KWL 130 (INOX), KWL 160 (INOX), KWL 180 (INOX),
KWL 220 (INOX), KWL 270 (INOX), KWL 320 (INOX),
KWL 370 (INOX)
KWL 130 H, KWL 160 H, KWL 180 H (INOX),
KWL 220 H (INOX), KWL 270 H (INOX),
KWL 320 H (INOX), KWL 370 H (INOX)
Air-cooled Chiller and
Air-cooled Chiller with Heat Pump function
Operation · Technology · Spare parts
Edition GB – C11
Contents
Safety notes
Environmental protection and recycling
Guarantee
Transport and packaging
System description
System configuration
Operation
Care and maintenance
Shut-down
Trouble-shooting and customer service
Installation instructions for qualified personnel
Installation
Condensate draining
and ensured discharge
4
4
4
5
5-6
7
7-13
14
14
15-17
18-20
21-25
25
Electrical connection
Electrical components
Electrical circuit diagram
Leak testing
Before commissioning
Commissioning
Unit dimensions
Characteristic curves
Exploded views
Spare parts lists
Technical data
Read these operating instructions carefully
before commissioning / using the device!
26-27
28
29-33
34
34-35
35-36
36
37-38
39/41
40/42
43-46
These instructions are an integral part of the system and must always
be kept near or on the device.
This operating manual is a translation of the German original.
Subject to modifications; no liability accepted for errors or misprints!
3
REMKO KWL (H)
Safety notes
Carefully read the operating
instructions before commissioning
the equipment for service. It
provides useful tips and information
as well as hazard warnings
to prevent injury or material
damage . Failure to follow the
directions in this manual can result
in endangerment to persons, the
environment and the equipment
itself and will void any claims for
liability.
■
Keep this manual and the
refrigerant data sheet near the
unit.
■ The unit should be set up
and installed only by qualified
personnel.
■ The installation, connection and
operation of the units and their
components must be carried
out in accordance with the
operating conditions stipulated
in this manual and comply with
all applicable local regulations.
■ Mobile units must be set up
securely on suitable surfaces and
in an upright position. Stationary
units must be permanently
installed for operation.
■ Modification of equipment
and components supplied by
REMKO is not permitted and
can cause malfunctions.
■ Equipment and components
may not be operated in areas
where there is an increased
risk of damage. Observe the
minimum clearances.
■ The electrical supply is to be
adapted to the requirements
of the equipment.
■ The operational safety of
equipment and components
is only assured if they are
fully assembled and used as
intended. Safety devices may
not be modified or bypassed.
■ Do not operate equipment
or components with obvious
defects or signs of damage.
■ All housing parts and openings
in the device, e.g. air intakes
and outlets, must be free of
foreign objects, fluids, or gases.
■ The equipment and components
must be kept an adequate
distance from flammable,
explosive, combustible, abrasive
and dirty areas or atmospheres.
■ Touching some parts of the
equipment can result in burns or
other injury.
■ Installation, repair and
maintenance work may be
carried out only by authorised
specialists. Visual inspections
and cleaning can be performed
by the operator as long as
power is disconnected from the
equipment.
■ To preclude any danger from
the equipment, take appropriate
hazard-prevention measures
when performing installation,
repair or maintenance work or
cleaning the equipment.
■ The equipment or components
are not to be exposed to any
mechanical stresses, extreme
levels of humidity or direct
sunlight.
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, e.g. using certified firms
and recycling specialists or at
collection points.
Guarantee
Prerequisite for any claims under
guarantee is that the that the ordering party or their representative
complete and return the "certificate
of guarantee" and "commissioning
report" to REMKO GmbH & Co. KG
at the time when the equipment
and that the said documents are
returned to REMKO GmbH & Co.
KG. Guarantee terms are listed in
the "General Business and Delivery
Conditions". Furthermore, only
the parties to a contract can strike
special agreements beyond these
conditions. In this case, first contact
the contractual partner.
4
Transport and
packaging
Intended use
The equipment is shipped in sturdy
transport packaging. Immediately
check the equipment on delivery
and make note of any damage or
missing parts on the delivery note
and inform the forwarding agent
and your contractual partner.
Claims under guarantee made at
a later date will not be accepted.
Depending on the model and the
equipment, the system is only
intended to be used as a chilled
water system for the cooling or
warming of the operating medium
water or a water-glycol mixture
within a closed cycle.
Any other use or use in a way that
dose not conform with the definition above is considered an incorrect use.
The manufacturer/supplier assumes no liability for damages
arising from the incorrect use of
the system or any part of it.
The user dose so at their own risk.
Using the system correctly means
working in accordance with the
operating manual, installation instructions and complying with the
maintenance requirements.
System description
In cooling mode, the unit (an air
to water chiller) takes heat out
of the operating medium to be
cooled, water or a mixture of
water and glycol, within a closed
medium circuit in the evaporator
(plate heat exchanger) and gives
it off to the closed cooling circuit.
As a consequence of the heat
exchange, the medium cools and
the refrigerant in the cooling circuit
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,
which, as a consequence of the
heat exchange, condenses the
refrigerant under high pressure to
a liquid. The air emerging at the
condenser heats the environment.
The liquid refrigerant is led by
7
means of a variable injector valve
back to the evaporator where the
circuit begins again.
In heating mode, an air-cooled
chiller with heat pump functions
(HP-function) can take up heat
from the ambient air in the finned
condenser and give it off to the
operating medium. A reversing
valve switches the cooling circuit
function.
A return temperature dependent,
adaptive control, which ensures
the unit's operation and all of the
safety functions, is used to control
the cooling or heating. A potentialfree contact provides for remote
enabling.
The unit is designed for outdoor
installation. Under certain circumstances, it can also be used indoors.
The unit cooling circuit comprises
an evaporator, compressor, thermal
injection valve, condenser, condenser fan, fan control system and
high and low pressure controllers
Units with heat pump function also
have a reversing valve and a collecting flask.
The medium circuit comprises
a circulation pump, expansion
vessel, safety valve and differential
pressure switch. A storage tank is
not mandatory.
Winter pressure controls, cabled
remote control, crank case heating, vibration dampers, heaters
for anti-freeze protection, external
medium storage tanks, glycol concentrate and a technical handover
are available as accessories.
5
REMKO KWL (H)
Construction
KWL 130 - KWL 220 Cooling mode
13
17
10
11
9
12
8
14
6
5
8
9
7
KWL 130 H - KWL 220 H
Cooling and heating mode
13
14
3
4
15
16
KWL 270 - KWL 370 Cooling mode
13
2
1
17
1111
1010
9
12
8
14
3
2
4
6
1
15
5
16
8
9
7
KWL 270 H - KWL 370 H
Cooling and heating mode
13
14
17
11
10
8
9
8
9
7
Legend:
1 Circulation pump
2 Manual bleeder
3 Plate evaporator
4 Differential pressure switch
5 Diaphragm expansion vessel
6 Safety valve
7 Compressor
8 Pressure monitor
9 Schrader valve
10 Fin condenser
11 Condenser fan
12 Filter dryer
13 Schrader valve
14 Thermal expansion valve cooling
15 Sensor medium intake
16 Sensor medium outlet
17 Fan control sensor
12
3
2
4
6
1
15
5
16
17
1111
3
2
4
1010
6
1
15
8
9
8
9
12
5
16
7
6
System configuration
System configuration
Indoor area 1
Condensate drain
Chilled water appliance
Infrared remote controlCabled remote control
Outdoor area
Condensate line (only
units with HP-function)
Indoor area 2Indoor area 3
Condensate drainCondensate drain
Condensate collecting pipe
Chilled water appliance
Room temperature control
Chiller
Chilled water appliance
Medium outlet
Medium intake
Operation
The system can be easily operated
via the fully automatic iChiLL
controller. If due to local conditions
programming via the internal
control can only be realised with
difficulty, the system can also be
controlled via a cabled remote
control (accessory) or an external,
v
Methods of operation
potential-free, enabling contact
(standard).
A centralised fault contact, part of
the standard equipment, can be
used for the external signalling of
a fault.
The unit is designed as a 2 conductor system.
The system has 2 medium pipes
(conductors: supply and return)
for cooling using a cold medium
(KWL) or heating using a warm
medium (units with HP function
KWL...H).
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.
NOTE
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 1975. That means the
escape of 1 kg of this refrigerant has an effect on global
warming that is 1975 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.
! CAUTION
If the letter "A" is shown in
the display with a two-digit
numeric code, there is a fault
in the chiller. (see chapter on
trouble-shooting and customer
service).
Enabling contact
On/OFF Cooling/Heating
(e.g. building management
system)
(Standard equipment)
Cable
remote control
(Accessories)
iChiLL controller
(Standard
equipment)
Centralised
fault signal
(Standard equipment)
TIP
Help save on energy consumption in stand-by mode! If the
device, system or component
is not in use, we recommend
disconnecting the power supply. Components with a safety
function is excluded from our
recommendation!
7
REMKO KWL (H)
Operating the controller
iChill adaptive
The controller has 3 modes:
1. Summer mode (cooling mode)
In cooling mode, the warmer medium temperature is cooled to the
preset, cooler target temperature.
2. Transition mode (heating mode)
SFlb(only units with HP function):
In heating mode, the cooler medium temperature is heated to the
preset, warmer target value.
3. Stand-By mode (Stand-by)
In the Stand-By mode, safety
equipment is active but no operating mode is set.
The controller is divided into a left
value display and a right
function display.
"M" key
With this key you reach the
function menu or can adjust
time and date.
"SET"
With this key the selection of a
target value or parameter can
take place.
"▼" key
Prolonged pressing (5 sec.)
allows switching between the
operating modes "Heating"
and "Stand-By" (units with HP
function).
By briefly pressing you can
change between medium
intake, outlet and condenser
temperature.
A value can also be reduced.
"▲" key
Prolonged pressing (5 sec.)
allows switching between the
operating modes "Cooling"
and "Stand-By".
By briefly pressing you can
change between outside air
temperature (accessory) and
defrost temperature. A value
can also be increased.
Control panel of the iChiLL controller
"▼ and SET" keys together
+
Simultaneously pressing ▼ and
"SET" enables a change of the
parameter level.
"▲ and SET" keys together for
longer than 5 seconds
+
Simultaneous, extended pressing of ▲ and "SET" enables
manual defrosting.
"Stand-By" icon
The LED indicates stand-by
mode.
"H / L Alarm"SFlb icons
indicates the fault message high
pressure (H) or low pressure (L).
Compressor 1 icon
The LED indicates that compressor 1 is in operation (illuminated). The LED flashes if the
compressor is in safety mode.
Compressor 2 icon
The LED indicates that compressor 2 is in operation (illuminated). The LED flashes if the
compressor is in safety mode.
General alarm LED
This LED, together with the
code, indicates the respective
fault.
Defrosting status LED
(only units with HP-function)
The LED indicates that the
defrosting cycle is in operation
(illuminated) in heating mode at
the fin condenser. The controller is calculating the necessary
defrosting time if the LED is
flashing.
The LED
Heating mode LED
(only units with HP function)
The LED indicates the selected
heating mode.
Cooling mode LED
The LED indicates the selected
cooling mode.
Value display
The value display shows current
values.
Parameter display
The parameter display shows
current values or parameters.
"bar" icon
indicates the value in "bar" for
accessories like "winter pressure
controller".
"Time" icon
indicates a value in a time unit.
The "Pump" icon
lights up, if the circulating
pump is triggered.
"Fan" icon
The icon lights up, if the condenser fan is triggered.
"Flow!" icon
indicates a medium flow which
is too high or too low.
"Menu" icon
illuminates if you are on the
parameter level.
Heater for anti-freeze protec-
tion LED
The LED provides information
about the operating status for
the anti-freeze protection heating medium.
"°C" icon
indicates a temperature value.
8
Key functions
/ Key
External enabling
Activate and/or deactivate the unit with the key
by pressing it for longer than 5 seconds. On the display screen
the current display of the the return temperature is shown.
min. 5 sec.min. 5 sec.
If a potential-free contect is used for the external enabling of the unit,
the controller shows "OFF" in the display and the display of the decimal
places blinks.
External contact
Enable open
External contact
Enable closed
The potential-free contact has precedence over operation through the controller. With the parameter CF 16 a negation of the contact can take place.
The normal display shows the current medium intake temperature and
the medium outlet temperature.
By pressing the key the condenser temperature (P63) can also be
read.
normal
display
short-term
temperature
medium intake
normal
display
short-term
short-term
temperature
medium outlet
condenser
temperature.
short-term
The unit has three modes: Stand-By mode, summer mode (cooling mode)
and transition mode (heating mode only for units with HP function). In
stand-by mode the stand-by display illuminates and the current values
are shown. All fault reports and anti-freeze protection resistors are active.
min. 5 sec.
min. 5 sec.
Operating mode
Stand-By
HEATING MODE
only KWL...H
COOLING
MODE
KWL and
KWL...H
min. 5 sec.
min. 5 sec.
Heating mode
Cooling mode
Attention: By changing the parameterisation a different functional
meaning of the display can be programmed!
9
REMKO KWL (H)
Adaptive cooling and heating function
If the programmed target temperature within the system is reached quickly or only a small share of cooling or
heating capacity is accepted by the internal equipment, the operating time of the compressor decreases. An operating time which is too short can have a negative long-term impact on the operation of the unit. The controller continuously calculates the "Adaptive target value SEtr", so that a minimum operating time and minimum
stand-by time of the compressor of 3 minutes can be assured. In the process, the switch-on and shut-off point
of the compressor changes (hysteresis). The unit remains at this operating point until the cooling or heating
capacity accepted in the internal equipment has changed.
The adjustment of the target value has the consequence that the medium temperature can fluctuate beyond
the normal measure depending on the acceptance of the cooling or heating capacity within the system. If this
fluctuation should be decreased, the medium volume should be increased above the minimum medium volume,
e.g. through an additional storage tank.
Adaptive cooling function
Adaptive target value
Compressor ON
Compressor OFF
Factory setting for hysteresis
Temperature
Medium intake
through sensor
Pb1
Adaptive heating function
Adaptive target value
Compressor ON
Compressor OFF
Factory setting for hysteresis
Temperature
Medium intake
through sensor
Pb1
Factory setting for target value
St01 = 12.5°C
B
St02 = 3.0°C
Adaptive hysteresis
Factory setting for target value
B
St04 = 3.0°C
Adaptive hysteresis
A
'St03 = 38.5°C
A
If the temperature at the medium intake exceeds the target
value, the compressor switches on (A) and cooling capacity
is generated. If the calculated operating time of the compressor falls below 3 minutes, an adjustment of the target
value is made. If the calculated operating time is longer
than 3 minutes, the current target value is kept. The medium temperature lowers and the compressor is switched
off when the shut-off point is reached (B).
If the temperature at the medium intake exceeds the
target value, the compressor switches on (A) and heating
capacity is generated. If the calculated operating time of
the compressor falls below 3 minutes, an adjustment of
the target value is made. If the calculated operating time
is longer than 3 minutes, the current target value is kept.
The medium temperature increases and the compressor is
switched off when the shut-off point is reached (B).
Programming target values
The input of the target values for summer mode (cooling mode) and the transition mode (heating mode only
for units with HP function) takes place on the user level. The following diagrams provide simplified illustrations
of the operating principles.
Target value input cooling mode
10
Using the SET key, the set value can be displayed during stand-by or
cooling mode. To change the set value, press the SET key for approx. 5
seconds. The display begins to blink. With the or keys the value can
be adjusted within the limits defined at the factory (St 05 + St 06).
St 05 = 10.0 °C Minimum target value cooling mode
St 06 = 18.0 ℃ Maximum target value cooling mode
Factory setting = 12.5 ℃
min. 5 sec.short-term
value inputopen program
part
short-term
storing
Target value input heating mode
Using the SET key, the set value can be displayed during stand-by or
heating mode for units with HP function. To change the set value, press
the key for approx. 5 seconds. The display begins to blink. With the
or keys the value can be adjusted within the limits defined at the
factory (St 07 + St 08).
St 07 = 36 °C Minimum target value heating mode
St 08 = 45 °C Maximum target value heating mode
Factory setting = 38.5 ℃
Query of the adaptive
target value
Display of the adaptive target value
min. 5 sec.short-term
value inputopen program
part
short-term
storing
During compressor operation the controller calculates the optimal operating time and stand-by time of the compressor. In order to query the
adaptive target value, please proceed as follows:
short-termshort-term
adaptive target
value
normal
display
normal
display
short-term
set target value
Querying operating statuses
Display of operating hours
The operating times can be queried at the menu level. The clock display
appears.
C1Hr = Operating hours compressor 1 in hours x 10
C2Hr = Operating hours compressor 2 in hours x 10
PFHr = Operating hours circulation pump in hours x 10
short-term3 seconds
normal
display
compressor 1
60 operating hours
circulation pump
70 operating hours
Operating hours can be reset at the menu level by pressing of the key
for 3 seconds.
11
REMKO KWL (H)
Querying the fault reports
(See chapter on troubleshooting and customer service)
Fault reset
In order to protect the unit from damage, the controller checks the components which are relevant for the safety of the unit by means of sensors for
temperature, pressure, configuration, etc. Through the display screen of the
controller a coded error message is shown as a fault code. The cause can be
determined by the code (see table "Coded fault reports").
After pressing the M code you reach the menu program and the
"MENU" display is activated. The following selections can be made:
1. Display and resetting of current faults
2. Display and resetting of operating hours
3. Remaining time until defrosting phase (only units with HP function)
4. Display of the fault record
5. Deletion of the fault record
The menu program is automatically closed after 15 seconds if the
controller is not actuated.
short-termshort-term
open ALrM
submenu
fault code A01
rSt = resettable
no = not resettable
fault code A07
Fault record
Fault acknowledgement
The controller can process up to 50 faults. The most important messages
are shown directly on the display, such as high pressure, low pressure
or differential pressure switch fault. Other faults are displayed and stored
in code (max. 50 faults).
open program
part
short-term
open ALoG
submenu
short-term
fault code A07
short-term
If more than 50 faults are displayed, the oldest fault is deleted. Stored
faults can be reset using a password.
short-term
short-term
12
open program
part
password input
open ALoG
submenu
short-termshort-term
fault code A07
short-term
open ArSt
submenu
Operating structure
< 2 sec.
Standard display
/
< 2 sec.
> 5 sec.
/
< 2 sec.
> 5 sec.< 2 sec.
Display of current values
Medium intake display
Current value (return)
Medium outlet display
Current value (supply)
Condenser display
Current value of condenser temperature or pressure (with winter
pressure controller accessory)
Menu without password
Current fault list
currently pending, nonresettable faults are displayed
with "no", resettable faults are
displayed with "rSt"; resetting
with the SET key.
Operating hours compressor 1
Value in hours, resettable after
maintenance, etc. by pressing the
SET key (5 sec.).
Operating hours compressor 2
Value in hours, resettable after
maintenance, etc. by pressing the
SET key (5 sec.).
Pump operating hours
Value in hours, resettable after
maintenance, etc. by pressing
the SET key (5 sec.).
Defrosting period
Value in min. and sec. until the
next defrosting interval
Parameter backup to
hotkey
Using a plugged-in hotkey
the current parameters of the
controller can be transferred to
the hotkey.
Reset fault list
Faults are displayed in the
sequence n01 (oldest) to n50
(most recent). Through input of
the password under "ArSt" the
list can be reset.
< 2 sec.
Display target values
Display target value cooling
Current target value in cooling mode
Display target value heating
Current target value in heating mode
Display adaptive target value
Current, adaptive target value
Change target values
C/H target value change
Value change in cooling
between 10.0 and 18.0 and in
heating between 36.0 and 43.0
with the key /, save with
"SET".
+
Open configuration
+
Close configuration
Open submenu/value
Close submenu
Value/parameter up
Value/parameter down
> 5 sec.
+
+
< 2 sec.
Param.level 1 without password
St 01 Target value cooling
St 02 Hysteresis cooling
St 03 Target value heating
St 04 Hysteresis heating
Sd 01 Dyn. target value configuration
Sd 02 Shut-off dyn. target value C
Sd 03 Shut-off dyn. target value H
Sd 04 Outside temp. sensor target value C
Sd 05 Outside temp. sensor target value H
Sd 06 Outside temp. sensor hysteresis C
Sd 07
Outside temp. sensor Hysteresis H
Pr2 Password
ES 01 Switch-on time
ES 02 Shut-off time
ES 03 Activation Monday
ES 04 Activation Tuesday
ES 05 Activation Wednesday
ES 06 Activation Thursday
ES 07 Activation Friday
ES 08 Activation Saturday
ES 09 Activation Sunday
ES 10 Target value cooling
ES 11 Hysteresis cooling
ES 12 Target value heating
ES 13 Hysteresis heating
Pr2 Password
Pr2 Password
Pr2 Password
Ar 03 Target value anti-freeze protection fault C
Ar 04 Hysteresis anti-freeze protection fault C
Ar 08 Target value anti-freeze protection heating C
Ar 09 Target value anti-freeze protection heating H
Ar 10 Target value cooling W/W
Ar 11 Hysteresis cooling W/W
Ar 12 Hysteresis heating W/W
Ar 13 Config. anti-freeze protection heating
Ar 14 Config. Cooling
Ar 20 E-heating active/operating mode
Ar 21 Target value air temp. active
Ar 22 Hysteresis air temp. active htg
Ar 24 After-run time E-heating 2
Ar 25 Target value air temp. active compr.
Ar 26 Target value air temp. locked compr.
Ar 27 Target value anti-freeze protection fault H
Ar 28 Hysteresis anti-freeze protection fault H
Ar 29 Target value external pump W/W
Ar 30 Hysteresis external pump W/W
Ar 31 Pump active/operating mode
Ar 32 Pump active/operating mode
Pr2 Password
dF 02 Defrosting input parameter
dF 03 Target value defrosting start
dF 04 Target value defrosting end
dF 05 Min. operating time before
defrosting start
dF 06 Minimum defrosting time
dF 07 Maximum defrosting time
dF 10 Min.time defrosting interval
dF 11 Target value defrosting begin (df 10)
dF 12 Target value defrosting (dF 10)
dF 16 Active fault low temperature
dF 19 Target value forced defrost. begin
dF 20 Hysteresis forced defrost. begin
Pr2 Password
Pr2 Password
Param.level 2 with password
All parameters of
the Submenus:
St, CF, Sd, ES, CO,
Ar, dF
All parameters
Input
Password
13
REMKO KWL (H)
Care and maintenanceShut-down
Regular care and observation
of some basic points will ensure
trouble-free operation and a long
service life.
! CAUTION
Prior to performing any
work, ensure the equipment
is isolated from the voltage
supply and secured to prevent
accidental switch-on!
Care
■
Ensure the unit is protected
against dirt, mould and other
deposits.
■
Clean the unit using a damp
cloth.
Do not use a jet of water.
■
Do not use any caustic, abrasive or solvent-based cleaning
products.
■
Clean the fins on the unit prior
to long shutdown periods.
Maintenance
■ We recommend
maintenance contract with annual maintenance interval with
an appropriate specialist company.
TIP
This ensures the operational
reliability of your
at all times!
NOTE
The law requires a leak test of
the cooling circuit with regard
to the quantity of cooling
medium. Inspection and documentation is to be carried out
by specialty technicians.
Temporary shut-down
1. Shut down the interior units
using the remote control.
2. Shut the unit off over the
internal control in the chiller (or
using the remote control).
3. Check the proportion
(percentage) of glycol.
4. Check the unit for visible signs
of damage and clean it as
described in the chapter "Care
and maintenance".
5. As much as possible, cover the
unit with a plastic foil to protect
it against the weather.
! CAUTION
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!
Type of task
Checks / maintenance / inspection
General
Clean dirt traps
Check medium filling
Check circulation pump
Dirt / damage condenser
Check quality of the glycol
Measure voltage and current
Check direction of rotation
Check compressor
Check fan
Check refrigerant fill quantity
Check condensation drain
Test insulation
Sealing test for refrigerant circuit
1) see note
14
Commis-
sioning
Monthly
Half-yearly
•
••
••
••
••
••
••
••
••
••
••
••
••
• •
Yearly
Permanent
shut-down
Ensure that equipment and
components are disposed of in
accordance with local regulations,
e.g. using certified firms 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
1)
near you.
Trouble-shooting and customer service
The unit has been manufactured using state-of-the-art production methods and tested several times to ensure its
correct function. If malfunctions should occur, please check the unit as detailed in the list below. For installations with
an indoor unit and outdoor unit, observe the chapter "Troubleshooting and customer service" in both operating
manuals.
Please inform your dealer if the unit is still not working correctly after all the function checks have been performed.
Malfunctions
FaultEffectPossible causeRemedial measures
Check the current connections at the
general supply terminals and the voltage
No power supply
Display is not illuminated
values.
Check breaker switches/fuses at the
secondary side of the supplemental
transformer.
The unit
does not
start
The unit
is working
with
reduced
cooling/
heating
capacity
Incorrect phase sequence.
The KA3 phase sequence relay
did not enable.
The display is illuminated but
he unit does not start
The display shows OFFNo external enabling
The unit does not start, the
compressor icon in the display
is flashing.
The lower display flashes
and alternately shows an
alphanumeric code and the
temperature value.
xxx
A03Insufficient temperature medium intakePB1x
A04Insufficient temperature medium outletPB2x
A05Excessive temperature condenserxxx
A06Excess temperature condenser
<2/hrs <2/hrs
xxx
A07Anti-freeze protection has respondedxxxx
A08Differential pressure switch has responded
<2/hrs <2/hrs
xxxx
A09Excess temperature compressor 1x
A10Excess temperature compressor 2x
A11Excessive temperature condenser fanx
A12Defrosting period exceededxdF07
A13Maintenance interval compressor 1Co14
A14Maintenance interval compressor 2Co15
A15Maintenance interval circulation pumpCo16
1. Faults with automatic reset: The resetting of the alarm takes place automatically.
2. Faults with manual reset: The resetting of the alarm can only be carried out by a specialist after the fault has been corrected.
3. Faults with semi-manual reset: The reset is first carried out automatically, afterwards only a manual reset is possible by a specialist,
after the fault has been corrected.
Anti-freeze
heating, cooling
medium
17
REMKO KWL (H)
Installation instructions for qualified personnel
■
Important information
before installing
■
Observe the manuals for the
cold water user (indoor units)
and chiller or heating system
when installing the entire
system.
■
The interior units user and the
chiller work independently. A
connection between the two is
not necessary.
■
Transport the unit in its original
packaging as close as possible
to the installation location.
This avoids transportation
damage.
■
The units may only be moved
as installed (upright) using
appropriate transport gear
(Figure 1).
Secure against tipping!
■
The unit must be kept upright
when transporting to a higher
elevation (Figure 2).
■
Check that the packaged
contents are complete and
inspect the unit for any visible
signs of transportation damage.
Report any damage
immediately to your contracting
party and the shipping
company.
Lift the unit only at intended
lifting points. Never stress the
medium or refrigerant piping.
■
The medium connection lines,
valves and connections must
be insulated against vapour
diffusion. If necessary, also
insulate the condensate line
(only units with HP-function).
In dual systems with cooling
and heating modes, the
requirements of the current
Energy-Savings-Ordinance
(EnEV) are to be complied with.
■
Seal off open lines against dirt
and never kink or crimp the
lines.
■
Avoid unnecessary bending.
■
Establish all electrical
connections connections in
accordance with the relevant
DIN- and VDE standards.
■
Always fasten electric wiring
properly to the terminals,
otherwise there is a risk of fire.
■
Comply with all regulations
governing structural and
building requirements and
conditions with regard to the
installation site.
■
In the selection of the
installation site, pay attention
to the site itself and to any
possible acoustic reflection from
surrounding units.
■
To avoid the transmission of
vibrations to the 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.
■
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.
2 Correct way to lift
Lifting point
■
Select an installation location
which allows air to freely
flow through the intake and
outlet. See section "Minimum
clearances".
■
Do not install the unit in the
immediate vicinity of devices
with intensive thermal radiation.
Installation near thermal radiation
reduces the unit output.
18
1 Correct way to move
Wall openings
■
We recommend that the inside
of the opening be padded or
lined for example with a PVC
pipe to prevent damage to the
lines.
■
After installation, the wall
opening should be closed off
with a suitable sealant. Do not
use materials containing cement
or lime!
Installation material
The unit is fastened on vibration
dampers (accessories) to the floor
by means of bolts. The carrying
capacity of the console and the
wall must be taken into account
when fastening to the wall.
Selection of 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
toppling.
The unit can be installed outside as
well as inside a building.
In the case of outdoor installation,
please follow the instructions given
below to protect the unit against
the weather.
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 can be accomplished with
a small roof covering.
However, the discharging warm air
flow may not be affected by the
measures.
Wind
If the unit is being installed where
it is windy, care must be taken that
the discharged warm air is carried
off in the prevailing wind direction.
If this is not possible, it may be
necessary to install a windbreak
on-site (Figure 3).
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 then be at
least 20 cm above the expected
level of snow to prevent snow
from getting into the outdoor unit
(Figure 4).
Installation inside buildings
■
Ensure that heat can dissipate
adequately when placing the
outdoor unit in cellars, attics,
adjoining rooms or halls (figure 5).
■
Install an additional fan with
the same air flow as that
of the outdoor unit being
installed in the room which
can compensate any additional
pressure losses with ventilation
ducts (Figure 5, Page 20).
■
Ensure a continuous and
unobstructed air flow from
outside, preferably using
sufficiently large air openings
(Figure 5, Page 20).
NOTE
Cooling or heating performance changes as a consequence of the ambient conditions influenced by rain, sun,
wind, and snow.
Rain
The unit should be at least 10 cm
off the ground when mounted on
the roof or ground. when mounted
on the roof or ground.
For cooling and heating units (only
HP-function) elevated installation
increases the generated heat
capacity.
Sun
The finned condenser gives off
heat in cooling mode.
3 Windbreak
Wind
4 Minimum clearance to snow
Snow
20 cm
19
REMKO KWL (H)
■
Comply with any regulations
and conditions affecting the
structure of the building. If
necessary, use sound reducing
material.
5 Installation inside buildings (cooling mode)
Warm air
Cold
Fresh air
Additional
Fan
Minimum clearances
The following illustration indicates
the minimum clearances for trouble-free operation of the system.
These protection zones serve to
ensure unrestricted air intake and
discharge, as well as providing sufficient room for performing maintenance and repairs and preventing the unit from being damaged.
Light
well
KWL 130(H) -
A350350800
B1500800800
C600800800
D350800800
E50018001800
220(H)
Warm air
Chiller
KWL 270(H) -
320(H)
Light
well
KWL 370 (H)
All values in mm
Minimum clearances
KWL 130(H) - 220(H)KWL 270(H) - 320(H)KWL 370 (H)
E
E
A
B
20
A
D
C
B
D
C
A
B
E
D
C
Installation
NOTE
Installation may only be
undertaken by authorised
personnel.
Transport packaging
Unit installation
1. Install the vibration absorbers
(accessories) under the system
(Figure 6).
2. Attach the unit to the building
Separating the
Transport pallet
The system is supplied with a pallet
where structurally permitted.
3. Ensure that structure-borne
noise is not transferred to other
parts of the building.
for the purpose of transportation.
Remove this before installation.
Load point A4041586246485841436165484961
Load point B4041687251546142437176545564
Load point C4041606156586941436464596172
Load point D4444697548505646477280515159
Load point E----535564----555667
Load point F----555972----586075
E
F
KWL
130
KWL
160
B
D
KWL
180
KWL
220
KWL
270
KWL
320
KWL
370
KWL
130H
KWL
160H
KWL
180H
KWL
220H
KWL
270H
KWL
320H
All values in kg
D
KWL
370H
21
REMKO KWL (H)
Connection of the
medium piping
■
The connection of the lines
on-site takes place on the front
side of the unit.
■
For the purpose of servicing,
connections must be equipped
with shut-off valves and flow
volumes adjusted using pipe leg
regulating valves.
■
Additional automatic bleed
valves are to be provided in the
supply and return at the installation's highest point.
■
The medium piping may not
exert any structural load on the
unit.
■
The line connections may not
generate any thermal or mechanical stresses on the unit.
If necessary cool line or support
with the second tool.
Necessary system components
Diagram of the System components
KWL 130(H) - 370(H)
KWL 130(H) - 370(H) with external medium storage tank (accessory)
■
If the unit is at first to be operated with only a part of the
entire system, the medium flow
for the missing system components is to be simulated using
a pipe leg regulating valve.
■
The pipe sizing is to be designed so that the required
minimum flow volume is not
under-cut.
! CAUTION
A permanent large flow volume
must be ensured to realise the
minimum flow volume.
KWL 130 (H) - 370 (H) with external medium storage tank (hydr. switch)
8 Safety valve
9 Circulation pump
10 Valve for hydronic balancing
11 Diaphragm expansion vessel
12 Bleeding valve
13 Medium storage tank (accessory)
KWL 270(H) - 370(H)
free pipe
routeing
possible
22
no pipe
routeing possible
No pipe routeing possible
Minimum/maximum medium flow
The chiller`s circulation pump generates a constant medium flow;
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 minimum flow volume is undercut.
The medium flow limit may likewise not be exceeded (maximum
flow volume).
A 3-way valve with bypass and
a hydraulic switch to establish a
primary and secondary circuit or
a volume dependent bypass are
necessary to ensure a constant
flow volume.
Minimum medium volume, of the
system
As a consequence of the adaptive
controller a storage tank is not
mandatory. However, the minimum medium volume may not be
fallen short of in order to ensure
fault-free operation of the unit.
NOTE
To regulate the circulation pump
we recommend a main
pipe regulating valve near the unit.
! CAUTION
Medium piping
Medium piping can be made of
copper, steel or plastic. To minimise
pressure losses, only streamlined
fittings should be used.
When designing the layout, the
large flow volumes 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 EnergySavings-Ordinance (EnEV) must to
be observed. UV resistance must
be realised outdoors.
Pressure gauge and thermometer
The pressure gauge and thermometer to be installed on-site at
the intake and outlet serve to set
the medium flow. The display
should mean shut down In the
system there are temperature
sensors in the medium intake and
medium outlet.
The temperature at the probes can
be seen on the controller.
Valves for hydronic balancing
Through valves for hydronic balancing to be installed on-site,
individual pressure losses of each
individual unit in the pipeline
network design must be adjusted
to the entire system. The nominal flow volumes for the medium
adjust to the necessary values as
a consequence of the pressure loss.
Frost protection (accessories)
As a medium for a cold water
system, a water-glycol mixture
is used as a rule. 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 antifreeze 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.
During use and
disposal the product and safety
data sheets of the glycol type
which is used must be observed.
! CAUTION
Use the required type and
mixture to ensure the freezing
point.
Propor-
tion
glycol
Vol. %°CK
00111,01211
20-90,9810,9881,0121,0401,19
35-210,9710,9821,0181,0901,35
40-260,9680,9811,0191,1051,51
Frost
protection
+-2°C
Cooling
capacity
L
Correction factors when using a
mixture of glycol * and water
Compressor capacity
Cooling Heating
K
P cooling
K
P heating
Flow
volume
K
V
* We recommend using an ethylene glycol mixture. Observe the safety and
product data sheets for the glycol type being used.
Pressure
loss
K
D
23
REMKO KWL (H)
Configuration parameter Ar 03
5 seconds
Configuration antifreeze protection parameters
It can be necessary to reconfigure the anti-freeze protection parameters
when using a water-glycol mixture. In the menu item Ar the parameter
Ar 03 can be changed within the limits of parameters Ar 01 and Ar 02
without password input.
Factory setting:
Lower anti-freeze protection setting Parameter Ar 01 = +3°C
Upper anti-freeze protection setting Parameter Ar 02 = +7°C
Activation anti-freeze protection fault Parameter Ar 03 = +4°C
The following program sequence must be programmed.
short
short
shortshort
change value5 seconds
short
short
If a lower anti-freeze protection setting below the possible limits of parameter Ar 01 is necessary, a lower setting can be made after password
input. For this purpose, please contact REMKO. The following values
must then be input:
0% Ethylene
glycol
(Factory setting)
Value Ar 013°C-2°C-6°C-15°C-19°C
Value Ar 034°C0°C-4°C-13°C-17°C
10 % Ethylene
glycol
(Password)
20 % Ethylene
glycol
(Password)
30 % Ethylene
glycol
(Password)
short
35 % Ethylene
glycol
(Password)
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.
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 coolingheating 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 parts of the system.
Safety valve
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 intake and
medium outlet must be equipped
with shut-off valves (if necessary
safety valves).
Air bleeding valves
The unit has manual air bleeding
valves. The unit can be vented
separately after the system
has been filled. Automatic air
bleeder must also be installed at
the highest point in the collective
lines.
! CAUTION
Glycol suitable valves are
necessary when using medium
that contain glycol.
Compensators
Shut-off valveCompensator
Structural
fastening
KWL
connection
24
+
+
+
+
Fill and drain connection
Condensate draining and
ensured discharge
A connection should be provided
in an area safe from frost for the
draining of the pipe lines (especially if water is used as a medium).
Applicable local disposal regulations must be observed if glycol is
used.
Dirt trap
A self cleaning dirt trap must be
installed on the intake side of the
unit. The mesh size should not be
less than 10 mesh/cm². Shutoff
valves should be installed on both
sides of the dirt trap.
! CAUTION
Improperly installed or missing
dirt traps can cause fouling of
the plate heat exchanger.
External medium reservoir
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 reservoir
installed to increase compressor
operating time.
A reservoir should, as a rule, be
provided if the minimum medium
volume is not reached.
Condensate connection
If the temperature falls below the
dew point, condensation will form
on the finned condenser during
heating operation.
A condensate pan should be installed on the underside of the unit
to drain any condensate.
■
The condensate line to be installed on-site must be installed
with a pitch of at least 2 %.
If necessary, fit vapour diffusion
tight insulation.
■
When operating the unit at
outdoor temperatures below
4 °C, care must be taken that
the condensate line is antifreeze protected. The lower part
of the housing and condensate
pan is also to be kept frost free
in order to ensure permanent
draining of the condensate.
If necessary, fit supplementary
pipe heating.
■
After completed installation,
check that the condensate run
off is unobstructed and ensure
that the line is durably leak
tight.
Condensate drain
+
+
Condensation tray
Condensate drain
NOTE
Cumulative ice formation in
the lower part of the finned
heated exchanger can develop
under certain weather conditions. To prevent this ice
formation, we recommend
keeping the heat exchanger
frost free on both sides using
a heating band for example.
Ensured discharge in the event of
leakage
Local regulations or environmental laws, for example the German
Water Resource Law (WHG), can
require suitable precautions to protect against uncontrolled draining
in case of leakage to provide for
safe disposal of escaping refrigerator oil or hazardous media.
NOTE
Malfunctions can result if the
minimum medium volume is
undercut.
25
REMKO KWL (H)
Electrical connection
■
! CAUTION
All electrical installation work
is to be performed by specialty
companies. Disconnect the
voltage supply when connecting the electrical terminals.
■
The power supply is made at
the chiller; a control cable to
the interior unit is not necessary.
■
An all pole separating switch,
which activates individual phase
conductors in the event of
a malfunction, must be installed
in the supply line upstream
from the unit.
■
Electric connections must be
carried out as fixed connections
in accordance with the applicable regulations.
■
Check all terminal points for
stability.
■
The supply line must be adequately insulated on-site
and the voltage drop may not
exceed permissible values.
■
Make sure that the electrical system is adequate for the
operation of the unit and and
can supply the operating current necessary for other already
operated units.
■
Determine before installation,
when connecting to existing
system components, whether
the unit's service connection is
adequately sized for the unit's
rated input.
■
The connection of the units
must always be carried out with
adequately sized, low-resistance
protective earthing conductors
and if necessary more than
once (especially with plastic
tubing).
■
When installing the units on
flat roofs, lightning protection
measures may be necessary.
All electrical connections such
as network supply, cable remote
control etc. must be carried out
in the unit's switch cabinet.
■
The lines to be installed are to
be pulled into the switch cabinet through the cable conduits.
■
An electrician must determine
the sizing and selection of the
fuses and the cross section of
the the lines to be installed.
Note that starting current may
be up to 10 times nominal current.
The following electrical connections must be provided:
■
Connection to the power supply.
■
Possible enabling contact for
the set mode or stand-by.
■
Possible operating mode
contact for cooling or heating
mode (units with HP-function)
■
Possible connection of a winter
pressure controller (accessory)
■
Possible connection of crank
case heating (accessory).
■
Possible connection of a cable
remote control
(accessories).
■
Possible connection of antifreeze protection heating medium (accessory, factory installation only).
! CAUTION
Check all plugged and
clamped terminals to verify
they are seated correctly and
make a permanent contact.
Tighten as required.
Power supply
The unit requires a fixed three
phase alternating current connection. The mains connection is to be
connected to the L1, L2, L3, N and
PE terminals.
NOTE
We recommend the use of safety
fuses.
Please proceed as follows to connect:
1. Open the control panel and
switch cabinet cover by
removing the screws and
lifting off the cover.
2. Feed the voltage-free cable
through the conduits into the
switch cabinet and clamp the
cable to the strain relief.
3. Then connect the cable in accordance with the connection
diagram.
In addition to being operated with
the controller or the cable remote
control, the unit can be switched
on (normal mode) and switched
off (Stand-By) over an external potential free contact (programmable
as opener or closer) (Figure 7).
The controller must be configured
if a closer is used for the external
enabling.
26
(See section "Configuration external enabling").
This enable is used for example to
realise standstill times at night or
for the activation/deactivation of
a building control system.
General fault signal
(Standard equipment)
The connection of a potential free
general fault 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 (Figure 8).
Winter pressure controller
(Accessories)
It serves for the expansion of the
operating range in cooling mode
from +15 °C to -15 °C. The set
consists of crank case heating and
the pressure controller. Use respective installation instructions for this
purpose.
Crankcase heater
Compressor (standard/accessory)
External operating mode contact
Cooling mode/heating mode
(units with HP-function)
By default, the unit is programmed
to be operated using the controller
or cable remote control. If a switch
from cooling or heating mode is
to be carried out over an external
potential free contact (intake),
(Figure 7), the CF 28 parameter
must be reprogrammed to 1 (programming see section "Configuration external enabling"). Only the
external enabling cooling/heating
mode can be used after switching.
Configuration parameter CF 16
8 External potential free contacts
The heating serves for the expansion of the operating range
in cooling mode from +15°C to
Unit
+5°C. For this purpose, use the
respective installation instructions.
For units with HP function this is
factory-installed.
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.
External enabling configuration
With the use of a normally open contact as an external contact a parameter of the controller must be reconfigured. The parameter CF 16 must
be switched from 0 to 1. If this does not happen, the controller does not
recognise the external contact as a normally closed contact. In the menu item CF the parameter CF 16 can be changed in Level 2. The following
program sequence must be programmed.
5 sec.short
short
■
After the programming, "stand
by" mode is activated with the
contact open between terminals
2 and 3.
Display = OFF.
short
short
short
change value
■
After the programming the
"cooling mode" is activated
with a closed contact between
terminals 2 and 3.
Display = temperatures
short
27
REMKO KWL (H)
Electrical components
Electric components and safety
equipment
Pressure switch cooling cycle HP
and LP
There is a high pressure switch
(HP) on the heat gas side within
the cooling cycle to switch off the
unit in the event of a temperature
increase.
A low pressure switch (LP) on the
suction side or in the compressor
switches off the unit if the
refrigerant charge is too low.
Differential pressure switch
The differential pressure switch is
installed parallel to the evaporator
in the medium circuit. It measures
the pressure differential between
the intake and outlet pressure and
switches the unit off when the
minimum flow volume is fallen
short of or with extremely large
flow volumes.
Thermal contacts
Condenser fans
The condenser fan's thermal contacts prevent overheating of the
motors.
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
voltage supply. The controller will
not be enabled if the direction of
rotation is wrong.
Low noise fan control board
With a modulating output voltage,
the condenser fan's speed can be
adjusted to the condenser temperature and in this way hold the
noise level to a minimum.
The iCHiLL controller determines
the current condensation temperature at the condenser through the
sensor Pb 3. The target value is
then regulated over the fan control
board.
Sensor Pb 1 medium intake
The sensor is located at the unit's
medium intake (system return).
It serves to capture the current
temperature to control the target
value.
Sensor Pb 2 medium outlet
The sensor is located at the unit's
medium outlet (system supply).
It serves to capture the current
temperature and regulate the antifreeze protection temperature.
Sensor Pb 3 fan controller
The sensor is located on the cooling circuit's condenser. It detects
the current condensing temperature in cooling mode for the lownoise fan controller.
Measurement
temperature
°C
-2067770 Ω
-1553410 Ω
-1042470 Ω
-533900 Ω
027280 Ω
+522050 Ω
+1017960 Ω
+1514690 Ω
+2012090 Ω
+2510000 Ω
+308313 Ω
+356940 Ω
+405827 Ω
+454911 Ω
+504160 Ω
+553536 Ω
+603020 Ω
+652588 Ω
+702228 Ω
+751924 Ω
+801668 Ω
+851451 Ω
+901266 Ω
+951108 Ω
+100973 Ω
Sensor resistance value
NTC 103 AT
28
Electrical circuit diagram
KWL 130(H) - 160(H)
Fan controller
KWL 130(H) - 160(H)
Compressor
Circulation pump
Condenser
fan 1
Condenser
fan 2
Probe
Intake
Probe
Outlet
Probe
LN-contr.
Pressure transducer
pressure reg.
(Accessories)
High
pressure
switch
Low pres-
sure switch
Diff.press.
switch
2-3 External enabling
4-5 General fault signal
2-6 Cooling-heating switching
7 12V
8 0V
9-10 Cable remote control
29
REMKO KWL (H)
KWL 130(H) - 160(H)
KWL 180(H) - 320(H)
Anti-freeze heating, cooling medium
(Accessories)
Reversing valve
(only KWL...H)
CW heater
(Accessories)
Fan controller
30
CompressorCirculation pump
Condenser
fan 1
Condenser
fan 2
KWL 180(H) - 320(H)
Probe
Intake
Probe
Outlet
Probe
LN-contr.
Pressure transducer
pressure reg.
(Accessories)
High
pressure
switch
Low pres-
sure switch
2-3 External enabling
4-5 General fault signal
2-6 Cooling-heating switching
7 12V
8 0V
9-10 Cable remote control
Diff.press.
switch
KWL 180(H) - 320(H)
Anti-freeze heating, cooling medium
(Accessories)
Reversing valve
(only KWL...H)
CW heater
(Accessories)
31
REMKO KWL (H)
KWL 370 (H)
Fan controller
KWL 370 (H)
Compressor
Circulation pump
Condenser
fan 1
Condenser
fan 2
Condenser
fan 3
Condenser
fan 4
32
Probe
Intake
Probe
Outlet
Probe
LN-contr.
Pressure transducer
pressure reg.
(Accessories)
High
pressure
switch
Low pres-
sure switch
Diff.press.
switch
2-3 External enabling
4-5 General fault signal
2-6 Cooling-heating switching
7 12V
8 0V
9-10 Cable remote control
KWL 370 (H)
Legend:
A1 iChiLL controller
A2 Fan controller
B1 Probe medium intake
B2 Probe medium outlet
B3 Probe fan controller
B4 not used
EV1 Reversing valve
FL Differential pressure switch
Anti-freeze heating, cooling medium
(Accessories)
HP High pressure monitor
KA3 Phase sequence relay
LP Low pressure monitor
M1 Compressor
M2 Circulation pump
M3 Condenser fan 3
M4 Condenser fan 4
M10 Condenser fan 1
Reversing valve
(only KWL...H)
M11 Condenser fan 2
RC1 Compressor crank case heating
TA Transformer 230/12V
TR 3 not used (accessory - pressure transducer)
TX1 Thermal contact fan 1
TX2 Thermal contact fan 2
CW heater
(Accessories)
Component equipment
KWL 130KWL 160KWL 180KWL 220KWL 270KWL 320KWL 370
KM 15.5kW-AC35.5kW-AC37.5kW-AC311kW-AC311kW-AC315kW-AC315kW-AC3
KM 24kW-AC34kW-AC34kW-AC34kW-AC34kW-AC34kW-AC34kW-AC3
QM 116A-D320A-D320A-D320A-D325A-D332A-D340A-D3
33
REMKO KWL (H)
Before
Leak testing
Leak testing is carried out after all
the pipes and fittings have been
connected.
1. Flush the system twice with
water.
2. Clean the sieve insert of the dirt
trap provided by customer.
3. Fill the system with water again
and vent the system at the
manual air bleeder.
4. Adjust the test pressure to
250 kPa (2.5 bar).
5. Check the connections after a period of 24 hrs for leaking water.
If water is visible, the connection
has not been secured.
Tighten the connection or make a
new connection.
6. After a successful leak test, remove the excess pressure from
the medium line. If a waterglycol mixture is used, adjust
the non circulating pressure as
required.
commissioning
Filling the system
The system is filled on-site at the
filling and draining connection.
Anti-freeze protection for the medium
If a water-glycol mixture is used,
it is to be pre-mixed 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 (0.1bar) per metre
difference in altitude (geodetic
altitude). The value measured at
the highest point is identified as
the standstill 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 is to be set to at least
70 kPa (0.7 bar)
■
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 (0.1bar) x geodetic system
altitude.
■
If the unit is positioned at the
highest point in the system,
the unit preliminary pressure
(=standstill 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!
Bleeding the system
■
Air may still be in the pipe
lines after the leak test. This is
carried during operation of the
circulation pump to the next
highest point or to the cold
water drain. Here it is necessary
to vent again (Figure 10).
■
Also vent the pump if necessary.
■
The standstill pressure must
then be adjusted to the required system pressure.
10 Manual bleeding
.
9 Unit preliminary pressure
Unit preliminary
pressure
34
Geodetic
System altitude
Non-circulating
pressure
Unit preliminary
pressure
Manual
bleeder
MAG
■
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.
■
If necessary, change the installation site. For this, the manufacturer's authorisation is required.
■
For cooling and heating systems, the volume and the
preliminary pressure for the diaphragm expansion vessel must
be adjusted to both operating
modes; integrate an additional
diaphragm expansion vessel in
the system if necessary.
Valves for hydronic balancing
■
The calculated excess pressure
in the pipe network layout at
the individual cold water outlets
must be adjusted in the pipe leg
regulating valves.
Safety valve
■
The safety valves and their correct function must be checked.
■
The drain line for the valves are
to be checked for function and
leak tightness.
■
If necessary, change the installation site. For this, the
manufacturer's authorisation is
required.
Additional checks
General checks
■
Checking that minimum clearances are correct.
■
Check the outlet possibility of
cooling and heating capacity over the cold or hot water
outlet (indoor unit).
Electrical checks
■
Checking electrical connections
for correct phase sequencing.
■
Function check of the enable
mode / Stand-By (option).
Checking the medium cycle
■
Check the circulating pump for
free flow.
■
Check that all valves are open.
■
Check the medium cycle.
■
Set the circulation pump’s flow
volume.
Checking the cooling cycle
■
Checking the cooling cycle for
adequate oil/coolant.
■
Check the cooling cycle for
leaks.
NOTE
The systems are equipped
with a phase sequence relay
which prevents the operation
of the controller if the phrase
sequence for the electric mains
connection is wrong.
The phrase sequence must be
corrected if the controller is
not activated during
commissioning.
NOTE
During manual bleeding, escaped glycol mixtures must be
disposed of separately.
Commissioning
NOTE
Commissioning should only be
Carried out by trained personnel and after certification to be
documented.
■
Observe the manuals for the
unit and all other components
when commissioning the entire
system.
Working test for cooling
mode
1. Switch the power supply on.
2. Open all shut-off valves if
necessary.
3. Switch the system and the corresponding circulating pump on
to the highest stage.
The outlet temperature must lie
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 blink
and the compressor will begin
to work after approx. 3 to 5
minutes.
5. Please note that the supply
temperature at the nominal
medium flow lies approx. 5 K
below the return temperature.
- If the supply temperature falls
below the factory setting of
4°C, a fault signal is triggers. If
this is the case, a higher target
temperature must be selected.
If the spread is too great or too
small, the medium flow must
be checked.
6. Measure and record all the
required values in the commissioning report and check the
safety functions.
■
Function check of the cooling
mode/heating mode enable
(option).
7. Check the system control using
the functions described in the
“Operation” chapter.
35
REMKO KWL (H)
Working test for heating
mode
(only units with HP-function)
1. Switch the power supply on.
2. Open all shut-off valves if necessary.
3. Switch the chilled water system
and the corresponding circulating pump to the highest stage.
The outlet temperature must lie
between +35 and +45°C.
4. Switch the unit on and select
the heating operating mode.
If the return temperature is
colder than the setting, the
compressor display will blink
and the compressor will begin
Unit dimensions
KWL 130(H) - 160(H)
to work after approx. 3 minutes.
5. Please note that the supply
temperature at the nominal
medium flow lies approx. 5 K
above the intake temperature.
- The circulation pump starts
and the controller checks the
medium flow over the flow
switch.
If the flow is insufficient, a
fault shut-down will be carried
out and the cooling cycle will
not work.
6. Measure and record all the
required values in the commissioning report and check the
safety functions.
KWL 180(H) - 220(H)
7. Check the system control using
the functions described in the
“Operation” chapter.
Final tasks
■
Reassemble all disassembled
parts.
■
Familiarise the operator with
the system.
NOTE
The system is delivered from
the factory with all parameters
set.
If during commissioning it is
necessary to change a parameter it can only be done by
authorised personnel.
1115
155
KWL 270(H) - 320(H)
100
1300
823823
156
12201420427532
Intake
229
Outlet
548
1195
385
128
KWL 370 (H)
1670620
Intake
Outlet
247
666
175
1215
225
Intake
Outlet
1395
1300
755755
228
648
485
15351160
Intake
Outlet
188
418
580
All dimensions are given in mm
Vibration dampers sized in accordance with the different unit sizes are available as
accessories. Their dimensions must be added to the dimensions listed above.
36
1116
We reserve the right to modify the dimensions and constructional design as part of the ongoing technical development process.
Characteristic curves
Pressure loss
KWL 130 (H)KWL 160 (H)
l/sec
KWL 180 (H)KWL 220 (H)
KWL 320 (H)KWL 270 (H)
l/sec
l/sec
KWL 370 (H)
l/sec
Circulation pump
UPI
KWL 130(H) -
320(H)
KWL 370 (H)230/400V1.2kW4.3/2.5A
l/secl/sec
230/400V 0.37/0.5kW 2.5/1.4A
l/sec
37
REMKO KWL (H)
Equipment pressure, available
KWL 130 (H)
kPakPa
l/sec
KWL 160 (H)
KWL 180 (H)KWL 220 (H)
kPakPa
l/sec
l/sec
KWL 320 (H)KWL 270 (H)
kPakPa
l/sec
KWL 370 (H)
kPa
l/sec
l/sec
38
l/sec
Exploded view KWL 130(H) - 220(H)
3
9
15
9
16
7
2
5
10
14
12
1
4
We reserve the right to modify the dimensions and constructional design as part of the ongoing technical development process.
Ice forms on the fins in heating mode as a consequence of the heat
absorption. The amount of ice depends on the percentage of humidity in the ambient air. Under certain cycles and temperature conditions, defrosting cycles are run through in which no heat capacity
can be generated. The following reduction factors for the defrosting
cycles must be taken into account even when planning the layout:
KWL 130 to 370: Air intake temperature TK 35°C, medium intake 12 °C, medium outlet 7 °C, 0% glycol concentration
KWL 130 H to 370 H:Air intake temperature TK 7°C / 85%r.h., medium intake 40 °C, medium outlet 45 °C, 0% glycol concentration
KWL
160
KWL
180
KWL
220
KWL
270
KWL
320
Sound pressure level Lp in dB(A), distance 1m
Sound pressure level Lp in dB(A), distance 10m
KWL
370
KWL
130 H
KWL
160 H
KWL
180 H
KWL
220 H
KWL
270 H
KWL
320 H
KWL
370 H
44
Technical data
Series
Operating mode
Nominal cooling capacity
KWL
130
1)
kW12,915,918,121,827,131,537,2
KWL
160
KWL
180
KWL
220
KWL
270
Air-cooled compact chiller with adaptive function
for cooling
KWL
320
KWL
Energy efficiency ratio cooling EER2,422,592,572,562,672,672,65
Setting range return temp. Cooling°C+10 to +18
Operating range - cooling°C+15 to +45
Operating range cooling (extension)°C+5 to +45 5) / -15 to +45
kPa150
Medium connection, intakeInches1 /1/4 indoors
Medium connection, outletInches1 /1/4 indoors
Medium content, pipe linesl2,12,53,13,74,24,86,4
Minimum medium volume, per unitl40,047,051,062,080,091,0104,0
Dimensions - heightmm1115121513001300
widthmm4275326201160
depthmm1220142016701535
Weightkg165,0168,0255,0270,0310,0325,0380,0
Operating weight, approx.kg167,1170,5258,1273,7314,2329,8386,4
Standard coloursimilar to RAL 9018 / INOX
Serial number INOX
EDP no. INOX
Serial number RAL 9018
EDP no. RAL 9018
1) Air intake temperature TK 35°C, medium intake 12 °C, medium outlet 7 °C, 0% glycol concentration
2) Air intake temperature TK 7 °C, medium intake 45 °C, medium outlet 50 °C, 0% glycol concentration
3) Distance 10 m free field
4) Air intake temperature TK 45 °C, medium intake 18 °C, medium outlet 15 °C, 0% glycol concentration
5) Only with compressor crank case heating accessory
6) Only with winter pressure regulation accessory, set
7) Contains greenhouse gas according to Kyoto protocol
Max. operating pressure, refrigerantkPa1900 / 2800
Compressor, number / type1 / Scroll
Air flow rate, max.m³/h957097401024010240119401172016300
Sound pressure level
3)
dB(A)48,248,248,748,448,548,651,3
Sound power leveldB(A)79,279,279,779,479,579,682,3
Power supplyV / Hz400/3~/50
Protection classIP24
Elec. power consumption, max.
Elec. current consumption, max.
4)
4)
kW11,5612,9015,0317,0818,5921,9431,08
A16,6918,6221,7024,6626,8331,6744,86
Nom. electrical power consumption, cooling 1)kW5,336,137,048,5110,1611,8114,02
Elec. nominal current consumption cooling
1)
A11,4512,7716,0416,9619,5422,3530,06
Nom. electrical power consumption, heating 2)kW5,906,727,688,9710,6612,6414,63
Elec. nominal current consumption
kPa150
Medium connection, intakeInches1 /1/4 indoors
Medium connection, outletInches1 /1/4 indoors
Medium content, pipe linesl2,12,53,13,74,24,86,4
Minimum medium volume, per unitl40,047,051,062,080,091,0104,0
Dimensions - heightmm1115121513001300
widthmm4275326201160
depthmm1220142016701535
Weightkg170,0176,0268,0285,0325,0332,0398,0
Operating weight, approx.kg172,1178,5271,1288,7329,2336,8404,4
Standard coloursimilar to RAL 9018 / INOX
Serial number INOX
EDP no. INOX
Serial number RAL 9018
EDP no. RAL 9018
1) Air intake temperature TK 35°C, medium intake 12 °C, medium outlet 7 °C, 0% glycol concentration
2) Air intake temperature TK 7°C, medium intake 40 °C, medium outlet 45 °C, 0% glycol concentration
3) Distance 10 m free field
4) Air intake temperature TK 45°C, medium intake 18 °C, medium outlet 15 °C, 0% glycol concentration
5) Crank case heating compressor (standard equipment)
6) Only with winter pressure regulation accessory, set
7) Contains greenhouse gas according to Kyoto protocol
46
REMKO INTERNATIONAL
... and also right in your neighbourhood!
Make use of our experience and advice
Consultation
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.
REMKO GmbH & Co. KG
Air conditioning and heating technology
Im Seelenkamp 12 · 32791 Lage
PO Box 1827 · 32777 Lage
Telephone +49 52 32 6 06-0
Fax +49 5232 606-2 60
E-mail info@remko.de
Website www.remko.de
Customer 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.
Hotline
+49 5232 606-0
Export
+49 5232 606-130
We reserve the right to make technical changes, and provide no guarantee as to the accuracy of this data!
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