REMKO KWE 440, KWE 370, KWE 150 INOX, KWE 250, KWE 180 INOX Assembly And Operating Instructions Manual

Assembly and operating instructions

REMKO KWE 150 - KWE 440 and

REMKO KWE 150 INOX - KWE 440 INOX

Chiller

0183-2018-05 Edition 1, en_GB

Read the instructions prior to performing any task!

Read these operating instructions carefully before commis­sioning / using this device!

These instructions are an integral part of the system and must
always be kept near or on the device.

Subject to modifications; No liability accepted for errors or mis­prints!

Installation and operating instructions (translation of the orig­inal)

Table of contents

1 Safety and usage instructions............................................................................................................. 4

1.1 General safety notes....................................................................................................................... 4

1.2 Identification of notes...................................................................................................................... 4

1.3 Personnel qualifications.................................................................................................................. 4

1.4 Dangers of failure to observe the safety notes................................................................................ 4

1.5 Safety-conscious working............................................................................................................... 4

1.6 Safety notes for the operator........................................................................................................... 5

1.7 Safety notes for installation, maintenance and inspection.............................................................. 5

1.8 Unauthorised modification and changes......................................................................................... 5

1.9 Intended use................................................................................................................................... 5

1.10 Warranty........................................................................................................................................ 5

1.11 Transport and packaging............................................................................................................... 6

1.12 Environmental protection and recycling........................................................................................ 6

2 Technical data........................................................................................................................................ 7

2.1 Unit data.......................................................................................................................................... 7

2.2 Unit dimensions............................................................................................................................. 15

2.3 Cooling capacity............................................................................................................................ 16

2.4 Sound pressure level.................................................................................................................... 19

2.5 Characteristic curves..................................................................................................................... 20

3 Design and function............................................................................................................................ 24

3.1 Unit description............................................................................................................................. 24

3.2 System layout................................................................................................................................ 24

3.3 Refrigeration unit construction...................................................................................................... 25

3.4 Hydraulic unit construction............................................................................................................ 25

4 Operation of the controller................................................................................................................. 27

5

Installation instructions for qualified personnel.............................................................................. 31

6 Installation........................................................................................................................................... 36

6.1 Unit installation.............................................................................................................................. 36

7 Condensate drainage connection and safe drainage...................................................................... 44

8 Electrical wiring................................................................................................................................... 45

8.1 General connection and safety instructions.................................................................................. 45

8.2 Unit connection............................................................................................................................. 46

8.3 Electrical components................................................................................................................... 48

9 Leak testing......................................................................................................................................... 48

10 Before commissioning....................................................................................................................... 49

11 Commissioning................................................................................................................................... 51

12 Shutdown............................................................................................................................................. 52

13 Troubleshooting and customer service............................................................................................ 53

14 Care and maintenance........................................................................................................................ 57

15 Index..................................................................................................................................................... 58

3

REMKO KWE

1 Safety and

usage instructions

1.1 General safety notes

Carefully read the operating manual before com­missioning the units for the first time. It contains
useful tips and notes such as hazard warnings to
prevent personal injury and material damage.
Failure to follow the directions in this manual not
only presents a danger to people, the environment
and the system itself, but will void any claims for

.

liability

Keep this operating manual and the refrigerant
data sheet near to the units.

1.2 Identification of notes

This section provides an overview of all important
safety aspects for proper protection of people and
safe and fault-free operation.The instructions and
safety notes contained within this manual must be
observed in order to prevent accidents, personal
injury and material damage.

Notes attached directly to the units must be
observed in their entirety and be kept in a fully
legible condition.

Safety notes in this manual are indicated by sym­bols. Safety notes are introduced with signal words
which help to highlight the magnitude of the danger
in question.

DANGER!

CAUTION!

This combination of symbol and signal word
warns of a potentially hazardous situation,
which if not avoided may cause injury or mate­rial and environmental damage.

NOTICE!

This combination of symbol and signal word
warns of a potentially hazardous situation,
which if not avoided may cause material and
environmental damage.

This symbol highlights useful tips and recom­mendations as well as information for efficient
and fault-free operation.

1.3 Personnel qualifications

Personnel responsible for commissioning, opera­tion, maintenance, inspection and installation must
be able to demonstrate that they hold a qualifica­tion which proves their ability to undertake the
work.

Contact with live parts poses an immediate
danger of death due to electric shock. Damage
to the insulation or individual components may
pose a danger of death.

DANGER!

This combination of symbol and signal word
warns of a situation in which there is immediate
danger
cause serious injury.

This combination of symbol and signal word
warns of a potentially hazardous situation,
which if not avoided may be fatal or cause
serious injury

, which if not avoided may be fatal or

WARNING!

.

1.4

Dangers of failure to observe the safety notes

Failure to observe the safety notes may pose a risk
to people, the environment and the units. Failure to
observe the safety notes may void any claims for
damages.

In particular, failure to observe the safety notes
may pose the following risks:

n The failure of important unit functions.
n The failure of prescribed methods of mainte-

nance and repair

n Danger to people on account of electrical and

mechanical effects.

.

1.5 Safety-conscious working

The safety notes contained in this manual, the
existing national regulations concerning accident
prevention as well as any internal company
working, operating and safety regulations must be
observed.

4

1.6 Safety notes for the operator

The operational safety of the units and compo­nents is only assured providing they are used as
intended and in a fully assembled state.

n The units and components may only be set up,

installed and maintained by qualified per­sonnel.

n Protective covers (grille) over moving parts

must not be removed from units that are in
operation.

n Do not operate units or components with

obvious defects or signs of damage.

n Contact with certain unit parts or components

may lead to burns or injury

n The units and components must not be

exposed to any mechanical load, extreme
levels of humidity or extreme temperature.

n Spaces in which refrigerant can leak sufficient

to load and vent. Otherwise there is danger of
suffocation.

n All housing parts and device openings, e.g. air

inlets and outlets, must be free from foreign
objects, fluids or gases.

n The units must be inspected by a service tech-

nician at least once annually. Visual inspec­tions and cleaning may be performed by the
operator when the units are disconnected from
the mains.

.

1.7 Safety notes for installation, maintenance and inspection

n Appropriate hazard prevention measures must

be taken to prevent risks to people when per­forming installation, repair
cleaning work on the units.

n The setup, connection and operation of the

units and its components must be undertaken
in accordance with the usage and operating
conditions stipulated in this manual and comply
with all applicable regional regulations.

n Local regulations and laws such as Water

Ecology Act must be observed.

n The power supply should be adapted to the

requirements of the units.

n Units may only be mounted at the points pro-

vided for this purpose at the factory. The units
may only be secured or mounted on stable
structures, walls or floors.

n Mobile units must be set up securely on suit-

able surfaces and in an upright position. Sta­tionary units must be permanently installed for
operation.

n The units and components should not be oper-

ated in areas where there is a heightened risk
of damage. Observe the minimum clearances.

, maintenance or

n The units and components must be kept at an

adequate distance from flammable, explosive,
combustible, abrasive and dirty areas or
atmospheres.

n Safety devices must not be altered or

bypassed.

Unauthorised modification

1.8
and changes

Modifications or changes to units and components
are not permitted and may cause malfunctions.
Safety devices may not be modified or bypassed.
Original replacement parts and accessories
authorised by the manufactured ensure safety
use of other parts may invalidate liability for
resulting consequences.

. The

1.9 Intended use

Depending on the model and the unit, the units are
only intended to be used as a chiller for the cooling
or warming of the operating medium water or a
water-glycol mixture within a closed medium cycle.

Any different or additional use is a non-intended
use. The manufacturer / supplier assumes no lia­bility for damages arising from non-intended use.
The user bears the sole risk in such cases.
Intended use also includes working in accordance
with the operating and installation instructions and
complying with the maintenance requirements.

The threshold values specified in the technical
data must not be exceeded.

1.10 Warranty

For warranty claims to be considered, it is essential
that the ordering party or its representative com­plete and return the "certificate of warranty" to
REMKO GmbH & Co. KG at the time when the
units are purchased and commissioned.

The warranty conditions are detailed in the "Gen­eral business and delivery conditions". Further­more, only the parties to a contract can conclude
special agreements beyond these conditions. In
this case, contact your contractual partner in the
first instance.

5

REMKO KWE

1.11 Transport and packaging

The devices are supplied in a sturdy shipping con-

. Please check the equipment immediately

tainer
upon delivery and note any damage or missing
parts on the delivery and inform the shipper and
your contractual partner. For later complaints can
not be guaranteed.

WARNING!

Plastic films and bags etc. are dangerous
toys for children!

Why:

- Leave packaging material are not around.

- Packaging material may not be accessible to
children!

1.12 Environmental protection and recycling

Disposal of packaging

All products are packed for transport in environ­mentally friendly materials. Make a valuable contri­bution to reducing waste and sustaining raw mate­rials. Only dispose of packaging at approved
collection points.

Disposal of equipment and components

Only recyclable materials are used in the manufac­ture of the devices and components. Help protect
the environment by ensuring that the devices or
components (for example batteries) are not dis­posed in household waste, but only in accordance
with local regulations and in an environmentally
safe manner
cling specialists or at collection points.

, e.g. using certified firms and recy-

6

2 Technical data

2.1 Unit data

Unit data KWE 150 - KWE 250

Series KWE 150 KWE 180 KWE 220 KWE 250

Operating mode Air-cooled compact chiller

Nominal cooling output

Energy efficiency rating EER

1)

1)

SEER 3.84 3.83 3.85 3.85

kW 15.01 17.44 21.58 24.72

3.50

Annual room cooling efficiency ŋ

S,C

Adjustment range - return temperature
cooling

% 151 150 151 151

°C +9 to +22

Operating range, cooling °C +15 to +45

Operating range cooling (extension) °C

-7 to +45 2) / -15 to +45

3)

Cooling circuits, number 1

Refrigerant

R410A

4)

GWP value 2088

Refrigerant filling quantity

5)

kg 5.6 6.2 8.1 8.7

CO2 equivalent t 11.69 12.95 16.91 18.17

Compressor, number / type 1 / Scroll

Max. airflow volume

m3/h

10,500 10,000 11,000 20,500

Number of fans 1 2

Sound pressure level

6)

dB (A) 40.4 39.8 41.1 43.3

Sound power level dB (A) 71.9 71.3 72.5 74.9

Power supply V/Ph/Hz 400/3~/50

Enclosure class IP X4

Electrical power consumption, max. kW 6.5 8.7 9.5 12.3

Electrical current consumption, max. A 11.68 15.61 17.07 22.16

Electrical rated power consumption,
cooling

Electrical rated current consumption,
cooling

kW 4.22 4.99 6.1 6.99

A 7.4 8.7 10.6 12.2

Electrical starting current, max. A 65.6 76.6 102.6 114.2

Operating medium max. 35% ethylene glycol, max. 35% propylene glycol

Operating pressure, medium, max. kPa 600

Nominal flow rate, medium - cooling

Minimum flow volume, medium

m3/h

m3/h

2.59 2.99 3.71 4.25

1.61 1.87 2.32 2.65

7

REMKO KWE

Series KWE 150 KWE 180 KWE 220 KWE 250

Maximum flow volume, medium

m3/h

4.30 4.99 6.18 7.08

Pressure loss, indoor kPa 11 10 11 11

Diaphragm expansion vessel, volume l 6

Diaphragm expansion vessel MAG, pre­liminary pressure

kPa 1.5

Medium connection, inlet Inches 1 1/4 1 1/2

Medium connection, outlet Inches 1 1/4 1 1/2

Medium content, pipe lines l 4.82 5.39 5.95 7.72

Minimum medium volume, per unit l 45 53 65 75

Height mm 1297 1550

Width mm 1590 1990

Depth mm 780 900

Weight kg 217 225 235 331

Operating weight, approx. kg 221.8 230.4 241.0 338.7

Serial number INOX 1790 1791 1792 1793

EDP no. INOX 1656151 1656181 1656221 1656251

Serial number RAL 9018 1742... 1743... 1744... 1745...

EDP no. RAL 9018 1656150 1656180 1656220 1656250

1)

Air intake temperature TK 35℃, medium inlet 12 ℃, medium outlet 7 ℃,

2)

Only with compressor crankcase heating accessory

3)

Only with winter pressure regulation accessory, set

4)

Contains greenhouse gas per Kyoto protocol

5)

The refrigerant filling quantity is subject to continuous optimisation. Therefore, the exact filling quantity can

0% glycol concentration

be found on the name plate

6)

Distance 10 m free field

8

Chiller with standard pump

Series KWE 150 KWE 180 KWE 220 KWE 250

Nominal pump pressure, max. kPa 90 87 78 74

System pressure available, cooling kPa 79 77 67 63

Power consumption, pump kW 0.2

Current consumption, pump A 1.3

Weight kg 227 235 245 343

Operating weight, approx. kg 232 240 250 350

Chiller with high-pressure pump

Series KWE 150 KWE 180 KWE 220 KWE 250

Nominal pump pressure, max. kPa 174 166 147 168

System pressure available, cooling kPa 163 156 136 157

Power consumption, pump kW 0.6 1.1

Current consumption, pump A 1.5 2.4

Weight kg 232 240 250 350

Operating weight, approx. kg 237 246 256 358

Chiller with high-performance pump

Series KWE 150 KWE 180 KWE 220 KWE 250

Nominal pump pressure, max. kPa 277 272 256 258

System pressure available, cooling kPa 266 262 245 247

Power consumption, pump kW 1.1 1.5

Current consumption, pump A 2.4 3.2

Weight kg 237 245 255 353

Operating weight, approx. kg 242 250 261 361

Chiller with storage tank and standard pump

Series KWE 150 KWE 180 KWE 220 KWE 250

Medium content, storage tank kPa 60 90

Weight kPa 247 255 265 369

Operating weight, approx. kW 311 320 331 466

9

REMKO KWE

Chiller with storage tank and high-pressure pump

Series KWE 150 KWE 180 KWE 220 KWE 250

Medium content, storage tank kPa 60 90

Weight kPa 252 260 270 376

Operating weight, approx. kW 317 326 336 474

Chiller with storage tank and high-performance pump

Series KWE 150 KWE 180 KWE 220 KWE 250

Medium content, storage tank kPa 60 90

Weight kPa 257 265 275 379

Operating weight, approx. kW 322 330 341 477

10

Unit data KWE 300 - KWE 440

Series KWE 300 KWE 320 KWE 370 KWE 440

Operating mode Air-cooled compact chiller

Nominal cooling output

1)

Energy efficiency rating EER

1)

kW 29.32 32.00 37.04 43.37

3.50

SEER 3.93 3.91 3.84 3.85

Annual room cooling efficiency ŋ

S,C

Adjustment range - return temperature
cooling

% 154 154 150 151

°C +9 to +22

Operating range, cooling °C +15 to +45

Operating range cooling (extension) °C

-7 to +45 2) / -15 to +45

3)

Cooling circuits, number 1

Refrigerant

R410A

4)

GWP value 2088

Refrigerant filling quantity

5)

kg 11.5 12.0 12.6 15.6

CO2 equivalent t 24.01 25.06 26.31 32.57

Compressor, number / type 1 / Scroll

Max. airflow volume

m3/h

20,000 21,000 22,500 22,500

Number of fans 2

Sound pressure level

6)

dB (A) 42.3 43.9 44.5 45.2

Sound power level dB (A) 73.9 75.5 76.1 76.8

Power supply V/Ph/Hz 400/3~/50

Enclosure class IP X4

Electrical power consumption, max. kW 12.7 14.6 18.1 19.9

Electrical current consumption, max. A 22.83 26.36 32.67 35.84

Electrical rated power consumption,
cooling

Electrical rated current consumption,
cooling

kW 8.1 9.02 10.53 14.22

A 14.1 15.7 18.4 21.3

Electrical starting current, max. A 142.2 121.2 143.2 177.2

Operating medium max. 35% ethylene glycol, max. 35% propylene glycol

Operating pressure, medium, max. kPa 600

Nominal flow rate, medium - cooling

Minimum flow volume, medium

Maximum flow volume, medium

m3/h

m3/h

m3/h

5.04 5.51 6.37 7.45

3.15 3.44 3.98 4.66

8.40 9.16 10.61 12.42

Pressure loss, indoor kPa 12 12 13 14

Diaphragm expansion vessel, volume l 6

11

REMKO KWE

Series KWE 300 KWE 320 KWE 370 KWE 440

Diaphragm expansion vessel MAG, pre­liminary pressure

kPa 1.5

Medium connection, inlet Inches 1 1/2

Medium connection, outlet Inches 1 1/2

Medium content, pipe lines l 8.29 8.85 9.42 10.55

Minimum medium volume, per unit l 88 96 112 131

Height mm 1550

Width mm 1990

Depth mm 900

Weight kg 365 381 391 406

Operating weight, approx. kg 373.3 389.9 400.4 416.6

Serial number INOX 1794 1795 1796 1797

EDP no. INOX 1656301 1656321 1656371 1656441

Serial number RAL 9018 1746... 1747... 1748... 1749...

EDP no. RAL 9018 1656300 1656320 1656370 1656440

1)

Air intake temperature TK 35℃, medium inlet 12 ℃, medium outlet 7 ℃,

2)

Only with compressor crankcase heating accessory

3)

Only with winter pressure regulation accessory, set

4)

Contains greenhouse gas per Kyoto protocol

5)

The refrigerant filling quantity is subject to continuous optimisation. Therefore, the exact filling quantity can

0% glycol concentration

be found on the name plate

6)

Distance 10 m free field

12

Chiller with standard pump

Series KWE 300 KWE 320 KWE 370 KWE 440

Nominal pump pressure, max. kPa 95 92 83 70

System pressure available, cooling kPa 83 80 70 56

Power consumption, pump kW 0.3

Current consumption, pump A 1.3

Weight kg 379 395 405 420

Operating weight, approx. kg 387 403 414 430

Chiller with high-pressure pump

Series KWE 300 KWE 320 KWE 370 KWE 440

Nominal pump pressure, max. kPa 155 148 132 110

System pressure available, cooling kPa 143 136 119 96

Power consumption, pump kW 1.1

Current consumption, pump A 2.4

Weight kg 384 400 410 425

Operating weight, approx. kg 392 409 419 436

Chiller with high-performance pump

Series KWE 300 KWE 320 KWE 370 KWE 440

Nominal pump pressure, max. kPa 245 237 220 196

System pressure available, cooling kPa 233 225 207 182

Power consumption, pump kW 1.5

Current consumption, pump A 3.2

Weight kg 387 403 413 428

Operating weight, approx. kg 395 412 423 439

Chiller with storage tank and standard pump

Series KWE 300 KWE 320 KWE 370 KWE 440

Medium content, storage tank kPa 90

Weight kPa 404 420 430 445

Operating weight, approx. kW 502 519 529 546

13

REMKO KWE

Chiller with storage tank and high-pressure pump

Series KWE 300 KWE 320 KWE 370 KWE 440

Medium content, storage tank kPa 90

Weight kPa 410 426 436 451

Operating weight, approx. kW 508 525 535 552

Chiller with storage tank and high-performance pump

Series KWE 300 KWE 320 KWE 370 KWE 440

Medium content, storage tank kPa 90

Weight kPa 413 429 439 454

Operating weight, approx. kW 511 528 539 555

14

2.2 Unit dimensions

Fig. 1: Dimensions KWE 150 - 220 (all measurements in mm)

Fig. 2: Dimensions KWE 250 - 440 (all measurements in mm)

15

REMKO KWE

We reserve the right to modify the dimensions and design as part of the ongoing technical development
process.

2.3

Cooling capacity

KWE 150 KWE 180

IL Air intake temperature IL Air intake temperature

°C 20 25 30 35 40 °C 20 25 30 35 40

5 16.64 15.70 14.88 13.98 13.02 5 19.39 18.42 17.39 16.31 15.20

6 17.03 16.25 15.41 14.49 13.51 6 20.04 19.03 17.98 16.87 15.72

7 17.61 16.81 15.95 15.01 14.01 7 20.70 19.66 18.58 17.44 16.26

8 18.19 17.39 16.50 15.54 14.52 8 21.37 20.31 19.19 18.03 16.82

9 18.81 17.99 17.08 16.10 15.05 9 22.07 20.98 19.83 18.63 17.39

10 19.43 18.58 17.65 16.65 15.58 10 22.76 21.64 20.46 19.23 17.96

11 20.09 19.21 18.26 17.23 16.14 11 23.49 22.34 21.12 19.86 18.56

12 20.74 19.84 18.86 17.81 16.69 12 24.22 23.03 21.78 20.49 19.16

13 21.43 20.50 19.49 18.42 17.27 13 24.98 23.75 22.47 21.15 19.78

14 22.11 21.15 20.12 19.02 17.85 14 25.73 24.47 23.16 21.80 20.40

15 22.83 21.84 20.78 19.66 18.46 15 26.52 25.22 23.88 22.49 21.05

16 23.55 22.53 21.44 20.29 19.07 16 27.30 25.97 24.60 23.17 21.70

17 24.30 23.26 22.14 20.95 19.71 17 28.12 26.75 25.34 23.88 22.38

18 25.05 23.98 22.83 21.61 20.34 18 28.93 27.53 26.08 24.59 23.05

19 25.84 24.74 23.56 22.31 21.01 19 29.78 28.34 26.86 25.33 23.76

20 26.62 25.49 24.28 23.00 21.67 20 30.62 29.15 27.63 26.06 24.46

KWE 220 KWE 250

IL Air intake temperature IL Air intake temperature

°C 20 25 30 35 40 °C 20 25 30 35 40

5 23.85 22.66 21.44 20.18 18.87 5 27.27 25.93 24.55 23.11 21.61

6 24.66 23.43 22.17 20.87 19.53 6 28.20 26.81 25.38 23.91 22.37

7 25.48 24.21 22.91 21.58 20.20 7 29.14 27.70 26.23 24.72 23.15

8 26.33 25.01 23.67 22.30 20.89 8 30.10 28.62 27.10 25.54 23.93

9 27.20 25.84 24.46 23.05 21.60 9 31.09 29.56 27.99 26.39 24.74

10 28.06 26.66 25.24 23.79 22.30 10 32.08 30.49 28.88 27.24 25.55

11 28.97 27.52 26.06 24.57 23.04 11 33.11 31.47 29.81 28.12 26.39

12 29.88 28.38 26.87 25.34 23.77 12 34.14 32.45 30.74 29.00 27.23

13 30.82 29.28 27.72 26.15 24.54 13 35.21 33.46 31.70 29.91 28.10

16

KWE 220 KWE 250

14 31.76 30.17 28.57 26.95 25.30 14 36.28 34.47 32.66 30.82 28.97

15 32.74 31.10 29.45 27.79 26.10 15 37.39 35.52 33.65 31.77 29.82

16 33.72 32.03 30.33 28.62 26.89 16 38.49 36.57 34.64 32.71 30.67

17 34.74 33.00 31.25 29.49 27.71 17 39.64 37.65 35.67 33.69 31.65

18 35.75 33.96 32.16 30.36 28.53 18 40.78 38.73 36.70 34.66 32.62

19 36.80 34.96 33.11 31.26 29.39 19 41.96 39.85 37.76 35.67 33.58

20 37.84 35.95 34.06 32.15 30.24 20 43.13 40.97 38.82 36.67 34.53

KWE 300 KWE 320

IL Air intake temperature IL Air intake temperature

°C 20 25 30 35 40 °C 20 25 30 35 40

5 32.17 30.62 29.04 27.41 25.71 5 35.58 33.73 31.85 29.91 27.89

6 33.26 31.66 30.04 28.36 26.61 6 36.79 34.87 32.93 30.94 28.88

7 34.35 32.73 31.05 29.32 27.53 7 38.03 36.05 34.05 32.00 29.88

8 35.50 33.82 32.10 30.31 28.47 8 39.30 37.26 35.19 33.08 30.91

9 36.69 34.96 33.18 31.34 29.45 9 40.63 38.51 35.33 34.21 31.98

10 37.88 36.09 34.25 32.36 30.42 10 41.95 39.76 37.56 35.33 33.04

11 39.12 37.28 35.38 33.43 31.44 11 43.34 41.07 37.67 36.50 34.16

12 40.36 38.46 36.50 34.50 32.46 12 44.72 42.38 40.03 37.67 35.27

13 41.66 39.69 37.68 35.62 33.52 13 46.17 43.75 40.13 38.90 36.44

14 42.96 40.92 38.85 36.73 34.58 14 47.62 45.12 42.63 40.13 37.60

15 44.31 42.21 40.07 37.90 35.69 15 49.14 46.55 42.69 41.41 38.82

16 45.66 43.50 41.29 39.06 36.79 16 50.65 47.98 45.34 42.69 40.03

17 47.07 44.84 42.57 40.27 37.95 17 52.23 49.48 46.76 44.03 41.30

18 48.47 46.17 43.84 41.48 39.10 18 53.81 50.97 48.17 45.37 42.57

19 49.93 47.56 45.16 42.74 40.30 19 55.45 52.54 49.65 46.77 43.90

20 51.38 48.94 46.48 44.00 41.50 20 57.09 54.10 51.12 48.17 45.22

17

REMKO KWE

KWE 370 KWE 440

IL Air intake temperature IL Air intake temperature

°C 20 25 30 35 40 °C 20 25 30 35 40

5 40.95 38.97 36.88 34.68 32.38 5 47.81 45.47 43.08 40.61 38.03

6 42.32 40.27 38.11 35.85 33.47 6 49.42 47.00 44.53 41.97 39.32

7 43.72 41.60 39.37 37.04 34.60 7 51.07 48.56 46.00 43.37 40.63

8 45.16 42.97 40.66 38.26 35.74 8 52.76 50.16 47.52 44.80 41.98

9 46.66 44.38 42.00 39.52 36.93 9 54.52 51.83 49.09 46.28 43.37

10 48.15 45.79 43.34 40.78 38.11 10 56.27 53.49 50.66 47.76 44.76

11 49.72 47.27 44.74 42.10 39.35 11 58.12 55.23 52.31 49.31 46.22

12 51.28 48.75 46.13 43.41 40.59 12 59.96 56.97 53.95 50.86 47.68

13 52.91 50.30 47.59 44.79 41.89 13 61.89 58.80 55.67 52.48 49.21

14 54.54 51.84 49.05 46.16 43.18 14 63.81 60.62 57.39 54.10 50.74

15 56.25 53.46 50.57 47.60 44.53 15 65.83 62.53 59.19 55.78 52.34

16 57.96 55.07 52.06 49.03 45.88 16 67.85 64.44 60.99 57.46 53.93

17 59.74 56.75 53.68 50.53 47.29 17 69.96 66.43 62.87 59.25 55.60

18 61.52 58.43 55.27 52.02 48.69 18 72.06 68.42 64.75 61.04 57.27

19 63.37 60.19 56.92 53.58 50.16 19 74.25 70.50 66.72 62.90 59.02

20 65.21 61.94 58.57 55.13 51.62 20 76.44 72.58 68.68 64.75 60.76

18

2.4 Sound pressure level

KWE 150 - KWE 250

KWE 150 KWE 180 KWE 220 KWE 250

Hz Sound pressure level Lp in dB(A), distance 10 m

63 11.60 11.60 11.60 14.50

125 24.60 24.60 24.60 27.50

250 24.20 23.70 24.40 27.10

500 32.50 31.40 33.60 36.50

1000 36.50 33.70 36.50 37.60

2000 33.50 33.60 34.80 37.90

4000 31.50 33.10 32.90 35.30

8000 27.90 30.30 26.00 27.90

Complete 40.4 41.10 43.30 42.30

KWE 300 - KWE 440

KWE 300 KWE 320 KWE 370 KWE 440

Hz Sound pressure level Lp in dB(A), distance 10 m

63 14.50 14.50 14.50 14.50

125 27.50 27.50 27.50 27.50

250 28.90 26.70 27.00 27.00

500 34.40 35.50 36.80 36.40

1000 36.80 38.80 39.30 39.90

2000 36.00 38.70 39.40 40.80

4000 35.20 35.70 36.50 36.90

8000 28.70 29.70 29.00 29.80

Complete 43.90 44.50 45.20 76.80

19

50
45
40
35
30
25
20
15
10
5
0

0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2

50
45
40
35
30
25
20
15
10
5
0

1,30,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2

50
45
40
35
30
25
20
15
10
5
0

0,3 0,5 0,6 0,8 0,9 1,1 1,2 1,4 1,5 1,7 1,8

50
45
40
35
30
25
20
15
10
5
0

0,4 0,6 0,7 0,9 1,0 1,2 1,3 1,5 1,6 1,8 1,9

50
45
40
35
30
25
20
15
10
5
0

0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4

50
45
40
35
30
25
20
15
10
5
0

0,5 0,7 0,9 1,1 1,3 1,5 1,7 1,9 2,1 2,3 2,5

50
45
40
35
30
25
20
15
10
5
0

0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 2,6 2,8

5

0
45
40
35
30
25
20
15
10
5
0

1,1 1,3 1,5 1,7 1,9 2,1 2,3 2,5 2,7 2,8 3,1

KWE 150 KWE 180

KWE 220 KWE 250

KWE 300 KWE 320

KWE 370 KWE 440

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

REMKO KWE

2.5 Characteristic curves

Pressure loss

1: Pressure loss [kPa]
2: Medium flow rate [l/sec]

20

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

1,21,11,00,90,80,70,60,50,40,30,2

140
120
100

80
60
40
20

0

1,31,21,11,00,90,80,70,60,50,40,3

140

120

100

80
60
40
20

0

1,51,41,31,21,11,00,90,80,70,60,5

140
120
100

80
60
40
20

0

1,71,61,51,41,31,21,11,00,90,80,7

140

120

100

80
60
40
20

0

2,22,11,91,81,61,51,31,21,00,90,7

140
120
100

80
60
40
20

0

2,22,01,91,71,61,41,31,11,00,8

140

120

100

80
60
40
20

0

2,42,22,01,81,61,41,21,0

140
120
100

80
60

40
20

0

2,82,72,52,42,22,11,91,81,61,51,3

140

120

100

80
60
40
20

0

2,3

KWE 180KWE 150

KWE 220 KWE 250

KWE 300

KWE 320

KWE 370 KWE 440

System pressure available - standard pump

1: System pressure available [kPa]
2: Medium flow rate [l/sec]

21

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

200

160

120

80

40

0

0,1 0,2 0,4 0,5 0,6 0,8 0,9 1,0 1,1 1,3 1,4

200

160

120

80

40

0

0,1 0,3 0,4 0,6 0,7 0,9 1,0 1,2 1,3 1,5 1,6

200

160

120

80

40

0

0,3 0,5 0,6 0,8 0,9 1,1 1,2 1,4 1,5 1,7

1,8

200

160

120

80

40

0

0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2

200

160

120

80

40

0

0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4

200

160

120

80

40

0

0,4 0,6 0,9 1,1 1,3 1,6 1,8 2,0 2,2 2,5 2,7

200

160

120

80

40

0

0,6 0,8 1,1 1,3 1,5 1,8 2,0 2,2 2,4 2,7 2,9

200

160

120

80

40

0

0,9 1,1 1,4 1,6 1,8 2,1 2,3 2,5 2,7 3,0 3,2

KWE 150 KWE 180

KWE 220 KWE

250

KWE 300

KWE 320

KWE 370 KWE 440

REMKO KWE

System pressure available - high-pressure pump

1: System pressure available [kPa]
2: Medium flow rate [l/sec]

22

System pressure available - high-performance pump

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

350
300
250
200
150
100

50

0

0,1 0,2 0,4 0,5 0,6 0,8 0,9 1,0 1,1 1,3 1,4

KWE 150 KWE 180

KWE 220 KWE 250

KWE 300

KWE 320

KWE 370 KWE 440

350
300
250
200
150

100

50

0

0,1 0,3 0,4 0,6 0,7 0,9 1,0 1,2 1,3 1,5 1,6

350
300
250
200
150
100

50

0

350
300
250
200
150

100

50

0

350
300
250
200
150
100

50

0

350
300
250
200
150

100

50

0

350
300
250
200
150
100

50

0

350
300
250
200
150

100

50

0

0,3 0,5 0,6 0,8 0,9 1,1 1,2 1,4 1,5 1,7 1,8 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2

0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0 2,2 2,4 0,4 0,6 0,9 1,

1 1,3 1,6 1,8 2,0 2,2 2,5 2,7

0,6 0,8 1,1 1,3 1,5 1,8 2,0 2,2 2,4 2,7 2,9 0,9 1,1 1,4 1,6 1,8 2,1 2,3 2,5 2,7 3,0 3,2

1: System pressure available [kPa]
2: Medium flow rate [l/sec]

23

B1

A

4

1a

3

1

2

1 1

1c1b

3

3

B3B2

5

6

3a

REMKO KWE

3 Design and function

3.1 Unit description

In cooling mode, the unit (an air-cooled chiller)
takes heat out of the operating medium to be
cooled, water or a mixture of water and glycol,
within a closed medium cycle in the evaporator
(plate heat exchanger) and passes it on to the
closed cooling cycle.

As a consequence of the heat exchange, the
medium cools and the refrigerant in the cooling
cycle vaporises under low pressure. The gaseous
refrigerant enters an electric compressor (scroll
construction) which increases the pressure and the
temperature of the refrigerant.

The gaseous refrigerant is led into a finned con­denser
exchange, condenses the refrigerant under high
pressure to a liquid.

The air emerging at the condenser heats the envi­ronment. The liquid refrigerant is fed by means of a
variable injector valve back to the evaporator
where the circuit begins again. In heating mode, a
chiller with heat pump functions (HP-function) can
take up heat from the ambient air in the finned con­denser and pass it on to the operating medium. A
reversing valve switches the cooling cycle function.

A return temperature dependent, adaptive con­troller, which ensures the unit's operation and all of
the safety functions, is used to control the cooling
or heating capacity. A potential-free contact pro­vides for remote enabling.

The unit is designed for outdoor installation. Under
certain circumstances, it can also be used in
indoor areas.

The unit cooling cycle comprises an evaporator,
compressor, thermal injection valve, condenser,
condenser fan, fan control system and high and
low pressure switches. Units with heat pump func­tion also have a reversing valve and a collecting
flask.

The medium cycle comprises a circulation pump,
expansion vessel, safety valve and differential
pressure switch.

A storage tank is not mandatory.

Winter pressure controls, cabled remote control,
crankcase heating, vibration dampers, heaters for
anti-freeze protection, external medium storage
tanks, glycol concentrate and a technical assis­tance commissioning are available as accessories.

, which, as a consequence of the heat

3.2 System layout

The unit is designed for a 2-conductor system.

The system has 2 medium pipes (conductors:
Supply and return flow) for cooling using a cold
medium. In combination with a corresponding
system, the output can be transmitted to the room
to be cooled via the floor, the building structure or
by means of ceiling cooling. For each of the dif­ferent systems, a minimum flow volume and a min­imum medium volume must be ensured for the
plant.

Fig. 3: System layout

A: Outdoor area
B1-3: Indoor area 1,2,3
1: Cold water drain
1a: Infrared remote control
1b: Room temperature controller
1c: Cabled remote control
2: Chiller
3: Condensate drainage line
3a: Condensate drainage line

(only units with HP-function)
4: Condensate collecting drainage
5: Medium outlet
6: Medium inlet

24

NOTICE!

PZH PSH

PZL

TC

KWE 150-220

KWE 250-440

PZH PSH

PZL

TC

∆P

KWE 150-220

KWE 250-440

∆P

KWE 150-220

∆P

KWE 250-440

∆P

The escape of refrigerant contributes to climatic
change. In the event of escape, refrigerant with
a low greenhouse potential has a lesser impact
on global warming than those with a high
greenhouse potential. This device contains
refrigerant with a greenhouse potential of 2088.
That means the escape of 1 kg of this refrig­erant has an ef

fect on global warming that is
2088 times greater than 1 kg CO2, based on
100 years. Do not conduct any work on the
refrigerant circuit or dismantle the device ­always enlist the help of qualified experts.

3.3 Refrigeration unit construction

3.4 Hydraulic unit construction

Fig. 4: Standard

Fig. 5: Standard

Fig. 6: With pump

Fig. 7: With pump

25

KWE 150-220

∆P

KWE 250-440

∆P

KWE 150-220

∆P

KWE 250-440

∆P

KWE 150-220

∆P

KWE 250-440

∆P

REMKO KWE

Fig. 8: With storage tank and pump

Fig. 9: With storage tank and pump

Fig. 12: With storage tank and high-pressure or
high-performance pump

Fig. 13: With storage tank and high-pressure or
high-performance pump

Fig. 10: With high-pressure or high-performance
pump

Fig. 11: With high-pressure or high-performance
pump

26

2

1

4

3

5

6

4

7

8 9

10

11 12

1

2

3

4

5

6

7

8

9

10

11

12

4 Operation of the

controller

Explanation of the keys

“Alarm” key

By pressing this key
selected. Pressing the key again acknowledges
that a malfunction has been rectified. The error
memory can be called up by subsequently
pressing the “Enter” key.

“Main menu” key

This key takes you to the main menu in which the
8 submenus are located. T
arrow keys and the “Enter” key to select a sub­menu.

“Back” key

Press this key to cancel an entry or to return to the
previous menu.

, a current malfunction can be

o navigate, press the

“Compressor” display

When this symbol appears, the compressor is acti­vated and in operation.

“Operating mode” display

This symbol indicates the current operating mode.
If e.g. cooling capacity is requested, a snowflake
appears here and the system is in cooling mode.

“Pump” display

If the circulation pump is activated, this symbol
appears and the pump is in operation.

“Operating status” display

Displays the current operating status of the
system, e.g. the “On” operating status is displayed
while the system is running.

“System temperature” display

Displays the system temperature measured at the
return flow

.

Main menu

Access to the main menu is possible by pressing
the “Main menu” key. The main menu provides
access to the 8 submenus. To navigate, press the
arrow keys and then the “Enter” key to select a
submenu.

A. On / Off Unit

“Arrow up / down” key

Use the arrow keys to navigate within the menus

The operating status can be selected here. OFF,
Auto, Energy Save and ON are available.

and set the parameter values

B. Setpoint

In the “Setpoint” submenu, the return flow temper-

“Enter” key

The “Enter” key can be used to select a parameter

ature can be set in nominal mode and in Energy
save mode.

or setpoint or to confirm the setting of a setpoint.

C. Clock / Scheduler

Meanings of the displays

T

ime and date display

The current time and date are displayed here.

In this menu it is possible to set the time and date.
In addition, a time program can be stored in which
it can be determined when the system is to be On,

Off or operated in Energy Save mode.
Under the “C. Clock / Scheduler” submenu, the
time and date can be adjusted manually.

“Identification number” display

Displays the system identification number for a
building management system. It can be adjusted
under the “F

. Board switch” submenu.

D. Input / Output

Under “Input / Output” current probe values and

information about the current operating status of

various components can be read.

27

!

12:22 19/02/18 Unit:01

Ou tside T: - - -- C°
Sy stem T: 1 9.5 C°

STATUS:
Off

1 x

!

Main menu 1/8

B.Setpoint

C.Clock/Scheduler

A.On/Off Unit

1 x

REMKO KWE

E. Data Logger

This is the error memory of the system, in which up
to 50 malfunctions can be stored. If all 50 spaces
are occupied, the oldest malfunction is deleted and
overwritten.

F

. Board switch

This menu allows the addressing of the system for
a building management system.

G. Service

In this menu you can configure the settings on the
system. Access is password protected. If you have
any questions, please contact our service depart­ment.

H. Manufacturer

This menu level is only accessible to the manufac­turer. If you have any questions, please contact our
service department.

The desired operating status can be set as follows:

To enter the main menu, press the “Menu” key on
the start screen.

Operating states

The unit has four adjustable operating states:

Off: The unit is in standby mode. The safety equip­ment is still active.

Auto: Automatic switching between heating and
cooling. This operating state is intended for units
with heat pump function.

Energy Save: In the Energy Save operating state,
the system runs the stored Energy Save setpoints
and time program.

On: The unit is activated and complies with the
normal setpoints.

In the main menu, use the arrow keys to select the
“A. On / Of
“Enter” key

f Unit” submenu and confirm with the

28

!

On/Off Unit A01

Unit

Off

Cooling only

In the “On / Off Unit” window, press the “Enter” key.

1 x

!

On/Off Unit A01

Unit

Off

Cooling only

!

On/Off Unit A01

Unit

On

Cooling only

1 x

!

On/Off Unit A01

Unit

On

Cooling only

!

12:22 19/02/18 Unit:01

Ou tside T: - - -- C°
Sy stem T: 1 9.5 C°

STATUS:
Off

1 x

!

Main menu 2/8

C.Clock/Scheduler

A.On/Off Unit

B.Setpoint

1 x

!

Thermoreg. Unit B01

Heat pump temperature
Nominal setpoint (ON)

Cooling: 23.0 C°
Heating: 0.0 C°

Setpoint return temperature sensor

Two different values can be set for the return flow
temperature:

Nominal setpoint: The setpoint for normal opera­tion

Energy Save setpoint: The setpoint for the
energy-saving mode

The respective “heating” setting is intended for
units with heat pump function and therefore has no
function.

The setpoints can be set as follows:

The value can now be changed using the two
arrow keys.

Press the “Enter” key to confirm your selection.

To enter the main menu, press the “Menu” key on
the start screen.

In the main menu, use the arrow keys to select the
“B. Setpoint” submenu and confirm with the “Enter”
key

The setting is now made and saved.

29

1 x

!

Thermoreg. Unit B01

Heat pump temperature
Nominal setpoint (ON)

Cooling: 23.0 C°
Heating: 0.0 C°

!

Thermoreg. Unit B01

Heat pump temperature
Nominal setpoint (ON)

Cooling: 9.0 C°
Heating: 0.0 C°

1 x

!

Thermoreg. Unit B01

Heat pump temperature
Nominal setpoint (ON)

Cooling: 9.0 C°
Heating: 0.0 C°

!

12:22 19/02/18 Unit:01

Ou tside T: - - -- C°
Sy stem T: 1 9.5 C°

STATUS:
Alarm-Off

1 x

!

!

Alarms ALF01

Position: ID1

Fan overload

2 x

!

!

Thermoreg. Unit B01

Heat pump temperature
Nominal setpoint (ON)

Cooling: 23.0 C°
Heating: 0.0 C°

Unit

Alarms ALF01

No active alarm
Press ENTER

to DATA LOGGER

REMKO KWE

In the “Thermoreg. Unit” field, use the arrow keys
to select the window for the setpoint in nominal or
energy-saving mode and press the “Enter” key

The value can now be changed using the two
arrow keys.

.

Display and acknowledge malfunctions

In order to protect the unit from damage, the con­troller checks the components that are relevant for
the safety of the unit by means of sensors for tem­perature, pressure, configuration, etc.

An error code and a brief description of the mal­function are displayed in the error view of the con­troller

. A rectified error can be acknowledged in the

error view:

To enter the error view, press the “Alarm” key on
the start screen.

Press the “Enter” key to confirm your selection.

The setting is now made and saved.

An active malfunction is now displayed in the alarm
menu. After eliminating the cause of the error
acknowledge the malfunction by pressing the
“Alarm” key twice.

The malfunction is now acknowledged. The last 50
malfunctions can be found in the error memory for
subsequent review

.

,

30

!

12:22 19/02/18 Unit:01

Ou tside T: - - -- C°
Sy stem T: 1 9.5 C°

STATUS:
Off

1 x

!

Main menu 1/8

B.Setpoint

C.Clock/Scheduler

A.On/Off Unit

Main menu 5/8

D.Input/Output

F.Board switch

E.Data logger

1 x

!

Data logger E17

ALF01 10:51 21/02/18
Fan Overload

Inlet Outlet

Plant: 17.0 C 17.2 C° °
Ext.T: 0.0 C°
DHW: 0.0 C°
Press:Hp 12.4 LP 0.0

Error memory

In the event of a malfunction, the error memory of
the controller collects and stores the most impor­tant data such as time of the malfunction, designa­tion and error code of the malfunction, and meas­ured values of the sensors. This means that
information on past malfunctions can also be
retrieved at a later point in time.

The controller stores up to 50 malfunctions. If all
50 spaces are occupied, the oldest malfunction is
deleted.

The error memory can be called up as follows:

To enter the main menu, press the “Menu” key on
the start screen.

5 Installation instructions

for qualified personnel

Important notes prior to installation

Observe the instruction manuals for the indoor
units and the chiller or heating system when instal­ling the entire system.

n Observe the operating manuals for the indoor

unit and the chiller or heating system when
installing the entire system.

n The indoor units and chillers work independ-

. A connecting line between the two is not

ently
necessary.

n Transport the unit in its original packaging as

close as possible to the installation location.
You avoid transport damage by doing so.

n The units may only be moved as installed

(upright) using appropriate transport gear.
Secure against tipping!

In the main menu, use the arrow keys to select the
“E. Data Logger” submenu and confirm with the
“Enter” key

Use the arrow keys to navigate in the error
memory

.

31

Fig. 14: Upright unit transport

1

REMKO KWE

n The unit must be kept upright when trans-

porting to a higher elevation.

Fig. 15: Vertical unit transport

1: Pick-up point

n Check the contents of the packaging for com-

pleteness and check the unit for visible trans­port damage. Report any damage immediately
to your contractual partner and the shipping
company

n Select an installation location which allows air

to freely flow through the air inlet and outlet
(see section "Minimum clearances").

n Do not install the unit in the immediate vicinity

of devices which generate intensive thermal
radiation. Installation in the vicinity of thermal
radiation reduces the unit output.

n Lift the unit only at intended lifting points.

Never place the medium or refrigerant piping
under load.

n The medium connection lines, valves and con-

nections must have vapour density insulation.
If necessary, also insulate the condensate
drainage line. In dual systems with cooling and
heating modes, the requirements of the current
Energy Savings Ordinance (EnEV) are to be
complied with.

n Seal off open lines to prevent dirt getting in and

never kink or crimp the lines.

n Avoid unnecessary bends. This minimises the

pressure loss in the lines.

n Install all electrical wiring in accordance with

applicable DIN and VDE standards.

n Ensure the electrical cables are properly con-

nected to the terminals. Otherwise there is a
risk of fire.

n Comply with all regulations governing structural

and building requirements and conditions with
regard to the installation site.

n In the selection of the installation site, pay

attention to the site itself and to any possible
acoustic reflection from surrounding units.

.

o avoid the transmission of vibrations to the

n T

installation site, the units must be installed on
vibration absorbing material or on vibration
decoupled foundations. In doing so, make sure
that the lines are also vibration decoupled

n If the installation site must fulfil special sound

emission requirements, these must be realised
on-site when appropriate adjustments can be
made. In these cases, please consult an
appropriate acoustics expert.

Wall openings

e recommend that the inside of the opening

n W

be padded or lined for example with a PVC
pipe to prevent damage to the lines.

n After installation, the wall opening should be

closed off by the customer with a suitable
sealant. Do not use substances containing lime
or cement!

Installation materials

The unit is fastened on vibration dampers (acces­sories) to the floor by means of bolts. The carrying
capacity of the bracket and the wall must be taken
into account when fastening to the wall.

Selecting the installation location

The unit is designed for horizontal installation on a
base in outdoor areas. The installation site must be
level, flat and firm. The unit should also be secured
to prevent it from tipping over
installed outside as well as inside a building. For
external installation, please observe the following
instructions to protect the unit from the influence of
the weather.

Rain

The unit should be at least 10 cm off the ground
when mounted on the roof or ground. A floor
bracket is available as an accessory.

Increasing the installation height will also increase
the heating capacity generated by the heating /
cooling unit (only HP function).

. The unit can be

32

1

20 cm

1

Sun

The finned condenser gives of

f heat in cooling

mode.

Exposure to sunlight further increases the temper­ature of the fins and reduces the heat released by
the finned heat exchanger.

The unit should, whenever possible, be installed
on the north side of the building.

If necessary, take measures to provide sufficient
shade (responsibility of customer).

This could be a small roof.

However, the discharging warm air flow must not
be affected by the measures

Wind

If the unit is being installed in windy areas, ensure
that the warm outlet air is discharged in the pre­vailing wind direction. If this is not the possible, it
may be necessary to install a windbreak (to be pro­vided by the customer).

Ensure that the windbreak does not adversely
affect the air intake to the unit.

Snow

The unit should be wall-mounted in areas of heavy
snowfall. Installation should be at least 20 cm
above the expected level of snow to prevent snow
from entering the outdoor unit.

Fig. 17: Minimum clearance to snow

1: Snow

Fig. 16: Windbreak

1: Wind

33

2

1

K

3

W

3

W

REMKO KWE

Installation inside buildings

n Ensure that heat can dissipate adequately when placing the outdoor unit in cellars, lofts, adjoining rooms

or halls (Fig. 18).

n Install an additional fan with a rated flow similar to that of the outdoor unit being installed in the room and

that can compensate any additional pressure loss in ventilation ducts (Fig. 18).

n Ensure a continuous and unobstructed air flow from outside, preferably using sufficiently large air intakes

located immediately opposite if possible (Fig. 18).

n Comply with any regulations and conditions affecting the statics of the building. If necessary, fit acoustic

installation.

Fig. 18: Outdoor installation inside buildings

K: Cold fresh air
W: Warm air
1: Chiller
2: Additional fan
3: Air shaft

34

A

B

C

D

E

A

B

C

D

E

Minimum clearances

The following illustrations indicate the minimum
clearances for trouble-free operation of the equip­ment.

The protective zones serve to provide unhindered
air intake and outlet, as well as providing suf
room for performing maintenance and repairs and
preventing the unit from being damaged.

ficient

Minimum clearances (all measurements in mm)

KWE 150-220 KWE 250-440

A 1000 1000

B 1500 1000

C 1000 1500

D 1500 1500

E 500 2500

Fig. 19: Minimum clearances KWE 150-220

Fig. 20: Minimum clearances KWE 250-440

35

A

REMKO KWE

6 Installation

6.1 Unit installation

NOTICE!

Installation should only be performed by author­ised specialists.

Perform the unit installation as follows:

1. Install the vibration dampers (accessories)
under the unit / medium storage tank (acces­sories).

2. Attach the unit to the building where structur­ally permitted.

3. Ensure that structure-borne sound is not
transferred to parts of the building.

4. Connect the medium piping.

Disassembly of the transport pallets

The units are supplied with transport pallets for the
purpose of transportation. Remove these before
installation.

Connection of the medium piping

n The connection of the lines on-site takes place

on the front side of the unit.

n For the purpose of servicing, connections must

be equipped with shut-of
medium flow rate adjusted using hydronic bal­ancing valves.

n Additional automatic bleed valves are to be

provided in the supply and return flow at the
installation’s highest point.

n The medium piping may not exert any struc-

tural load on the unit.

n The line connections may not generate any

thermal or mechanical stresses on the unit. If
necessary cool the piping or support with the
second tool.

n If the unit is at first to be operated with only a

part of the entire system, the medium flow rate
for the missing system components is to be
simulated using a pipe leg regulating valve.

n The pipe sizing is to be designed so that the

flow rate does not fall below the required min­imum flow volume.

A permanently large medium flow rate must be
ensured to realise the minimum flow volume.

f valves and the

A: Transport pallet

36

Installation diagrams

2

1

∆P

∆P

3

Fig. 21: Installation diagrams KWE 150-220

1: Standard design
2: Standard pump
3: Standard pump and storage tank

37

2

1

∆P

∆P

∆P

3

REMKO KWE

Fig. 22: Installation diagrams KWE 150-220

1: High-pressure or high-performance pump
2: High-pressure or high-performance pump with

storage tank

3: Standard pump and external medium storage

tank (hydraulic compensator)

38

2

1

3

∆P

∆P

∆P

Fig. 23: Installation diagrams KWE 250-440

1: Standard design
2: Standard pump
3: Standard pump and storage tank

39

2

1

3

∆P

∆P

∆P

REMKO KWE

Fig. 24: Installation diagrams KWE 250-440

1: High-pressure or high-performance pump
2: High-pressure or high-performance pump with

storage tank

3: Standard pump and external medium storage

tank (hydraulic compensator)

40

Minimum / maximum flow volume

The circulation pump of the chiller generates a
constant medium flow rate; the result is a loss of
pressure in the system and in the chiller

The differential pressure switch in the chiller meas­ures the medium pressure loss over the evaporator
and switches the unit off if the flow rate drops
below the minimum medium volume.

The medium flow rate limit may likewise not be
exceeded (maximum flow volume).

A 3-way valve with bypass and a hydraulic com­pensator to establish a primary and secondary cir­cuit or a volume-dependent bypass are necessary
to ensure a constant medium flow rate.

Minimum medium volume, per unit

As a consequence of the adaptive controller a
storage tank is not mandatory. However, the flow
rate shall not drop below the minimum medium
volume in order to ensure trouble-free operation of
the unit.

.

Medium piping

Medium piping can be made of copper, steel or
plastic. T
lined fittings should be used.

When designing the layout, the large medium flow
rates in cold water systems, high pressure losses
in connection with water-glycol mixtures and the
chiller's minimum flow volume must be taken into
account.

The lines are to be insulated against vapour diffu­sion and, if necessary, the current German Energy­Savings-Ordinance (EnEV) must be observed. UV
resistance must be realised outdoors.

Pressure and temperature displays

The pressure and temperature displays to be
installed on-site at the intake and outlet serve to
set the medium flow rate. The display should be
able to be shut off.

Temperature sensors are located in the chiller's
medium inlet and outlet. Sensor values can be
queried via the controller.

o minimise pressure losses, only stream-

NOTICE!

The product and safety data sheets of the
glycol type used must be observed during use
and disposal.

NOTICE!

Use the required type and mix ratio appropriate
for the application area to ensure the freezing
point.

To adjust the circulation pump, we recommend
that a main hydronic balancing valve is pro­vided in the vicinity of the unit.

Valves for hydronic balancing

The calculated individual pressure losses in the
pipeline network layout for each individual unit are
adjusted to the entire system with hydronic bal­ancing valves to be provided by the customer. The
nominal flow rates for the medium adjust to the
values needed as a consequence of the pressure
loss.

Anti-freeze protection (accessories)

A water glycol mix is generally used as the medium
for a cold water system. Depending on the use to
which the glycol type and quantity is put, the vis­cosity changes, the loss in pressure increases and
the unit's cooling or heating capacity reduces. All
system components must be approved for use with
glycol.

As a rule, the addition to the water of ethylene
glycol, in a proportion of 34%, with inhibitors for
corrosion protection is recommended. This con­centration ensures anti-freeze protection to -20 °C;
at lower temperatures, an ice porridge forms which
has no explosive effect.

The toxicologically harmless propylene glycol
should be used if there is a risk that the medium
can come into contact with drinking water or food
stuffs. To inhibit the explosive effects, a proportion
of 38% is necessary as a rule.

41

!

12:22 19/02/18 Unit:01

Ou tside T: - - -- C°
Sy stem T: 1 9.5 C°

STATUS:
Off

1 x

!

Main menu 7/8

E.Data logger

F.Board switch

G.Service

+

!

Service menu 6/7

e.BMS config

f.Service settings

d.Working hours

+

Password entry

+

x 4

!

Service menu 3/4

b.Probe adjustment

c.Thermoregulation

a.Working hour set

Service menu 3/4

b.Probe adjustment

c.Thermoregulation

a.Working hour set

REMKO KWE

Frost

Glycol

con-

tent

Vol. % ° C

20 -9 0.981 0.988 1.012 1.040 1.19

35 -21 0.971 0.982 1.018 1.090 1.35

40 -26 0.968 0.981 1.019 1.105 1.51

*) We recommend using an ethylene glycol mixture. Observe the safety and product data sheets for the type
of glycol used.

Configuration anti-freeze protection parameters

It can be necessary to reconfigure the anti-freeze
protection parameters when using a water-glycol
mixture. Adjustment is only possible after pass­word input. For this purpose, please contact
REMKO.

Perform the configuration as follows:

protec-

tion

+-2 °C

0 0 1 1 1.012 1 1

capacity

Correction factors when using a mixture of glycol *) and water

Cooling

K

L

Compressor capacity

K

P cooling

K

P heating

Volume flow Pressure lossCooling Heating

K

V

K

D

Call up the main menu.

Select the “Service” menu.

Select the submenu “f. Service setting”.

Enter the 4-digit password.

42

+

!

Service menu 2/7

Thermoreg. Gfc16

Service menu 2/7

Thermoreg. Gfc16

Primary circuit

Primary cir.antifreeze

°C

Primary cir.antifreeze
alarm diff.: 3.0°C

alarm setp.: 4.0

+

!

Service menu 2/7

Thermoreg. Gfc16

Service menu 2/7

Thermoreg. Gfc16

Primary circuit

Primary cir.antifreeze

°C

Primary cir.antifreeze

°C

alarm setp.: -15.0

alarm diff.: 3.0

+

!

Service menu 2/7

Thermoreg. Gfc16

Service menu 2/7

Thermoreg. Gfc16

Primary circuit

Primary cir.antifreeze

°C

Primary cir.antifreeze

°C-

alarm setp.: -15.0

alarm diff.: 4.0

2

1

4

3

Open the window “c. Thermal regulation”.

Set the frost protection alarm value.

The unit's standard equipment includes one dia­phragm expansion vessel. The preliminary pres­sure must be set on the system; an increase in
volume or

, in the event of the realisation of a
cooling-heating system, the installation of another
diaphragm expansion vessel may be necessary.

Compensators

Compensators are used to connect lines to the unit
to prevent vibration in the chiller from transmitting
to other system components.

1: Static fastening
2: Shut-off valve
3: Compensator
4: Connection KWE

Set the value for the alarm difference. If the differ­ence is exceeded, the alarm is reset.

This completes the configuration.

Diaphragm expansion vessel (MAG)

To avoid pressure fluctuations during standstill
because of temperature changes, diaphragm
expansion vessels filled with nitrogen (moisture
neutral) must be integrated in the system.

Safety valves

Safety valves limit excess operating pressure due
to excess warming or overfilling of the operating
medium. The valve outlet requires unobstructed
draining into a drain line. Applicable local disposal
ordinances must be observed if glycol is used. The
unit's standard equipment includes one safety
valve.

Shut-off valves

As a rule, in cold water systems, shut-off valves
with full admission should be used. For the pur­pose of servicing, medium inlet and medium outlet
must be equipped with shut-of

f valves (if necessary

safety valves).

Air bleeding valves

The unit has manual air bleeding valves. The unit
can be bled separately after the system has been
filled. Automatic bleeding valves must also be
installed at the highest point in the collector line.

NOTICE!

Glycol tolerant air bleeding valves are neces­sary when using media that contain glycol.

43

2

1

REMKO KWE

Fill and drain connection

A connection should be provided in an area safe
from frost for the draining of pipe lines (especially if
water is used as a medium). Applicable local dis­posal ordinances must be observed if glycol is
used.

Dirt trap

A rinsable dirt trap must be installed upstream from
the unit intake. The mesh size should not be less
than 10 mesh/cm2. Shut-of
installed upstream and downstream from the dirt
trap.

NOTICE!

Improperly installed or missing dirt traps can
cause fouling of the plate heat exchanger

External medium storage tank

If, for example, the necessary capacity of the cold
water outlet is significantly less than the cooling
capacity generated by the chiller, an increase in
the medium content is recommended. As an
example, the medium piping can be oversized or
an additional storage tank installed to increase
compressor operating time. A storage tank should,
as a rule, be provided if the minimum medium
volume is not reached.

f valves should be

.

7 Condensate drainage

connection and safe
drainage

Condensate drainage connection

If the temperature falls below the dew point, con­densation will form on the finned condenser during
heating mode.

A condensate tray should be installed on the
underside of the unit to drain any condensate.

n The condensate drainage line should have an

incline of min. 2%. This is the responsibility of
the customer
proof insulation.

n When operating the unit at outdoor tempera-

tures below 4 ℃, care must be taken that the
condensate drainage line is anti-freeze pro­tected. The lower part of the housing and con­densate tray is also to be kept frost free in
order to ensure permanent draining of the con­densate. If necessary, fit a pipe heater.

n Following installation, check that the conden-

sate run off is unobstructed and ensure that the
line is durably leak tight.

. If necessary, fit vapour-diffusion-

NOTICE!

Malfunctions can result if the flow rate drops
below the minimum medium volume.

1: Condensate tray
2: Condensate drainage

Safe drainage in the event of leakages

Local regulations or environmental laws, for
example the German W
can require suitable precautions to protect against
uncontrolled drainage in case of leakage to provide
for safe disposal of escaping air conditioning fluid
or hazardous media.

ater Resource Act (WHG),

44

8 Electrical wiring

8.1 General connection and safety instructions

DANGER!

All electrical installation work is to be performed
by specialist companies. Disconnect the power
supply when connecting the electrical terminals.

n The power supply is made at the chiller; a con-

trol line to the indoor unit is not necessary.

n An all-pole separating switch, which discon-

nects individual phase conductors in the event
of a malfunction, must be installed in the
supply line upstream from the unit.

n Electrical wiring must be carried out as fixed

connections in accordance with the applicable
regulations!

n Check all terminal points for stability.
n The supply line must be adequately insulated

on-site and the voltage drop may not exceed
permissible values.

n Make sure that the electrical system is ade-

quate for the operation of the unit and can
supply the operating current necessary for
other units already installed.

n Determine before installation, when connecting

to existing system components, whether the
unit's service connection is adequately sized
for the unit's rated power consumption.

n The connection of the units must always be

carried out with adequately sized, low-resist­ance earth conductors, and, if necessary, car­ried out several times (especially with plastic
pipes).

n When installing the units on flat roofs, lightning

protection measures may be necessary.

n All electrical connections such as network

supply, cable remote control etc. must be car­ried out in the unit's switch cabinet.

n The lines to be installed are to be fed into the

switch cabinet through the cable glands pro­vided.

n An electrician must determine the sizing and

selection of the fuses and the cross section of
the lines to be installed. Note that starting cur­rent max. may be up to 10 times nominal cur­rent

Carry out the following electrical wiring:

n Connection to the power supply
n Possible enabling contact for the set mode or

standby.

n Possible operating mode contact for cooling or

heating mode (units with HP function).

n Possible connection of a winter pressure con-

troller (accessory).

n Possible connection of crankcase heating

(accessory).

n Possible connection of cabled remote control

(accessory).

n Possible connection of a heater for anti-freeze

protection medium (accessory, factory installa­tion only).

Check all plugged and clamped terminals to
verify that they are seated correctly and make
permanent contact. T

Power supply

The unit requires a fixed three phase current con­nection. The mains power supply is to be con­nected to the L1, L2, L3, N and PE terminals.

ighten as required.

.

45

2

1

XU

XU-9

XU-5

XU-4

XU-3

XU-2

XU-11

XU-10

XU-6

REMKO KWE

8.2 Unit connection

Proceed as follows to connect:

1. Open the control box covers by removing the
fixing screws and lifting of

2. Feed the voltage-free cable through the
glands into the switch cabinet and clamp the
cable to the strain relief.

3. Then connect the cable in accordance with
the connection diagram.

4. Ensure a correct rotating field.

5. Mount all removed parts.

f the covers.

General alarm signal (standard equipment)

The connection of a potential-free general alarm
signal, for example, for signalling or for further pro­cessing to a building control system is possible as
standard equipment. Use the respective connec­tion diagram for this purpose and pay attention to
the maximum contact loads.

Fig. 26: External potential-free contacts

1: Unit
2: User

2-3 = Enable operation / disable (potential-free)

4-5 = External alarm code (max. 230V~, 2A)

Fig. 25: Control box cover KWE 250-440

External enabling contact Operation / Standby

In addition to being operated with the controller or
the cable remote control, the unit can be switched
on (normal operation) and switched of
via an external potential-free contact (program­mable as normally-open or normally-closed).

The controller must be configured if a normally­open contact is used for the external enable (see
section “External enabling configuration”).

This enable is used for example to realise standstill
times at night or for the activation / deactivation of
a building control system.

f (Stand-By)

Winter pressure controller (accessory)

It serves for the expansion of the operating range
in cooling mode from +15℃ to -15℃. The set con­sists of crankcase heating and the pressure con-

. Use respective installation instructions for

troller
this purpose.

Crankcase heating compressor (standard /
accessory)

The heating serves for the expansion of the oper­ating range in cooling mode from +15℃ to -5℃.
For this purpose, use the respective installation
instructions.

Cabled remote control (accessory)

The cable remote control is used, for example, for
the querying, programming or operation of the unit
from a remote location. Use respective installation
instructions for this purpose.

46

External enabling configuration

!

12:22 19/02/18 Unit:01

Ou tside T: - - -- C°
Sy stem T: 1 9.5 C°

STATUS:
Off

1 x

!

Main menu 8/8

F.Board switch

G.Service

H.Manufacturer

+

!

Manufacturer menu 2/5

b.I/O Configuration

c.Factory settings

a.Configuration

+

Password entry

+

x 4

!

I/O Config. Hb04

Digital inputs

ID07

ID08
Remote On/Off: NC

General alarm: NC

+

!

I/O Config. Hb04

Digital inputs

ID07

ID08

General alarm: NO

Remote On/Off: NC

+

!

I/O Config. Hb04

Digital inputs

ID07

ID08

General alarm: NO

Remote On/Off: NO

With the use of a normally open contact as an
external contact, a controller parameter must be
reconfigured. The parameter “Id08” must be
switched from “NC” to “NO”. If this does not
happen, the controller does not recognise the
external contact as a normally closed contact. The
“Id08” parameter can be changed in the “I/O Con­figuration” menu item. The following program
sequence must be programmed.

Enter the 4-digit password.

Call up the main menu.

Select the following submenu:

Set the alarm contact.

Set the external enabling contact.

Open the window “b . I/O Configuration”.

47

This completes the configuration.

REMKO KWE

8.3 Electrical components

Electrical components and safety equipment

Pressure switch cooling cycle HP and LP

There is a high pressure switch (HP) in the hot gas
line within the cooling circuit to for switching of
chiller in the event of insufficient heat dissipation. A
low pressure switch (LP) in the suction pipe or in
the compressor switches off the chiller if the fill
level for the refrigerant is too low.

Differential pressure switch

The differential pressure switch is installed parallel
to the evaporator in the medium cycle. It measures
the pressure differential between the inlet and
outlet pressure and switches the unit off when the
flow rate drops below the minimum flow volume or
with extremely large medium flow rates.

Condenser fan thermal contacts

The condenser fan's thermal contacts prevent
overheating of the motors.

f the

9 Leak testing

The leak test is carried out after the connection
has been made.

1. Flush the system twice with tap water

2. Clean the sieve insert on the dirt trap.

3. Fill the system with water again and bleed

the unit at the manual bleed valves.

4. Adjust the test pressure to at least 200 kPa
(2.0 bar).

5. Check the connections after a period of at
least 24 hours for leaking water
visible, the connection has not been estab­lished properly. Tighten the connection or
establish a new connection.

6. After a successful leak test, remove the
excess pressure from the medium piping if a
water-glycol mixture is used or adjust the
non-circulating pressure to the required
system pressure.

.

. If water is

Compressor thermal contact

The thermal contact is located within the com­pressor and limits its hot gas end temperature.

Phase sequence relay

The phase sequence relay controls the direction of
rotation for the power supply. The controller will not
be enabled if the direction of rotation is wrong.

Probe B4 medium inlet

The probe is located at the unit's medium inlet
(system return flow). It serves to capture the cur­rent temperature to control the target value.

Probe B7 medium outlet

The probe is located at the unit's medium outlet
(system inlet). It serves to capture the current tem­perature and regulate the anti-freeze protection
temperature.

48

A

A

B

C

10 Before commissioning

Filling the system

The system is filled at the customer-provided filling
and draining connections.

Anti-freeze protection for the medium

If a water-glycol mixture is used, it is to be pre­mixed before being put in the system. The desired
concentration is then to be checked.

Unit preliminary pressure for the medium

The preliminary pressure of the medium (without
operation of the circulation pump) varies within the
system. From the highest point, the pressure
increases by approx.10 kPa (0.1 bar) per metre dif­ference in altitude (geodetic altitude). The value
measured at the highest point is identified as the
non-circulating pressure.

The position of the unit in the system is decisive in
the calculation of the unit's preliminary pressure
(pressure of the manometer on the unit installed by
the customer). The pressure must be set to at least
70 kPa (0.7 bar).

n If the unit is positioned at the lowest point in

the system, the unit preliminary pressure
(=standstill pressure+geodetic system altitude)
must be set to at least 70 kPa (0.7 bar) + 10
kPa (0.1 bar) x geodetic system altitude.

n If the unit is positioned at the highest point in

the system, the unit preliminary pressure
(=non-circulating pressure) must be set to at
least 70 kPa (0.7 bar). Please note that the
system pressure at the lowest point is
increased by the geodetic system altitude!
(See Fig. 27)

Fig. 27: Unit preliminary pressure

A: Unit preliminary pressure
B: Geodetic system altitude
C: Non-circulating pressure

Bleeding the system

n Air may still be in the pipe lines after the leak

testing. This is carried during operation of the
circulation pump to the automatic bleeding
valves or to the cold water drain. It is neces­sary to bleed again here.

n Also bleed the pump if necessary.
n The non-circulating pressure must then be

adjusted to the required system pressure.

NOTICE!

During manual bleeding, any glycol mixtures
which escape must be disposed of separately
Do not feed them into the condensate tray!

.

49

REMKO KWE

Diaphragm expansion vessel

n The preliminary pressure for the diaphragm

expansion vessel must be adjusted individually
to the system layout, the volume of the medium
and the installation site.

n If necessary

this, the manufacturer's authorisation is
required.

Valves for hydronic balancing

n The calculated excess pressure in the pipe net-

work layout at the individual cold water outlets
must be adjusted with the hydronic balancing
valves.

Safety valve

n The safety valves and their correct function

must be checked.

n The drain line for the valves is to be checked

for function and leak tightness.

n If necessary

this, the manufacturer's authorisation is
required.

, change the installation site. For

, change the installation site. For

Checking the cooling circuit

n Checking the cooling circuit for adequate oil /

refrigerant.

n Checking the cooling circuit for leak tightness.
n Checking the medium cycle.
n Setting the circulation pump's nominal flow

rate.

The units are equipped with a phase sequence
relay which prevents the operation of the con­troller if the direction of rotation of the electric
power supply is wrong. The rotary field must be
replaced if the controller is not activated during
commissioning of the unit.

Additional checks

General checks

n Checking that minimum clearances are correct.
n Checking the possibility of transferring cooling

and heating capacity via the cold or hot water
consumer (indoor unit).

Electrical checks

n Checking electrical connections for correct

phase sequencing.

n Function check of the cooling mode / heating

mode enable (option).

n Function check of the enable Operation /

Standby (option).

Checking the medium cycle

n Checking the circulation pump for freedom of

movement.

n Checking whether all valves are open.
n Checking the medium cycle.
n Setting the circulation pump's nominal flow

rate.

50

11 Commissioning

NOTICE!

Commissioning should only be performed by
specially trained personnel and documented
after the certificate has been issued.

NOTICE!

Observe the manuals for the unit and all other
components when commissioning the entire
system.

Function test for cooling operating mode

1. Switch the power supply on.

2. Open all shut-of

3. Switch on the chiller and the corresponding

circulation pump. The outlet temperature
must be between +4 and +18 °C.

4. Switch the unit on and select the cooling
operating mode. If the return temperature is
warmer than the setting, the compressor dis­play will flash and the compressor will begin
to work after approx. 3 to 5 minutes.

5. Please note that the inlet temperature at the
nominal flow rate of the medium lies approx.
5 K below the return temperature.

- If the inlet temperature falls below the fac­tory setting of 4 °C, an alarm triggers. If this
is the case, a higher return temperature must
be selected. If the spread is too great or too
small, the medium flow rate must be
checked.

- The circulation pump starts and the con­troller checks the medium flow rate via the
dif

ferential pressure switch. If the volume is
insufficient, a fault shut-off will be carried out
and the cooling cycle will not be enabled.

6. Measure and record all the required values in
the commissioning report and check the
safety functions.

7. Check the unit control system using the func­tions described in the "Operation" chapter

f valves if necessary.

.

Final tasks

n Mount all removed parts.
n Familiarise the operator with the system.

The delivery of the unit from the factory takes
place with standard parameterisation of the
output control. If necessary during commis­sioning a system-specific parameterisation
must be carried out by authorised personnel.

51

REMKO KWE

12 Shutdown

Temporary shutdown

1. Shut down the indoor units using the remote

control.

2. Switch the unit of
the chiller (or using the remote control).

3. Check the percentage concentration of
glycol.

4. Check the unit for visible signs of damage
and clean it as described in the “Care and
maintenance” chapter

5. As much as possible, cover the unit with a
plastic foil to protect it against the weather

f via the internal controller in

.

.

NOTICE!

If only water and not a mixture of water and
glycol is used, in regions subject to freezing,
water must be drained from components when
these are at standstill. The drained water
volume must be replaced when components
are put back into operation!

Permanent shutdown

Ensure that units and components are disposed of
in accordance with local regulations, e.g. through
authorised disposal and recycling specialists or at
collection points.

REMKO GmbH & Co. KG or your contractual
partner will be pleased to provide a list of certified
firms in your area.

52

13 Troubleshooting and customer service

The unit and components are manufactured using state-of-the-art production methods and tested several
times to verify that they function correctly
as detailed in the list below. For systems with an indoor unit and outdoor unit, refer to the chapter "Trouble­shooting and customer service" in both operating manuals. Please inform your dealer if the unit is still not
working correctly after all function checks have been performed!

Operational malfunctions

Malfunction Possible causes Checks Remedial measures

Display is not illuminated.

. However, if malfunctions should occur, please check the functions

Check the power connec-

tions on the general supply
No power supply, power
failure, device fuse / main
switch switched of
tive

f / defec-

terminals and the voltage

values. Check the unit fuse,

the main switch and the

fuses on the secondary side

of the additional trans-

former.

The unit does not
start

The unit works at
reduced cooling
capacity

The display lights up and
shows “Phase sequence
error”.

Display shows status: “Off”.

The controller emits an
acoustic signal.

The compressor icon is dis­played, but the unit does
not start.

Thermal load too high.

Inlet temperature too high.

Air in the medium cycle.

Condenser temperature too
high.

Incorrect phase sequence.
The phase sequence relay
did not issue an enable
signal.

The unit is deactivated.
Change the operating
status in the “A. On / Of
Unit” submenu

One or more protective
devices have tripped. A
malfunction is present.

Compressor or compressor
contactor defective.

Thermal load was
increased.

Return flow temperature set
too high.

Medium cycle not bled, no
automatic bleeding valves
installed.

Slats dirty, exposed to
strong sunlight.

f

Swap the phase conductors

of the power supply on the

terminal block on the con-

trol panel.

Check error messages, rec-

tify the malfunction,

acknowledge the malfunc-

tion (see chapter “Error indi-

cation”).

Have specialist replace

contactor or compressor

If possible, reduce the

thermal load.

Reduce return temperature.

Manually bleed or install

automatic bleeding valves

at the highest point.

Clean fins, provide shade

for the unit, adhere to oper-

ating limits.

.

Pulse mode because of too
little demand.

53

System may be over­dimensioned

Increase medium flow rate

with the installation of a

storage tank.

REMKO KWE

Malfunction Possible causes Checks Remedial measures

Drop formation at connec­tion points of the pipeline.

Medium outlet

Condensate formation

Operational malfunctions (continued)

Mal­function

ALA04 Medium inlet probe defective Check resistance at B4 Replace defective probe.

ALA06

ALA07

ALA08

ALA09

Possible causes Checks Remedial measures

Outside temperature probe
fault (optional)

Medium outlet sensor defec­tive

Suction gas temperature
probe fault (optional)

Hot gas temperature probe
fault (optional)

Leakage of the joint Seal the joint.

Uninsulated cables or com­ponents, defective insula­tion.

Check resistance at B6
(optional)

Check resistance at B7 Replace defective probe.

Check resistance at B8
(optional)

Check resistance at B9 Replace defective probe.

Attach or repair the insula­tion.

Replace defective probe.

Replace defective probe.

ALA11 High-pressure probe fault Check resistance at B11 Replace defective probe.

ALA12

ALB01

ALB02

ALB03

ALB04

ALC01

ALP02

ALP03 Medium flow disturbance

Low-pressure probe fault
(optional)

High-pressure switch, high­pressure alarm

High-pressure probe high­pressure alarm

Low-pressure probe low-pres­sure alarm

Low-pressure switch low-pres­sure alarm

Compressor overload
(optional)

Overload circulation pump
(optional)

Check resistance at B12
(optional)

Condenser lined, dirty or
exposed to excessive sun­light? Condenser fan defec­tive?

Cooling cycle OK? Check the
flow sensor

Motor overload protection
switch triggered? Compressor
power consumption too high?

Motor overload protection
switch triggered? Circulation
pump power consumption too
high?

Check: Air in the medium
piping -Open shut-of
Medium pressure -Circulation
pump capacity -Switching
behaviour of the differential
pressure switch -Medium flow
rate

f devices -

Replace defective probe.

Clear condenser, clean,
shade, have condenser fan
checked by specialist per­sonnel.

Have the cooling cycle
checked by a specialist com­pany

, replace the flow sensor.

Check motor overload protec­tion switch (setting range),
have the compressor checked
by a specialist company

Check motor overload protec­tion switch (setting range),
have the pump checked by a
specialist company

-Bleed the medium cycle

-Open shut-off valves

-Raise medium pressure

Have the circulation pump, dif­ferential pressure and medium
flow rate checked by a spe­cialist company.

.

.

54

Mal­function

ALF01 Fan motor overload

ALT01 Compressor maintenance

ALT04 Pump maintenance

ALU02 Frost protection malfunction

ALD01 EEPROM malfunction

ALG01

Possible causes Checks Remedial measures

Motor overload protection
switch triggered? Fan power
consumption too high?

Compressor maintenance
interval has been reached

Pump maintenance interval
has been reached

Inlet temperature lower than
4 °C?

Mains current has incorrect
direction of rotation

Check the phase sequence
relay

Check motor overload protec­tion switch (setting range),
have the fan checked by a
specialist company

After maintenance by a spe­cialist company
operating hours. See chapter
“Resetting the operating
hours”.

After maintenance by a spe­cialist company
operating hours. See chapter
“Resetting the operating
hours”.

Raise return flow temperature,
increase medium flow rate,
adjust antifreeze temperature
to the operating medium.

Swap the phase conductors of
the power supply on the ter­minal block on the control
panel.

.

, reset the

, reset the

55

REMKO KWE

Error indication by code

Mal­function Possible causes

ALA04

ALA06

ALA07

Medium inlet probe
defective

Outside temperature
probe fault (optional)

Medium outlet sensor
defective

Suction gas tempera-

ALA08

ture probe fault
(optional)

ALA09

ALA11

ALA12

ALB01

ALB02

Hot gas temperature
probe fault (optional)

High-pressure probe
fault

Low-pressure probe
fault (optional)

High-pressure switch,
high-pressure alarm

High-pressure probe
high-pressure alarm

Reset Input type

l

l

l

l

l

l

l

l l l

l

5)

ReactionAuto. 1)Man. 2)Digi. 3)Ana. 4)Soft.

l

l

l

l

l

l

l

System deactivated

Dynamic setting disa­bled (optional)

System deactivated

System deactivated

System deactivated

System deactivated

System deactivated

System deactivated

l

System deactivated

ALB03

ALB04

ALC01

ALP02

ALP03

Low-pressure probe
low-pressure alarm

Low-pressure switch
low-pressure alarm

Compressor overload
(optional)

Overload circulation
pump (optional)

Medium flow disturb­ance

ALF01 Fan motor overload

ALT01

Compressor mainte­nance

ALT04 Pump maintenance

ALU02

Frost protection mal­function

ALD01 EEPROM malfunction

Mains current has

ALG01

incorrect direction of
rotation

l

l

System deactivated

l l

l l

l l

l l

l l

l

l

l

l

System deactivated

System deactivated

System deactivated

System deactivated

System deactivated

Only alarm signal

l

Only alarm signal

l

System deactivated

l

System deactivated

l

System deactivated

l

1)

Auto. = automatic,

2)

Man. = manual,

3)

Digi. = digital,

4)

Ana. = analogue,

5)

Soft. = Software parameters

56

14 Care and maintenance

Regular care and observation of some basic points
will ensure trouble-free operation and a long
service life.

DANGER!

Prior to performing any work, ensure the equip­ment is disconnected from the voltage supply
and secured to prevent accidental switch-on!

Care

n Ensure the unit is protected against dirt, mould

and other deposits.

n Only clean the unit using a damp cloth. Do not

use any caustic, abrasive or solvent-based
cleaning products. Do not use a jet of water.

n Clean the fins on the unit prior to long shut-

down periods.

Maintenance

n It is recommended that you take out a mainte-

nance contract with an annual service from an
appropriate specialist firm.

This enables you to ensure the operational reli­ability of the plant at all times!

NOTICE!

Statutory regulations require a leak test for the
cooling cycle dependent on the refrigerant
capacity. Inspection and documentation of the
work performed is to be carried out by specialist
technicians.

Type of task

Checks / maintenance / inspection

General

Check voltage and current

Check function of compressor / fans

Dirt on condenser / evaporator

Check the refrigerant volume

Check condensate drainage

Check insulation

Check moving parts

Sealing test for cooling cycle

1)

see note

Commis-

sioning Monthly Half-yearly Yearly

l

l

l

l l

l

l

l

l

l

l

l

l

l

l

l

l

l

1)

57

REMKO KWE

15 Index

A

Air bleeding valves ...................... 43

Anti-freeze protection .................... 41

C

Cabled remote control ....................46

Care and maintenance ................... 57

Characteristic curves ............ 20,

Commissioning ......................... 51

Compensators ..........................43

Compressor thermal contact ............... 48

Condensate drainage connection ........... 44

Condenser fan thermal contacts ............ 48

Configuration anti-freeze protection parameters 42

Connection of the medium piping ........... 36

Cooling capacity .................. 16, 17, 18

Crankcase heating, compressor ............ 46

Customer service ....................... 53

21, 22, 23

D

Description of the unit .................... 24

Diaphragm expansion vessel .............. 50

Diaphragm expansion vessel (MAG) ......... 43

Differential pressure switch ................ 48

Dirt trap ............................... 44

Disassembly of the transport pallet .......... 36

Disposal of equipment .....................6

Drain connection ........................ 44

E

Electrical components .................... 48

Electrical components and safety equipment .. 48

Electrical unit connection ..................46

Electrical wiring ......................... 45

Environmental protection ...................6

Error indication by code ...................56

External enabling configuration ............. 47

External enabling contact Operation / Standby . 46

External enabling, configuration ............ 47

External medium storage tank ..............44

F

Fill and drain connection .................. 44

Fill the system .......................... 49

Filling the system ....................... 49

Frost protection parameters, configuration .... 42

Function test for cooling operating mode ......51

G

General alarm signal ..................... 46

H

Hydraulic unit construction ................ 25

I

Installation .............................36

Installation diagrams ............ 37, 38, 39, 40

Installation location, selection .............. 32

Installation materials ..................... 32

Intended use ............................ 5

L

Leak testing ............................48

M

MAG - Diaphragm expansion vessel ......... 43

Maintenance ........................... 57

Malfunctions

Checks .............................53

Possible causes ...................... 53

Remedial measures ................... 53

Medium piping ..........................41

Medium piping, connection ................ 36

Medium storage tank, external ............. 44

Minimum / maximum flow volume ........... 41

Minimum clearances ..................... 35

Minimum medium volume, per unit .......... 41

O

Operational malfunctions ...............53

, 54

P

Phase sequence relay ....................48

Power supply .......................... 45

Pressure and temperature displays ..........41

Pressure loss .......................... 20

Pressure switch cooling cycle HP and LP ..... 48

Probe B4 medium inlet ................... 48

Probe B7 medium outlet .................. 48

R

Refrigeration unit construction ..............25

S

Safe drainage in the event of leakages ....... 44

Safety

Dangers of failure to observe the safety

notes ............................... 4

General ............................. 4

Identification of notes ................... 4

Notes for inspection .................... 5

Notes for installation ....................5

Notes for maintenance .................. 5

Personnel qualifications ................. 4

Safety notes for the operator ............. 5

Safety-conscious working ................4

Unauthorised modification ...............5

Unauthorised replacement part manufacture . 5

Safety valve ........................... 50

Safety valves ...........................43

Selecting the installation location ........... 32

Shut-off valves ......................... 43

Shutdown

Permanent .......................... 52

Temporary .......................... 52

Sound pressure level .................... 19

System layout .......................... 24

58

System pressure available,

High-performance pump ................23

High-pressure pump ...................22

Standard pump ...................... 21

System pressure, available

High-performance pump ................23

High-pressure pump ...................22

Standard pump ...................... 21

T

T

ransport pallets ........................ 36

Troubleshooting and customer service ....... 53

U

Unit description ......................... 24

Unit installation ......................... 36

V

V

alves for hydronic balancing ........... 41, 50

W

Warranty ............................... 5

Winter pressure controller (accessory) ....... 46

59

Consulting

Thanks to intensive training,
our consultants are always
completely up-to-date in terms
of technical knowledge. This has
given us the reputation of being
more than just an excellent,
reliable supplier:
REMKO, a partner
helping you find solutions to
your problems.

Distribution

REMKO offers not just a well
established sales network both
nationally and internationally, but
also has exceptionally highly­qualified sales specialists.
REMKO field staff are more than
just sales representatives: above
all, they must act as advisers to
our customers in air conditioning
and heating technology.

SFlbCustomer Service

Our equipment operates
precisely and reliably. However,
in the event of a fault, REMKO
customer service is quickly at
the scene. Our comprehensive
network of experienced dealers
always guarantees quick and
reliable service.

REMKO INTERNATIONAL

… and also right in your neighbourhood!
Make use of our experience and advice

We reserve the right to make technical changes, and provide no guarantee as to the accuracy of this data!

REMKO GmbH & Co. KG
Air conditioning and heating technology

Im Seelenkamp 12 D-32791 Lage
Postfach 1827 D-32777 Lage
Telephone [phone]
Telefax [phone]
E-mail [e-mail]
Website www.remko.de