................................26

9.8 Flow switch ............................................................................................................................................26

9.9 Dirt trap .................................................................................................................................................26

10 Preventiv Maintenance ........................................................................................................................................ 27

11 TROUBLE SHOOTING ............................................................................................................................................ 29

12 Description of the individual parts ....................................................................................................................... 31

12.1 Compressor ...........................................................................................................................................31

12.2 Condenser .............................................................................................................................................59

12.2.1 Built-in Condenser....................................................................................................................................... 60

12.3 Fans ......................................................................................................................................................61

12.4 Evaporator .............................................................................................................................................67

12.5 Electronic temperature controller ...........................................................................................................67

12.6 Frequency Inverter .................................................................................................................................73

12.7 Pressure limiter .....................................................................................................................................78

12.7.1 Low pressure switch.................................................................................................................................... 78

12.7.2 High pressure switch ................................................................................................................................... 78

12.8 Pressure Transmitter .............................................................................................................................81

12.9 Sight glass .............................................................................................................................................85

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12.10 Filter drier ..............................................................................................................................................86

12.11 Thermo-Expansion valve ........................................................................................................................87

12.12 Drier + Core ...........................................................................................................................................88

12.13 Liquid receiver .......................................................................................................................................89

12.14 Water pump ..........................................................................................................................................90

12.15 Flow switch (Type KPC 108-L-U/S) ........................................................................................................101

12.16 Water heater (Type KPC 108-L-U/S) .....................................................................................................106

12.17 Air vent ................................................................................................................................................108

12.18 Membrane safety valve ........................................................................................................................109

12.19 Expansion vessel .................................................................................................................................110

12.20 Flow control valve ................................................................................................................................111

12.21 Dirt trap ...............................................................................................................................................112

12.22 Manometers ........................................................................................................................................112

13 Switch gear ........................................................................................................................................................ 113

13.1 Remote control panel ..........................................................................................................................113

13.1.1 Collective alarm ........................................................................................................................................ 113

14 Safety notes ....................................................................................................................................................... 113

14.1 Notes for refrigerant ..............................................................................................................................113

14.1 Instructions regarding machine oil .......................................................................................................114

15 Wiring diagram ................................................................................................................................................... 115

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Type KPC 108-L-U/S

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1 General Remarks

Industrial coolers Type KPC 108-L-U/S,

Manufacturer: ait-deutschland GmbH

Industriestraße 3
95359 Kasendorf

Germany

T [phone]
F [phone]
E [e-mail]
W www.kkt-chillers.com

After-sales: ait-deutschland GmbH

Industriestraße 3
95359 Kasendorf

Germany

T [phone]
F [phone]
E [e-mail]

W www.kkt-chillers.com

Refrigerant R134a

Total filling weight 7,0 kg outdoor model

Permitted working pressure: 19 bar

Cooling medium 62/38 % water/glycol mixture outdoor model

CAUTION! Ethylene glycol must be added at the rate of 38 % of the cooling medium volume anytime –

otherwise warranty void!

Do not use automotive antifreeze.

Never install automatic water refill system.

After the connect the refrigerant circuit –check the valve of the low pressure manometer.

IN CASES OF EMERGENCY TURN OFF THE AGGREGATE BY THE MASTER SWITCH !

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1.1 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 at least twice a year by properly trained personnel.
 Only genuine KKT spare parts must be used.
 For KPC108-L-U/S: Ethylene glycol must be added to the rate of 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.

1.2 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.

-Nominal static filling pressure when Chiller has been switched off: 1,5bar. The pressure of the expansion tank is
without counter pressure from the “water / glycol – side” = 1,0 bar.

-Don`t handle valves while the Chiller is running

-Ethylene glycol must be added at the rate of 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 medical device has been switched off.

-Parts in the refrigerant circuit are hot, even the Chiller has been switched off.

Warranty void if manual removed from chiller.

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!

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.

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Cooling block Type KPC 108 - L - U/S 60 Hz

air-cooled design for outdoor use

2 General Description

The industrial coolers of the KPC series are fully assembled, factory inspected and tested, and suitable for fully­automatic operation.

The industrial cooler of the KPC series consists of the refrigerant circuit, the cooling medium circulation, the transfer
station, the switch box and the remote control panel.

The refrigerant circuit includes compressor, primary side of the heat exchanger, air cooled condenser, necessary
equipment for liquid and gaseous refrigerant, safety and control device.

The cooling medium circulation includes secondary side of the heat exchanger with automatic air vent, medium heating
(electrical), circulation pump, expansion receiver, pressure relief valve, necessary equipment for cooling medium,
safety and control device.

The transfer station includes supply and return connections with shut-off valves, necessary equipment for cooling
medium, filling and draining cocks.

The refrigerant circuit and the cooling medium circulation are designed as a cooling block with built in switch box

The control elements are integrated in the front of the switch box. The remote control panel includes control switch,
lamp “run” as a status massage and lamp “fault” as a general fault massage.

The temperature set on the controller is kept automatically.
The cooling medium is constantly circulated by the pump.

The process heat is being transmitted from the cooling medium to the heat exchanger (evaporator of the refrigerant
circuit) and used for refrigerant evaporating (cooling). The compressor raises the gaseous refrigerant to a higher
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 cooling medium supply temperature can be changed from +7 °C to +12 °C by the temperature controller in front
of switch box.

Attention! Changes in the settings should only be made by qualified operatives.

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 are powder-coated on the inside and outside. All outer fastening screws rust­proof, inspection-caps at the front easily removable for maintenance using casement-fastener caps.

Compressor, refrigerant and cooling medium mountings, additionally sound and rain-proofed using a galvanized cover­plate.

Condenser axial-fans, pressure switch controlled condenser pressure dependent. Ventilators equipped with protective­grating on the delivery side of the pump.

Laterally mounted condenser heat exchanger made of copper-aluminum with covering galvanized framework,
enameled fully in black.

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Compressor-unit, consisting of:

Stable base-frame construction made of steel-profiles, powder-coated. Vibration-absorbing-mounted fully hermetic
SCROLL compressor with motor and suction-gas cooling. Complete special shut-off valves placed at the pressure and
suction side. Refrigerant power-inputs of flexible design. Refrigerant circuit with collector, filter-dryer, inspection glass
and moisture indicator, solenoid valve, service-valves as well as the complete internal copper-pipe work with refrigerant
and special oil filling.

Thermostatic expansion-valve and plumb high-capacity copper-brazed plate heat exchanger – evaporator. The plates
with optimized profile for efficiency heat transfer.

Evaporator and suction-side pipe work with diffusion-seal insulation.

Safety pack, consisting of:

Crankcase heater, high / low pressure switches as well as protective motor relay.

Shut-off ball valve at the cooling medium entry, dirt absorber, expansion tank, feeder and safety valves. High-pressure
centrifugal-pump adjusted to the overall system, filling and drainage valves with piping terminal, automatic air vent,
manometers and machine-thermometers in forward and return flow. Quantity balancing-valve, connection piece for
computer terminal in cooling medium supply.

Temperature control as hot gas by-pass control with solenoid valve.

Electronic digital temperature controller with control range limitation for set point and actually temperature.

Condenser fan control via pressure transmitter in refrigerant circuit and frequency inverter.

The high pressure pressostat (pressure switch) for system safety.

Internal cooling medium copper-brazed piping with diffusion-seal insulation.

All necessary block and clip angles used for refrigerant und cooling medium construction are made of rust-proof and
powder-coated material.

Switch-box with front door 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". It is still possible to connect a remote board.

The switch box of the outdoor version contains a switch box heater and a switch box ventilator.

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Overview of outdoor industrial cooler KPC Series

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KPC 108-L-U/S

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2.1 Drawings

2.1.1 KPC 108-L-U/S Outdoor Model

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3 Brief operating instructions

3.1 Installing, maintenance and repair

Only qualified operatives with the requisite knowledge, equipment and facilities should maintenance and repair the
industrial cooler.
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.
OBSERVE THE SAFETY RULES
Before work on the industrial cooler, switch the plant to voltage-free and make sure against unauthorized switching
ON.

3.2 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
Switch Gear.
The industrial coolers of the KPC series are generally designed for a main supply of 480V 3Ph 60 Hz.
The connection L1, L2, L3, PE is performed via the terminal block in the switch box.
The cooling block is switched on via the master switch .

3.3 Filling the unit with cooling medium

The cooling circulation will be filled with cooling medium (mixture of 62 % clean water – drinking water quality – and
38 % glycol).
Open front panel and fill to a pressure of 1,5 bar via the feed cock.
After filling, check all connections for leakage.

3.4 EMC Compatibility and Grounding

This comments are compiled to help the field electrician to install the grounding of the power supply and to get a EMC
Compatibility.
All electrical equipment produces radio and line-borne interference at various frequencies. The cables pass this on to
the environment like an aerial.
The basic countermeasures are isolation of the wiring of control and power components, proper grounding and
shielding of cables.

A large contact area is necessary for low-impedance grounding of HF interference. The use of grounding straps
instead of cables is therefore definitely advisable.

Moreover, cable shields must be
connected with purpose-made ground
clips.

The grounding surface must be highly
conductive bare metal. Remove any
coats of varnish and paint.

The width of the grounding wire must be min. 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.

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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.

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remote control panel

main switch

control switch

"0"

"1"

"0"

"1"

"0"

"Auto"

"Hand"

standard

operation: pump

runs, compressor

and condenser fan

are running on

demand (water

temp. higher than

8°C), water heater

works on demand

(water temp. below

4°C),

overheating

protection: pump

switches of if water

temp. Is longer

than 30 minutes

higher than 30°C)

X X X

X

(or no
remote
control

connected

with chiller)

X

X

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 KCC215-L-U/S)

3.5 Draining air from the unit

The KPC 108 includes a cooling medium circulation.
In case air gets out of the system the cooling medium pressure drops down. If that happens you have to check the
cooling medium pressure and if its to low you have to refill the cooling medium circulation as shown in 3.3
The procedure should be repeated until no more air is in the cooling medium circulation.
After all these steps, turn both switches to position "1". If all the prerequisites for operation have been met, the
industrial cooler will start after 1 minute.
In case of malfunction: search for faults taken note of TROUBLE SHOOTING in this manual.

3.6 Switch settings of main chiller functions (exfactory settings)

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stand by mode:

refrigerant circuit is

"switched off",

pump and heater

are running on

demand (water

temp. below 4°C),

X

(or no
remote
control

connected

with chiller)

X X

X X X

X

X

switched off:

no function (switch

cabinet is not

under voltage)

position without effect

X position without effect

remark: with the position "Auto" on the control switch is the remote control panel active.

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4 Technical Specifications

4.1 Data sheet

Outdoor

Dimensions Depth 962 mm
Breadth 1,410 mm
Height 1,620 mm

Weight without refrigerant load 540 kg
Weight with refrigerant load 7.0 kg

Number of fans 2
Quantity of air 18,000

Refrigerant R134a
Required quantity of refrigerant 7 kg
Low-pressure switch see testreport
High-pressure switch 19 bar

Water connection inlet 1 1/4“ inside
Water connection outlet 1 1/4“ inside

Cold water temperature outlet min. 7 °C +/-0,5 K
Cold water temperature outlet max. 12 °C

Primary water pump type CR3-6
Rated water capacity max. 4.1 m³/h
Rated water pressure 3.0 bar

Ambient temperature min. -20 °C
max. +48 °C

Cooling capacity 15,0 kW
Rated cold water outlet temperature 11 °C
temperature of surroundings 40 °C
Exactitude of temperature ±0.5 K
Main supply 480 V/3Ph/60 Hz
Control voltage 24 V
Fluctuations in main voltage max. ±5 %
Fluctuations in output max. ±5 %
Power input max. 9 kW

Noise level at 5m 65 db(A) -

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5 Transport

Transport on company premises may be done with a forklift truck. The appliance must however be kept in an upright
position and on no account tipped to the side. A visual inspection should be made on delivery to check for any damage.
Complaints should be made immediately to the haulage contractor and the insurance company must be notified at
once.

When transporting by crane,

please ensure that the housing is not subjected to pressure at the sides.

Place the lifting tubes in the holes in the feet at the base of the chiller. Lock the ends of the tubes in position with
locking pins and split pins as shown.

The capacity of the lifting gear must be adequate to lift the load in question. Check the weight of the unit, the capacity
of the lifting gear and ropes and there condition.

Check the suitability of the aforementioned equipment.

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6 Installing the industrial cooler

The plant should be mounted in an upright position on a stable foundation.

(Weight with load: see technical specifications).

A distance of approx. 1 m should be kept free on all sides to allow sufficient access for operation and maintenance.

A space of 1,5 m must be left above the apparatus to ensure that air exhaust can leave freely by the outdoor model.

Further details can be found in the following installation plans.

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Type KPC 108-L-U/S Outdoor Unit
A distance of approx. 1 m should be kept free on all sides to allow sufficient access for operation and maintenance.
Picture is only to explain and not guilty for measurement.

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7 Notes on the cooling medium connections

The cooling medium connections between industrial cooler of the KPC series and the transfer station can be made of
steel, copper or plastic. The nominal widths of the piping for distances of up to approx. 45 m should match at least the
dimensions of the fittings on the appliance (see technical specifications).

The proper way to seal the European fittings can be done with any of following steps.
Pipe sealing cord. There are a number of brands available, however we use Loctite 55
Teflon Tape and a Anaerobic sealant.
Teflon Tape an Nylog sealant.
As with any sealant, the application instruction must be followed for proper use.

Reductions in diameter should be avoided. In case of longer pipelines, the pump pressure should be tested. When
choosing the pipe materials, ensure that no electrochemical series are created.

Transfer station

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 1.) regulation phase

2.) in operation 

 3. ) emergency cooling

Closed:

Open:

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8 Power supply

The power supply is wired to the terminal block in the junction box of the transformer (see technical specifications).

The layout of the main cable must comply with the current values and the regulations of the local electricity company.

The Type KPC 108 L-U/S (Outdoor-Version) must be run with fuses of no less than 35 A in size ( see nameplate).

The supply voltage must be 480V / 3ph / 60 Hz.

The master and control switches must be in the "OFF" position when the plant is connected.

The supply line is attached to the terminal PE, L1 L2, L3,

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9 Operating instructions

9.1 Switching ON the Industrial Cooler

The cooling medium circulation must be completely filled and all air must be removed.

Turn the “main switch” switch “ON” - to the position “1”
(For additional information about the switch settings please see chapter 3.8 “Swithch settings of main chiller functions
(exfactory settings).

Turn the control switch “ON” this means to “Automatik” if the remote control panel is installed otherwise to position
“HAND”.

The cold water pump starts.

The flow switch protection cuts off the compressor during start-up, if the water circuit has not enough water pressure.

The pressure on the pump supply side rises directly with the system pressure. If not: – the plant has either a leak or
insufficient cooling medium.

A flow switch acts to prevent freezing of the evaporator if and when water volumes drop.

The compressor switches on when the water becomes to warm.

The refrigeration compressor keeps running as long as cooling is required and the reference value for the water
temperature has not been reached. The fine adjustment is performed by hot gas by-pass solenoid valve.

The cooling medium pump remains in constant operation.

The compressor is switched off during circulation in cases of low or high pressure in the refrigerant circuit (fault
massage), or when the cooling is not required (normal).

When switched off in the normal way, the overload protection provides the compressor restart switching lag.

9.2 High/low pressure control

The high-pressure pressostat reacts by shutting off the compressor, when the refrigerant pressure after compressor is
higher then 19 bar.

Cause of this include - failure of condenser fans,

- high outdoor temperatures,

- a dirty condenser heat exchanger.

The compressor can only be put back in operation when the pressure has dropped and the reset switch on the high
pressure pressostat is activated.

An automatic start has not been provided for you have to do a reset on the high – pressure pressostat.

The low-pressure pressostat reacts by shutting off the compressor, when the refrigerant pressure before compressor
sinks to the magnitude mentioned in test report (Settings, Low-pressure-switch, different).

When the pressure rises to high enough, the compressor will switch on again automatically.

The start-up switching lag amount to the adjusted value in the testreport.

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9.3 Electronic controls

The control system consists of a 2-step controller. The reference value is set value see testreport for the outlet
temperature. The sensor for the controller is installed on the outlet side.

9.4 Regulating refrigerating capacity

The exact regulation of the leaving temperature is achieved by means of 2-step controllers and hot gas by-pass
injectors with solenoid valves. The setting is based on approx. 50% of each machine’s refrigerating capacity.

9.5 Condenser pressure regulation

the condenser-pressure is regulated with help of the Frequency Inverter.
– see caption “Frequency Inverter”

9.6 Safety functions to protect components of cooling water circuit

When the refrigerant cycle is failure the water pump heats up the cooling medium.

To prevent the components in the cooling circuit, there is a safety function which switches off the pump if the water
temperature is longer than 30 minutes over 30 °C.

When this function has worked, the lamp (7H3 – in switch gear) on the switch box lights and the water pump has
stopped.

The lamp is labelled “reset overheating water”.

When the problem in the refrigerant circuit is solved, you have to pull down the button “reset overheating water”. This
is the requirement that the pump can run again.

9.7 Collective alarm

The red warning lamp in the door of the switch box lights up when one of the safety sensors has been triggered. The
cause of the error can be identified more exactly by means of the LEDs in the switch box. For the purpose of external
evaluation of the error signal, the collective alarm message can be accessed, potential-free, from the terminal. (See
also circuit diagram)

9.8 Flow switch

Monitors the water flow volume through the evaporator and shuts the device down completely if the min. water
quantity is reached.

9.9 Dirt trap

The dirt trap is fully installed (see Shema in the appendix) and protects the evaporator from dirt.
As a matter of principle the plant is to be operated with clean water. With that regular servicing of the filter is
unnecessary.

Caution! Work on electric and refrigerant circuits should only be performed by qualified operatives.

Observe the safety rules!

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10 Preventiv Maintenance

Caution! Work on electric and refrigerant circuits should only be performed by qualified operatives.

Observe the safety rules!

Service and maintenance should always be carried out by skilled technician and, where possible, under a maintenance
contract. Nevertheless, certain routine work can be effectively carried out by non-specialists and may become
important factor in preventing future damage to the plant.

Weekly Check

1. Check the working of the compressor:
Look out for too high head temperatures or suspicious noises.

2. Check the R134a through the sight-glass

3. Check that fans are rotating normally and not making unusual noises

4. Check that the temperatures is within the accepted limit.
If it is not, check that all the separate elements of the unit are working, by switching them on individually.
If they are not, see the “ Trouble shooting”

Two –monthly Check

a. The air conditioner unit:

1. Check the air filter and replace it if necessary

2. Check the air circulation fans and check that the bearings are not heating up

3. Check that the heating elements work, by switching them to “MAN”

4. Switch cooling system to “MAN” and check that it is in full working order

5. Check the compressor temperature.

6. Check there is no ice accumulations on the evaporator.

7. Check that the warning lights on the display panel are working properly.

8. Check the main voltage between all the phases

9. Check the principal and secondary circuits thoroughly, inspect the overload cut-outs and thermal

relays.

10. Pull out the fuses to check that the safety system works.

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b. The condenser

1. Air cooled units:

Make sure that the fan motor and the condensing coil are working efficiently, if necessary clean the
coil.

c. Electric heater

1. Check the heater coil

2. Check the overheating protection switch in the head of the heater

3. Check the fuses

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KIND OF TROUBLE

CAUSE

ELIMINATION

 malfunction of

plant/system

1. power failure

2. feeler of temperatur controller

defective

3. feeler malfunction

- check mains connection

- check feeler:

clamp feeler and measure the resistance

- check thermostat:
bridge controller  the thermostat relay
should shut and the compressor should
start

- check feeler:

clamp feeler and measure the resistance

- replace feeler ( sensor ) is defect.

 malfunction of pump

1. main switch not switched on

2. control switch on 'OFF'

3. main fuse defective

4. fuse for control current defective

5. pump motor defective

6. flow controller responded

7. shortage of water

8. lamp “overheating water reset” lights

- switch on main switch

- switch control switch to 'AUTO'

- replace fuse

- replace fuse

- replace motor

- check water quantity

- check system pressure, clean strainer

- check the refrigerant circuit – see capture

“Water pump”

 still malfunction of

pump

1. overload trip of pump protection

interrupted control circuit

- main switch to '0', push in overload trip

 pump makes

gurgling noise

1. circuit is not completely vented

- vent and fill up with water

 compressor stops

1. Klixon tripped

2. Klixon defective

- wait until compressor cooled down;

perhaps clean condenser or provide fresh
air supply

- replace Klixon

 malfunction of

refrigerating machine

1. control thermostat stopped machine,

return temperature too cold

- to check function, level down adjustments,

wait until return temperature rised

11 TROUBLE SHOOTING

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KIND OF TROUBLE

CAUSE

ELIMINATION

 still malfunction of

refrigerating machine

1. low pressure in refrigerant circuit

- plant looses refrigerant

- dryer in liquid pipe dirty

- pressure relief valve defective

- solenoid valve in liquid pipe defective

2. high pressure in refrigerant circuit

- condenser dirty

- fan defective

- outside temperature too high

- condenser control pressostate

defective

- find leak, seal, refill circuit

- replace dryer

- replace pressure relief valve

- replace solenoid valve

- clean condenser

- put right electric cause;

check fuses

- spray condenser with water

- replace pressostate

 refrigerating machine

starts and stops
short-termed

1. not enough fresh air supply for

condenser;
high pressure pressostate tries to
protect refrigerating machine against
overload

2. not enough pressure of refrigerant

circuit;
refrigerant partly escaped; diminished
pressure switch shut down compressor

- provide enough fresh air supply and fresh

air removal;
get rid of short-circuit across fresh air and
exhaust air

- find leak, seal, refill circuit

 not enough

refrigeration power

1. air in water circuit

2. fallen below minimum water agitation

quantity

3. not enough fresh air supply for

condenser

4. not enough refrigerant in circuit

- vent system

- design cross-section of water pipe right;

perhaps open check valve in water circuit
completely, increase pipe cross-section

- provide enough fresh air supply and fresh

air removal;
get rid of short-circuit across fresh air and
exhaust air

- find leak, seal, refill circuit

 electrical heater in

water circuit does
not work

1. the electrical heating box becomes

more than 266°F (130°C)
=> the safety temperature limiter
breaks the contact

2. control the pressure from the water

circuit

3. control the Parameter of the

temperature controller witch switches
the heater.

- the reset (is under the cover of the heater)

must be reset manually

- if necessary: prepare the cause of water

lack and fill the water circuit

- if necessary: set the right Parameter in the

temperature controller (which switches the
electrical heater)

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