2 General description ...................................................................................................................................................... 6
3.1 Installing, maintenance and repair ......................................................................................................................... 11
3.2 Linking to power supply ......................................................................................................................................... 11
3.3 EMC Compatibility and Grounding .......................................................................................................................... 11
3.3 Filling the unit with water-ethylene glycol-mixture ................................................................................................... 12
3.4 Draining air from the unit ...................................................................................................................................... 12
3.5 Setting the clock in the SPS (Siemens S73) ........................................................................................................... 14
3.6 Connecting the Data Cable .................................................................................................................................... 17
4.1 Data sheet ............................................................................................................................................................ 18
4.2 Dimensional drawing Type KSC 215-L- U/S ............................................................................................................ 19
5 4. 3 Water chiller control scheme ............................................................................................................................... 19
5 Transport ................................................................................................................................................................... 21
6 Installing the chiller .................................................................................................................................................... 22
7 Notes on the water connections .................................................................................................................................. 24
8 Power supply .............................................................................................................................................................. 25
9.2 Explanations about the automatic restart of the Chiller KSC215-L-… ....................................................................... 32
9.2.1 Main switch: On => Off => On ...................................................................................................................... 32
9.2.2 Mains supply: ok => power failure => power returns ..................................................................................... 32
10 Preventive Maintenance: Weekly Check, Two times a year Check ................................................................................. 33
ELECTRIC CONTROL PANEL MSR ....................................................................................................................................... 34
11 Description of the individual parts ............................................................................................................................... 35
11.5 Frequency Inverter ................................................................................................................................................ 66
11.11 Primary water pump .............................................................................................................................................. 91
11.11.1 Motor of pump .......................................................................................................................................... 110
11.12 Air vent ............................................................................................................................................................... 123
After sales dept.
Industriestraße 3
95359 Kasendorf
Germany
T +49 9228 9977 7190
F +49 9228 9977 7474
Refrigerant R134a
Total filling weight outdoor model 2 x 12,0 kg
Permitted working pressure: 19 bar
page 4von138
1.2 Maintenance
The cooling block must be serviced at least twice a year by a Chiller company.
1.3 Warranty
The unit is supplied finished, tested and ready to work. The unit warranty will be void if any modification to the
unit is carried out without written agreement of KKT.
For warranty purposes, the following conditions must be satisfied:
•The initial start of the unit must be carried out by trained personnel from an Authorized KKT Service
Partner.
• Maintenance must be carried out by properly trained personnel.
• Only genuine KKT spare parts must be used.
• For KSC215-L-U/S: Ethylene glycol must be added to the rate of min. 35vol% to max. 38vol%.
• The manual (this document) must not remove from the chiller.
• All the scheduled maintenance operations detailed in this manual must be performed at the specified
times. Please use a higher amount of services if the local conditions require it.
•
The “Warranty Registration” has to be send return to KKT chillers.
Failure to satisfy any of these conditions will automatically void the
warranty.
The chiller KSC215-L-U/S are fully assembled, factory inspected and tested, and suitable for fully-automated
operation. The water ethylene glycol mixture that undergoes cooling is constantly circulated by the pump in a
closed system which is monitored by an flow switch and an expansion tank. The temperature is controlled by
an Siemens SPS. The settings on the governor is kept automatically within the limits that are possible for the
given degree of temperature exactitude.
The process heat is transmitted from the water in the in-built heat exchanger (evaporator) to the refrigerant
circuit (R 134a). The compressor raises the refrigerant to a higher temperature and pressure so that the
warmth can be released via the condenser to the surrounding air. Consequently good air supply and escape
are vital for the proper running of the plant. The condenser-pressure is controlled by a Frequency inverter for
the condenser fan speed.
The chiller KSC215-L-U/S are fitted with low-pressure sensor as protection against freezing and excess
temperature. With this, it is possible to set leaving water temperatures from +19°C to +22°C.
Ethylene glycol must be added at the rate of min. 35vol.% to max. 38vol.% and it depends not on the
ambient temperature!
Do not use automotive ethylene glycol!!!
Changes in the settings should only be made by qualified operatives
Cooling block Type KSC 215-L- U/S
Air-cooled design for outdoor use, consisting mainly of:
The housing with stable welded, galvanized framework-construction , lateral cover-plates with drawer-edges
made of galvanized steel plate with ventilating nozzles worked into the top plate.
Framework-construction and top-plates, powder-coated on the inside and outside, RAL 1013 -pearl white. All
outer fastening screws rust-proof, inspection-caps at the front easily removable for maintenance using
casement-fastener caps.
Compressors, cooling and cold-water/ethylene-glycol mountings, additionally sound and rain-proofed using a
galvanized cover-plate.
Condenser axial-fans controlled by frequency inverter depends of the condenser pressure. Ventilators equipped
with protective-grating on the delivery side
Laterally mounted capacitor heat-exchanger made of Cu-AL with covering galvanized framework, enameled fully
in black.
Stable base-frame construction made of steel-profiles, powder-coated. SCROLL-motor compressor, of fully
hermetic construction with suction-gas cooled design complete with special shut-off valves placed at the
pressure and suction side. Vibration-absorbing-mounted compressors. Cooling circulation with coolantcollectors, coolant shut-off mounting, filter-dryer, inspection glass and moisture indicator, fluid solenoid-valve,
service-valves as well as the complete internal cooling pipe work made of Cu-pipe with coolant and special oil
filling.
High-capacity plate-vaporizer of plumbed design. Heat-exchanger plates with optimized profile for safety
coolant and built in expansion-valve.
Vaporizer and suction-side pipe work, diffusion-seal insulated.
Safety pack for the cooling circuit, consisting of:
Crankcase heater, high pressure pressostat as well as protective motor relay.
Shut-off ball valve at the cold water / ethylene-glycol entry, dirt absorber, expansion tank, feeder and safety
valve. High-pressure centrifugal-pump adjusted to the overall system, filling and drainage valve with automatic,
ventilation, manometer in forward and reverse flow. Quantity balancing-valve, overflow valve with connection
piece for computer terminal in cold water / AFN exit.
Temperature control as hot gas by-pass control with one regulating solenoid valves for each circuit.
The supply temperature of the water circuit is controlled by a Siemens SPS.
Additionally there is an connections to the MR for signals “run” and several faults
Condenser pressure control via pressure transmitter in the cooling circuit and frequency inverter, overload relay
for system safety.
Internal cold water / ethylene-glycol (AFN) piping made of Cu-pipe, brazed, with diffusion sealer, surrounded by
armaflex insulation.
All necessary block and clip angles used for cooling and cold water / ethylene-glycol(AFN) construction are
made of rust-proof and powder-coated material.
Switch-cabinet integrated in cooling block, system of protection IP 54, wired according to VDE-regulations with
a main switch, supply-check indicator lamp, phase monitoring relay and Siemens components such as,
overload release, sliding-panel, motor safety-switch, control-switch and indicator lamps.
A pump post-relay for the safety of the vaporizer as well as pot. proof contacts for "supply-control" and
"collective fault messages".
The switch cabinet of the outdoor version contains a switch cabinet heater and a mechanical switch cabinet
ventilator.
All parts described above are assembled into a ready-to-connect unit.
2.1 Functional description
The cold water pump starts as soon as the master switch 5Q1 have been turned from “OFF” to “ON”.
The pump main switch should only to be turned to “On” when the aqueous medium circuit has been completely
filled and all air has been removed.
The flow switch protecting of the refrigerating compressors is cut off during start-up.
The pressure on the delivery side of the pump rises directly with the system pressure.
Should this fail to be in case the plant has either a leak or insufficient water. A flow switch acts to prevent
freezing of the evaporator when water volumes drop. The refrigerating machines switch on as soon as the
safety sequence, flow switch and control motor-protection pump is in order.
A lag in connection time has been allowed for in the refrigeration compressors to avoid surges in the current.
The refrigeration compressors keep running as long as cold is required and the reference value for the water
temperature has not been reached.
The water pump remains in constant operation.
Apart from which, the refrigerating machines are only ever switched off during circulation in cases of low or
high pressure in the refrigeration cycle.
When switched off in the normal way, a restart delay provides overload protection to the compressor.
The refrigerant circuits which starts first is changed after 24hours when the difference between the water
return and supply is smaller than 0,7K for a dedicated time .
2.1.1 High-/Low- pressure control
The
high-pressure sensor
In series the second compressor will run.
If the sensory high pressure control is not in function a high pressure pressostat is installed.
The
high-pressure pressostat
by shutting off the compressor.
Causes of this include
- failure of condenser fans,
- high outdoor temperatures,
- a dirty condenser.
The compressor can only be put back in operation when the reset switch is activated on the HP-pressure
control and the pressure has dropped.
An automatic start has not been provided for.
The
low-pressure sensor
by-passed during start-up for 30 s.
Causes of this include
- defective Expansion valve,
- low outdoor temperatures,
- low level of refrigerant.
If the pressure rises to 1,0 bar, the compressor will switch on again automatically.
shut off the compressor via SPS if the pressure rises up to 18,9bar.
reacts to excess pressure of the magnitude of 19,2 bar
also switches off the compressor when the pressure sinks to 0,5 bar. The sensor is
The control system consists of a Siemens SPS. The reference value is set at the works at 20°C for the outlet
temperature. The sensor for the SPS is installed on the outlet side.
Regulating refrigerating capacity
The exact regulation of the leaving temperature is achieved by means of controller and hot gas by-pass
solenoid valve. The setting is based on steady capacity regulating.
Condenser pressure regulation
the condenser-pressure is regulated with help of the Frequency Inverter.
– see captions 4.5 “Frequency Inverter Settings” and 11.5 “Frequency Inverter”
See also chapter 5 – 10 in this operating instruction
3.1 Installing, maintenance and repair
Only qualified operatives with the requisite knowledge, equipment and facilities should maintenance and
repair the KKT chiller.
If its necessary to change the filling weight of the refrigerant circuit, please note:
Fill only with the refrigerants listed on the manufacturer name plate, and only up to the indicated filling
weight.
See also the enclosed Installing instruction
page 11von138
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 wiring diagram page 2.
The industrial coolers of the KSC 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 X1 (power supply) in the switch cabinet.
The cooling block is switched on via the main switch 5Q1.
3.3 EMC Compatibility and Grounding
This comments are compiled to help the field electrician to install the grounding of the power supply and to
get a EMC Compatibility.
All electrical equipment produces radio and line-borne interference at various frequencies. The cables pass
this on to the environment like an aerial.
The basic countermeasures are isolation of the wiring of control and power components, proper grounding
and shielding of cables.
A large contact area is necessary for low-impedance grounding of HF interference. The use of grounding
straps instead of cables is therefore definitely advisable.
Moreover, cable shields must be
connected with purpose-made ground
clips.
The grounding surface must be highly
conductive bare metal. Remove any
coats of varnish and paint.
The width of the grounding wire must be min. 16mm² (AWG 6) or of the same width of the power supply.
The grounding must be an isolated ground and must connected on the ground terminal (X1) in the switch
cabinet. The ground resistance must be less than 10 Ohm.
Metal cable conduits are not allowed for grounding.
The piping of the chiller (supply and return) have to be grounded too.
Do not share the ground wire with other devices.
Always use a ground wire that complies with technical standards on electrical equipment and minimize the
length of the ground wire.
When using more than one Inverter, be careful not to loop the ground wire.
(e.g. a CT-Chiller KPC108-L-U/S stands near an Avanto-Chiller KSC215-L-U/S)
Type KSC 215-L-U/S
page 12von138
3.3 Filling the unit with water-ethylene glycol-mixture
Water to be used (de-ionized water / destilled water / VE water / bartly de-ionized water)
This type of water has to be purchased and provided locally
Mix it with Ethylene-glycol at the rate of min. 35% to max. 38%.
Use ethylene-glycol of only one manufacturer.
(e.g.: DOWTHERM SR1-Dow Chemical, Safeflow EG-Clariant)
Do not mix two ore more different manufacturer for one water-ethylene-glycol circuit.
Open front panel and fill to a pressure of min.1,5 bar via the feed cock when the pump is off.
After filling, check all connections for leakage.
Don’t use propylene-glycol or automotive antifreeze
See also the enclosed Installing instruction
3.4 Draining air from the unit
The KSC 215 includes a closed water system.
If air get out of the system the water pressure drops down. If that happens you had to check the water
pressure and if its to low you have to refill the water circuit.
The procedure should be repeated until no more air is in the system
After all these steps, turn the main switch in position "1". If all the prerequisites for operation have been met,
the chiller will start at the latest 1 minute.
In case of malfunctions: search for faults, take note of Chapter 9, TROUBLE SHOOTING, in this manual.
7. Press “Enter” and the “left arrow” and “right arrow” to set the cursor for change the values with the “up
arrow”, “down arrow”. Close with “Enter”.
8. Than change the cursor with up arrow to the date.
With left arrow” and “right arrow” change the possition of the cursor wihtin the date and with the “up
arrow”, “down arrow” change the values. Close with “Enter”
9. Press F2 for setting.The black sign show that the time will be set in the opertion panel.
Dimensions Depth 940 mm Breadth 3040 mm Height 1850 mm
Weight without refrigerant load ca. 1070 kg
Weight with load ca. 1100 kg
Shipping weight ca. 1600 kg
Weight total refrigerant load 24,0 kg
CO2 equivalent 34,4 t CO2
Number of fans 4
Quantity of air 2x 18000 m³/h
Refrigerant R134a
GWP 1430
Required quantity of refrigerant See name plate
High-pressure switch 19,2 bar
Water connection inlet 2“ G" female
Water connection outlet 2 “ G" female
Cold water temperature outlet min. 19 °C
Cold water temperature outlet max. 22 °C
Tolerance ±0,5 K
Primary water pump type CR 10- 05
Rated water capacity min. 7,8 m³/h
Rated water pressure 7,5 bar
Ambient temperature min. -20 °C
max. +48 °C
Cooling capacity 60,0 kW
Rated cold water outlet temperature 20 °C
Temperature of surroundings 48 °C
Main supply 480 V / 3Ph / 60 Hz
Control voltage 24 VDC
Fluctuations in main voltage max. -14/+10 %
Fluctuations in Frequency max. ±1 Hz
Power input max. 29 kW
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 chiller
units,
the capacity of the lifting gear
and ropes
and the condition and
suitability of the
aforementioned equipment.
The water connections between industrial coolers of the KSC series and the IFP of Siemens can be made of
stainless steel, copper or plastic. The nominal widths of the piping for distances of up to approx. 25 m should
match at least the dimensions of the fittings on the appliance. (see technical specifications)
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.
The proper way to seal the European fittings can be done with any of following steps.
1. Pipe sealing cord. There are a number of brands available, however we use Loctite 55
2. Teflon Tape and a Anaerobic sealant.
3. Teflon Tape an Nylog sealant.
As with any sealant, the application instruction must be followed for proper use.
The power supply is wired to the terminal block in the junction box (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 KSC 215 L-… must be run with fuses of no less than 60 in size.
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, .
9.2 Explanations about the automatic restart of the Chiller KSC215-L-…
The following power failure situations are considered:
1. Main switch: On => Off => On
2. Mains supply: ok => power failure => power returns
9.2.1 Main switch: On => Off => On
When switching the main switch off and on again, the operator’s display shows the a failure message called
„phase sequence“ (blinking) and at the electrical cabinet the green and the red indicator lamps are blinking to
indicate this failure. After a start-up time of around 20 sec., the chiller will restart automatically and the life bit
is on again. The red indicator lamp blinking goes off again and the green lamp continues blinking to indicate
that
in the past in this situation a power failure / interruption occurred.
The chiller restarts automatically!!!!
In case the chiller does not restart automatically, the failure is still pending!
9.2.2 Mains supply: ok => power failure => power returns
Once power returns after a failure (phase sequence or phase failure), the screen also displays the error
message „phase sequence“ and the green indicator lamp at the electrical cabinet blinks to indicate that a
failure
had occurred
The chiller restarts automatically!!!!
Once the power supply has stabilized again, the
20 secs, the red indicator lamp goes off, the life bit is on again, the green indicator lamp saying that a failure
was pending
In case the chiller does not restart automatically, the failure is still pending or another failure exists!
To set off the failure message at the operator’s display, press the „ACK-button“ at the display unit.
The blinking green or red indicator lamp at the electrical cabinet becomes permanent (green lamp) or goes off
(red lamp), if the „black RESET-button“ at the electrical cabinet is actuated.
is still blinking and at the display the failure message „phase sequence“ remains visible.
10 Preventive Maintenance: Weekly Check, Two times a year Check
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 refrigerant charge 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 fault finding guide (9 TROUBLE SHOOTING).
Two times a year Check
KKT chillers Inspection Requirements Task List
Tasks List Task List
Control Cabinet
• Check and clean filter
• Replace filter if required
• Check for contamination, corrosion, damage
• Vacuum clean the panel
• Check and tighten cable connections
• Check all control connections
• Check cabinet gaskets, replace if leaking or
damaged
• Check operation of controls
• Check and calibrate safeties
CHILLER COMPRESSOR
•Visual inspection of chiller, look for
o Signs of water, oil, or refrigerant leaks
o Contamination, Damage, corrosion
• Check for noise or excessive vibrations of compressor
• Log Compressor operation into maintellance report
o Compressor discharge and suction pressure
o Record refrigerant temperature at
compressor, evaporator and condenser
o Chilled water outlet temperature
o Chilled water Inlet temperature
o Record Compressor current and compare to
rated current
o Check oil level
• Check operation of crankcase heater
• Check operation of all electromechanical devices and
threaded connection: R = 1” I = 29,5 mm plates and connections: W.-1.4401 (AISI 316)
soldered connection: di = 35 mm I = 29,5 mm solder: copper 99,9 %
Operation Plate Heat Exchanger (PHE)
Before each operation make sure that the plate pack is clamped to the correct compression dimension "a" and
that the plate heat exchanger is anchored to the ground.
Additionally make sure that all connection pipes are screwed tight and that the permitted values for pressure
and temperature given on the fabrication label are not exceeded.
The correct compression dimension can be found on the supplied dimension sheet or fabrication label. Prevent
pressure surges when starting up the PHE or after brief stoppages.
If an operating PHE is shut down, it should be cooled down and cleaned afterwards. The plate pack should be
loosened to "a" + 10%, starting from the current "a" dimension. This action reduces the pressure on the
gaskets
The axial flow-fans suck the surrounding air through the condenser package and blow the warm air out at the
top. The chiller Type KSC215-L-… are fitted with 4 fans Type FE050 VDD.41.6.
The fans are fitted internally with a full motor protector (Klixon).
The fans are controlled by the Frequency Inverter.
Temperature regulation is attended to by the temperature controller installed in the switch cabinet. It controls
the leaving temperature of the medium and switches the refrigeration compressors and/or the capacity
reducing valve (hot gas solenoid valves) on or off.
The PLC shows the actual readings of the initial medium temperature.
The reference value is shown by pressing the reset button.
Monitors the condensation pressure and switches the compressor off before the max. permitted pressure of
19,2 bar has been reached.
Restarting the unit is only possible once the pressure has dropped and the reset button has been activated.
The pump is assembled with an 3,0kW Motor from the manufacturer VEM.
(see technical specifications item 11.12.1).
The pump is switched on by turning the master switch to position "Auto"/”Hand” and the control switch for the
pump likewise to position "Auto"/”Hand”!.
The water is kept in constant circulation. The water pump is interlocked with the compressor, i.e. cooling is
unable to take place if the pump is not on.
It is essential that the pump is filled with the cooling medium and de-aerated before it is started.