REMKO RKW 1000 – 9800 INOX
Stainless Steel Chiller
Operation
Technology
Spare Parts
Edition GB – M11
REMKO – powerful like a bear
Operating Instructions
Read these instructions carefully before setting up/operating the unit!
Our guarantee becomes null and void if the unit is used, set up
or maintained improperly,
or if modifications are made to the supplied unit without our prior consent.
Subject to alterations!
REMKO Stainless Steel Chiller
RKW 1000 INOX / 1600 INOX / 2600 INOX
3600 INOX / RKW 4500 INOX / 8000 INOX / 9800 INOX
Contents Page
Unit Description 4
Safety Hints 4
Transport and Packaging 5
Operation 5
Maintenance and Service 9
Shutting Down the Unit 10
Alarm Description 10
Troubleshooting 11
Technical Data 12
Dimensions 13
Always keep these operating instructions near or on the unit!
G
Contents Page
Assembly Instructions for Service Personnel 14
Unit Assembly 14
Storage Modules for RKW 3600 to 9800 I 17
Cable Remote Control 20
Electrical Connection 21
Hydraulic System 24
Initial Operation 25
Environment and Recycling 26
Service and Guarantee 26
G
3
Unit Description
REMKO chilled water air-conditioning systems consist
of an outer part ready which is ready to be connected,
the air-cooled chiller (REMKO RKW INOX) and one or
more inner units (cold water consumers: REMKO KLT,
WLT, DKT and FLG). All components required for cooling are located in the outer part.
A hermetically closed cooling cycle in the chiller cools
the water (or a brine made of water and antifreeze) to
up to 5 °C via a plate heat exchanger.
A circulation pump integrated either into the unit or in
the storage module transports the cold water to the inner unit(s). To expand the water volume and extend the
operating time, there is also a cold water tank with
safety assembly either in the unit or located in the separate storage module.
In the inner units, the air in the room is guided through
the heat exchanger of the inner units by means of a
quiet fan. When the air in the room leaves the unit, it is
cooled, demoisturized and filtered. The water warms up
and transports the heat absorbed from the room back to
the outer part where it is passed along to the cooling cycle and the surroundings.
The RKW 1000, 1600 and 2600 INOX chillers all have a
hydraulic system that is ready to be connected with a:
◊ Buffer tank
◊ Expansion vessel
◊ Safety valve
◊ Flow switch (differential pressure monitor)
◊ Manometer
◊ Ventilation
◊ Ventilation valve
◊ Drain valve
The RKW 3600 INOX chiller models and higher can be
easily equipped with a storage module that has an integrated hydraulic system, even at a later time.
The system is regulated by means of a self-sufficient
microprocessor that monitors system safety parameters
and displays any malfunctions and monitors the set cold
water temperature. A connection between the chiller
and the cold water consumers is not required.
To air condition rooms, an outer part is usually used in
connection with the appropriate inner units (consumers).
Here, there are various options available depending on
how the unit is being used. In addition to standalone
units, wall and ceiling chests, ceiling cassettes with various capacities can also be selected for mounting on intermediate walls.
REMKO chillers are suitable for almost every type of application when used with the right consumers if the priority is cooling according to needs.
Thanks to modern technology, the chillers require up to
80 % less coolant than other cooling and airconditioning systems.
The coolant is only necessary to cool the transport medium (water or brine). In conventional systems, the coolant is also required to transport the heat from the inner
units (consumers) to the outer part.
This makes another advantage of the REMKO chillers
evident; they do not require coolant lines to the inner
units (cold water consumers). All connection lines are
designed to be water lines with the correct dimensions
and heat insulation.
Ideally, lines of an existing heating network can be integrated into the overall system.
Proper use
The outdoor parts have been designed and fitted exclusively for operation with REMKO indoor units belonging
to the RKV series.
The manufacturer assumes no liability for damage resulting from non-compliance with manufacturer specifications and legal requirements, or if modifications are
made to the units.
Safety Hints
Extensive tests have been conducted on the material,
functionality and quality of these units before they were
shipped. These units may only be used in accordance
with their intended purpose. Hazards may arise if the
units are used improperly.
Please make sure to follow these safety instructions.
◊ Make sure that personnel trained in the operation of
the chiller check the unit for visible defects on the operating and safety mechanisms each time before
putting it into operation.
◊ Before any work on the unit is performed, it must be
disconnected from the power supply and secured
against switching on!
◊ The unit may only be filled up and operated with wa-
ter or a mixture of water and glycol (brine)!
◊ Ensure that the air intake and outlet openings are al-
ways clear of foreign objects.
◊ Do not insert any objects into the air intake and outlet
openings.
◊ Do not install the unit close to heat sources.
◊ Make sure to maintain the safety zones described
later in this manual!
◊ Do not use flammable gases such as spray paint in
the direct vicinity of the units.
◊ Make sure that the unit is kept at a safe distance
from flammable materials.
◊ Do not operate the unit if the atmosphere is contami-
nated by oil, sulfur or salt.
◊ If there is a cable remote control installed, make sure
to protect it against moisture and direct or indirect
sunlight!
4
◊ Operate the units exclusively within the permissible
operating ranges.
◊ Do not expose the unit to direct streams of water
High-pressure cleaners, etc.
◊ Protect the connection lines from being damaged, for
example, by animals.
◊ The unit may only be connected to a correctly in-
stalled and grounded power supply.
◊ Never open the unit housing.
There may cause an electric shock.
◊ Operate the unit only when assembled and for their
intended purpose. Keep in mind that it is dangerous
to remove covers protective grilles, etc., during operation; this can lead to uncontrolled operating situations.
◊ Never operate the unit in rooms susceptible to explo-
sions. The units are also not suitable for operation in
rooms containing large amounts of dust or aggressive air.
◊ Installation and repair work may only be performed by
authorised personnel.
◊ Cleaning and minor maintenance work made only be
performed by the operator or an authorised person
designated by him in accordance with the instructions
contained in the section "Maintenance and Service".
◊ If the unit is set up outside and is susceptible to being
hit by lightning, the appropriate countermeasures
must be implemented by an authorised company.
Instructions:
◊ When shipped, the units are packaged in a box and
mounted on a palette.
◊ The units must remain upright and be transported
with suitable means. They must also be adequately
secured from falling over.
◊ If the units are transported to a setup location that is
higher up, such as platforms or roofs, they must be
transported in an upright position as shown below.
Pulling point
Wooden boards to protect from pressure
Transport and Packaging
The unit is shipped in a stable transport box made of
wood and cardboard. Please examine the unit when it is
delivered
Make note of any damage or missing parts on the shipping bill and notify the shipping company and your contract partner.
We do not assume any liability for subsequent complaints.
Operation
The chiller is operated fully-automatically by an internal
regulation or by an external cable remote control installed by the customer.
Both types of unit operation allow some parameters to
be changed as well as the water return temperature to
be displayed.
Internal and external regulation
CH-DIN regulation Cable remote control
5
Regulation
CH–DIN regulation of all RKW INOX units
The CH–DIN microprocessor regulates the chiller for all
INOX units. It is located in the electrical switch box of
the unit and monitors all control and safety functions:
◊ Controls and displays incoming and outgoing cold
water temperatures
◊ Displays the time delay of the compressor and fan
◊ Checks that the outgoing water temperature is not
too low (frost monitoring)
◊ Displays and controls all safety mechanisms that
have been stopped due to a malfunction
◊ Displays the operating mode
◊ Regulates the condensation temperature
The regulator consists of the basic unit to control unit
operation. A fan board is connected to the basic unit
that controls the rotation of the fan motors by regulating
the output current depending on the liquefaction temperature.
Models RKW 3600 INOX and higher have two cold cycles. The second cycle cannot be regulated by the CH–
DIN basic unit because there are not enough inputs and
outputs. For this reason, the extra C2-DIN regulator
controls the second cycle. Programming is, however,
still performed using the CH–DIN basic unit.
CH– DIN panel
Value display Code display Arrow keys
Value Display
The value display shows the target value in degrees
with one decimal place in Celsius. It can also display:
◊ All parameter settings
◊ The codes for all alarms
◊ The status of the functions
◊ The operating hours
◊ The shut-off status
◊ The current delays
A square LED displays minus temperatures and an LED
in the top left-hand corner shows the multiplier of the
displayed value with 100.
Code Display
The code display indicates the number of the parameter
(or the function) whose value or status appears in the
value display. If a parameter is shown in the code display, the setting appears in the value display.
Arrow Keys
The set value for each parameter can be changed with
the arrow keys.
When the parameter programming operating mode is
accessed (via the MENU button), both displays show a
value (continuous display). After the SET button has
been pressed, the code display (parameters) starts
blinking. The displayed values can be increased or decreased using the arrow keys. If the SET is pressed a
second time, the value display blinks. The new values
are saved by pressing the SET button again. Both displays switch from a blinking display to a continuous display.
8
8
8
8
8.
8
MODE
Comp
SET
SET
8
STATUS MENU
ON/OFF
RESET
8
Alarm
Line
ON/OFF
RESET
ON/OFF
RESET button
8
Heat
Cool
CH-DIN
MODE button SET button
The panel has two displays: the value display (three
numbers on the left) and the code display (two numbers
on the right).
The buttons allow operating
processes (parameters) and their associated values to
be changed.
8.
e
MODE
MENU button STATUS button
STATUS
MENU
MODE Button with two LEDs
The regulation mechanism was designed for use of a
chiller in the cooling operating mode and as a
heat pump in the cooling and heating operating
modes.
Only the summer operating mode (cooling mode)
may be used for all INOX units.
MENU Button with one LED
The MENU button provides access to the parameter list
and displays the parameters on the code display and
the associated value on the value display.
STATUS Button with one LED
The STATUS button provides access to the status list
and displays the status settings by pressing the arrow
keys.
The code display shows the function number of the
function list and the value display shows the corresponding setting. The codes and their descriptions are
described in the table on page 8.
Heat
MODE
MENU
STATUS
Cool
e
Cool
e
6
ON/OFF/RESET Button
ON/OFF
RESET
This button is used to switch the unit on and off. If the
alarm has been set off and the unit has to be manually
reset, this button is pressed to prevent further alarms
from being acknowledged. At the same time, the normal
operating function of the unit is restored.
Alarm LED
Alarm
If this LED is lit up, the unit’s alarm has gone off and operation has been interrupted.
SET Button
SET
The parameters settings can be changed by pressing
the SET button together with the arrow keys.
Compressor LED
Comp
This LED is not lit up when the compressor is not in operation. If this LED is blinking, the compressor is currently in start-up time delay and will begin operation after this time has elapsed. If this LED is continuously lit
up, the compressor is in operation. The time delay is no
longer active.
C2–DIN Additional Regulations for Models RKW 3600
and higher
For chillers with cooling capacities higher than 26 kW,
the cooling capacity is divided among two cooling cycles. The second cycle cannot be regulated using the
CH-DIN regulation because there are not enough inputs
and outputs and requires an additional C2-DIN regulation. The C2-DIN regulation controls the same functions
together with the CH-DIN regulation. These functions
are only displayed by LEDs. An alarm from the second
cycle is displayed on the CH-DIN regulation display as a
code, e.g. “E 01”.
The CH-DIN regulation is still used to program the settings of the second cycle.
C2– DIN Additional Regulation
Operating display Compressor 2
Compr.
High press.
C2-DIN
Malfunction display Compressor 2
Err. compr.
Err. fan
Low press.
Line LED
Line
This LED is continuously lit up when the regulation is
connected to the power supply.
Fan Board
The fan board is connected to the CH–DIN regulation.
The CH-DIN (C2-DIN) regulation registers the current
condensation temperature via the sensor input ST 5 (ST
6) and passes along the corresponding programmed
output current to the CTK 1 (CTK 2) output of the TK 1
(TK 2) fan board.
The fan motor rotation can be controlled by the modulating output current.
Malfunction display
High pressure 2
C2- DIN additional regulation
Malfunction display
Fan 2
Operating Display Compressor 2
Malfunction display
Low pressure
CH- DIN regulation
Compr.
This display lights up when the compressor of the second cycle is in operation.
Malfunction Display Compressor 2
Err. compr.
This display lights up when there is a malfunction in the
compressor of the second cycle.
Malfunction Display Fan 2
Err. fan
This display lights up when there is a malfunction in the
fan of the second cycle.
Fan board TK 1
Fan board TK 2
High Pressure MalfunctionCycle 2
High press.
This display lights up when pressures that are too high
have been set in the second cycle.
Low Pressure MalfunctionCycle 2
Low press.
This display lights up when pressures that are too low
have been set in the second cycle.
7
Determining the Operating Mode (Status)
The Status menu is used to determine the current operating mode of the various system components such as operating hours, outputs currently set, the current actual values of the sensor inputs and any current malfunctions.
Pressing the STATUS button takes you to the Status menu (Status LED is lit up). The left-hand value display now
indicates the current operating mode of the statuses in the right-hand code display using the index described in the
table below. These can be listed by pressing the arrow keys in sequence:
Programming process
8
1
STATUS
0
1 0 4
0
Status Status Description Index Meaning
01
02
03
05
21
22
23
25
40
41
42
43
44
45
46
47
48
Compressor 1
Run time Compressor 1
Fan(s) Cycle 1
Rotations condenser fan(s) Cycle 1
Compressor 2
Run time Compressor 2
Fan(s) Cycle 2
Rotations condenser fan(s) Cycle 2
Sensor incoming water temperature
ST 1 (Cycle 1)
Remote control ON/OFF
Sensor outgoing water temperature
ST 2 (Cycle 1)
Sensor outgoing water temperature
ST 3 (Cycle 2)
Sensor condenser temperature
ST 5 (Cycle 1)
Sensor condenser temperature
ST 6 (Cycle 2)
Cold water pump
Run time cold water pump
Defrost heating
(not in use)
01
02
03
04
06
# (value in hours) Operating hours of Compressor 1
01
02
04
06
# (value as a %) Fan rotation as a percentage
- - 01
02
03
04
06
- - # (value in hours)
- - 01
02
04
06
- - %
- - # (value in °C)
ON
OFF
ERR
- - ON
OFF
- - # (value in °C)
ON
OFF
ERR
- - # (value in °C)
ON
OFF
ERR
- - # (value in °C)
ERR
- - # (value in °C)
ERR
- - 01
06
- - # (value in hours)
- - 01
06
Compressor 1 in cooling mode
Compressor 1 in heating mode (not in use)
Compressor 1 in defrost cycle (not in use)
Compressor 1 in time delay ON
Compressor 1 OFF
In operation
Off (defrost for heating pump)
Time delay ON
OFF
Not installed
Compressor 2 in cooling mode
Compressor 2 in heating mode (not in use)
Compressor 2 in defrost cycle (not in use)
Compressor 2 in time delay ON
Compressor 2 OFF
Not installed
Operating hours of Compressor 2
Not installed
Fans in operation
Off (not in use)
Time delay ON
OFF
Not installed
Fan rotation as a percentage
Not installed
Actual value in 0.1°C intervals
Sensor activated
Sensor not activated
Sensor malfunction or failure
Remote control not installed
Remote control active
Remote control locked
Not installed
Actual value Cycle 1
Sensor activated
Sensor not activated
Sensor malfunction or failure
Not installed
Actual value Cycle 2
Sensor activated
Sensor not activated
Sensor malfunction or failure
Not installed
Actual value condenser Cycle 1
Sensor malfunction or failure
Not installed
Actual value condenser Cycle 2
Sensor malfunction or failure
Not installed
Pump in operation
Pump not in operation
Not installed
Operating hours of the pump
Not installed
Heating in operation
Heating not in operation
2 0 6
STATUS
8
Changing the Target Values (Parameters)
First Parameter Level for the System Operator
A parameter is a modifiable value that can be set by the
operator/installer to adjust the chiller to the specific conditions and guarantee optimum operation.
For example, the return temperature, the frost protection alarm temperature and the new switch-on differential can be changed after the target temperature has
been reached.
Access rights for system operators and qualified maintenance and service personnel is divided into two parameter levels. The operator can only change basic parameters on the first level and the service personnel can
change system-specific parameters on the second level
after entering a password.
A technical data sheet which explains the second parameter level can be requested separately by a qualified
company from REMKO GmbH &Co. KG.
Programming process
8
1
MENU
0
2
The first parameter level is accessed by pressing the
ON/OFF/RESET button. The current return temperature
is displayed.
After pressing the MENU button, the programmed value
of Parameter 02 (right-hand code display) appears in
the left-hand display. The right-hand parameter display
begins to blink when the SET
button is pressed. This mode displays the options for
changing the parameters to the programmer.
If one of the arrow keys is now pressed, the parameter
jumps to the next higher or lower parameter.
Once the correct value has been reached for the parameter, the value display begins to blink after the SET
button has been pressed. The displayed value can now
also be changed using the arrow keys. The programming level can be exited by pressing the SET button a
third time. The settings are saved and the return temperature is displayed again.
SET
0
2
0
3
MENU
Table of the first parameter level
Parameter Function Unit
02
03
04
05
26
92
Target value regulation, cooling °C 12,0 12.0 12.0 12.0 12.0 12.0 12.0
Target value regulation, heating °C 45.0 45.0 45.0 45.0 45.0 45.0 45.0
Cooling hysteresis °C 1.0 1.0 1.0 0.8 0.8 0.8 0.8
Heating hysteresis °C 1.0 1.0 1.0 0.8 0.8 0.8 0.8
Frost protection alarm target value °C 4.0 4.0 4.0 4.0 4.0 4.0 4.0
Password entry - Technical data sheet
0
1
SET
Maintenance and Service
The unit almost never requires maintenance. Regular
care and the observation of a number of basic rules will
ensure the unit’s long service life and reliable operation.
◊ We recommend concluding a maintenance agree-
ment with a company who specialises in this type of
work. This will guarantee that the system operates
safely at all times!
◊ Keep the unit free of dirt, plants and other deposits
and only clean the units with a damp cloth.
Do not expose the units to a direct stream water.
◊ Do not use an abrasive cleaning agent or one that
contains solvent; if the units are extremely dirty, only
use suitable cleaning materials.
0
1
RKW INOX factory setting
1000 1600 2600 3600 4500 8000 9800
◊ Before taking the unit out of operation for a longer
period of time, clean the plate fins of the unit while
the ventilator is in operation and cover the unit with a
plastic sheet to prevent dirt from entering the unit.
◊ For systems with brine, check the ratio of water to
Antifreeze N or Antifreeze L before taking the unit out
of operation in winter to protect the system from
frost.
◊ We recommend having the unit checked at regular
intervals (once or twice a year) to ensure that it is
functioning properly and there are no leaks.
1 1
SET
9
Shutting Down the Unit
Temporary shutdown
If the unit is to be taken out of operation for a longer period of time, for example, over the winter, proceed as
follows:
1. Use the remote control to shut down all of the inner
units.
2. Switch off the internal regulation in the chiller (or the
remote control).
3. Have the percentage of glycol is checked by an
authorised company.
4. If only water was used in the hydraulic cycle and no
brine (water and antifreeze), this water must be
drained from system components in areas susceptible to frost during the period of non-operation. When
the unit is put back into operation, the amount of water that has been drained must be refilled!
5. Check the inner units and the chiller for any visible
damage.
6. Clean the inner units and outer parts as described in
section 5 “Maintenance” and cover the chiller, if possible, with a plastic sheet to protect it from weather
conditions.
When the unit is put back into operation after a long period of non-operation, it must first be checked for external damage before operation.
Permanent shutdown
For environmental safety reasons, the chiller may only
be disassembled by authorised service centres.
REMKO GmbH & Co. KG or your contract partner would
be happy to provide you with the name of a service centre in your area.
Alarm Description
To protect the unit, the CH-DIN regulation and the C2DIN additional regulation use sensors to check the unit’s
safety mechanisms for temperature, pressure, internal
configuration, etc.
The value display of the CH-DIN regulation indicates the
alarm code by displaying the letter E followed by two
numbers. The cause of the alarm can be determined by
finding the code in the table below. The C2-DIN additional module also displays the alarm with a corresponding LED.
On the second parameter level, resetting the alarm can
be programmed after the malfunction has been fixed
The alarms are pre-programmed to automatically reset
at the factory.
If the alarms have been reprogrammed to be reset
manually, the alarm must be reset after the problem has
been fixed by switching the CH-DIN and then on again
with the ON/OFF/RESET button (see programming example below).
Resetting the alarms after the problem has been fixed
The alarms can be reset by following the programming process below. As an example, the compressor switched off
due to a malfunction caused by dirt in the condenser fins.
Programming process
Overheating of the
condenser as a
result of dirt in the
fins
E
Alarm
1 2
Temperature of the
condenser is lowered and the fins of
the heat exchanger
are cleaned
0
ON/OFF
2
RESET
Alarm
ON/OFF
RESET
3 1
List of the alarm codes
Code Alarm Type AUTO MANUAL
E00
E01
E02
E03
E04
E05
E06
E07
E21
E22
E23
E24
E25
E26
E27
E40
E41
E42 Hardware defective
Remote control defective (open contact)
High pressure alarm Cycle 1
Low pressure alarm Cycle 1
Condenser overheating Cycle 1
Condenser temperature too high
Frost protection Cycle 1 activated
Sensor defective ST 2 outgoing water Cycle 1
Sensor defective ST 5 condenser Cycle 1
High pressure alarm Cycle 1
Lobe pressure alarm Cycle 1
Condenser overheating Cycle 2
Condenser temperature too high
Frost protection Cycle 2 activated
Sensor defective ST 3 outgoing water Cycle 2
Sensor defective ST 6 condenser Cycle 2
Sensor defective ST 1 incoming water
Flow switch (differential pressure monitor) activated
The second parameter level can be
programmed to reset the alarms.
Enter the changed resets in the left-
hand column.
All settings made at the factory
have been pre-programmed to
AUTOMATIC.
10
Troubleshooting
This unit has been designed based on state-of-the-art manufacturing methods and it has been tested repeatedly to
ensure that it is working properly. However, should problems occur, refer to the following list.
Problem Alarm Possible cause Check Remedy
The unit
does not
start or it
switches
itself off
automatically.
The unit is
either not
cooling at
all or only
a little bit
Water
leaks out
of the unit
Power failure
Waiting period too short Is the COMP LED blinking? Schedule longer waiting periods
Regulation is not working
E01/E02
E21/E22
E00/E21
E03/E23 Compressor overheating
E04/E24
E05/E25 Frost protection activated
E06/E07/
E26/E27/
E40
Power fuse / power supply defective
Incorrect electrical rotational
direction
Incorrect discharge temperature or parameter setting
High-low pressure alarm
Remote control / Connection
to C2-DIN defective
Liquefaction temperature too
high
Sensors defective ST1 to ST6
Are all other electrical components
working?
Are all other electrical components
working?
Did the phase-sequence relay switch
through?
Is the LINE LED and to the
COOL LED lit up?
Check setting Change setting
Are the fans rotating?
Is the pressure in the cold cycle OK?
Is the display working?
Is the connection OK?
Is the temperature of the compressor
above approx. 100 °C?
Are the fins clean and have the oper-
ating ranges been maintained?
Is the supply temperature 4°C or
lower?
It is the alarm activated when the
sensor is replaced?
Are the following values OK:
◊ Volume of current (too large/small)
◊ No air in the monitoring pipes
◊ Circulation pump
◊ Does the monitor switch on and off
E41
Flow switch (differential pressure monitor) activated
◊ Stop mechanisms are open
◊ Water pressure too high/low
E42 Hardware defective
Compressor contact defective
Supply temperature too high
Air in the system
Incorrect parameter settings Check settings Change settings
Heating capacity was increased
Liquefaction temperature too
hot
Sporadic operation because
cooling requirements are too
low
Leaks in pipes or defective insulation
Does the regulation function
smoothly?
Is the COMP LED lit up and is there
current on the contact?
Has there been a structural change? Maintain safety zones
Is the supply temperature approx.
5 ... 10 °C?
Have automatic ventilators been
mounted on the highest possible position?
Are the fins clean and have the operating ranges been maintained?
Has the system been designed for
smaller measurements?
Are there leaks and have all lines
been insulated?
Check voltage and wait for the
unit to start again.
Maintenance by authorised
personnel
Change the rotational direction
Connect current and select the
COOL operating mode
Have checked by authorised
company
Replace remote control or reestablish connection between
CH-DIN and C2-DIN
Maintain operating ranges, clean
fins
Clean fins, place unit in the
shade
Increase discharge temperature
Replace defective sensors
Have checked by authorised
company
Have regulation replaced by
authorised company
Have the contact or compressor
replaced by an authorised company
Reduce discharge temperature
Ventilate manually or integrate
ventilators
Clean fins, place unit in the
shade, maintain operating ranges
Increase the quantity of water by
installing a storage module
Seal and insulate
11
Technical Data
Type
RKW INOX
1000 1600 2600 3600 4500 8000 9800
Cooling capacity
Air performance max.
Number of fans / diameters
Rated flow rate water
Minimum flow rate water
Pump pressure max.
Internal pressure losses for rated flow rate kPa 25 37 40 32 29 19 20
Available external pressure differential
Operating pressure max.
Incoming water chiller
Outgoing water chiller
Filling connection
Sound pressure level
1)
2)
kW 10,0 16,0 25,6 35,9 44,3 78,0 98,0
m³/h 3000 6200 10000 17000 19000 35000 39000
-/mm 2/450 2/450 1/630 2/630 2/630 2/800 2/800
m³/h 1,8 2,8 4,4 6,2 7,6 13,4 16,9
m³/h 1,3 1,9 3,0 4,5 5,2 8,8 10,8
kPa 70 90 74 - - - -
kPa 45 53 34 - - - kPa 250
inch
inch 1¼ 1½
inch
dB(A) 43 44 49 48 48 53 54
1¼ 1 2 2 x 2
2
1/2 -
2 x 2
Refrigerant
Cold cycles/Compressor type
Refrigerant amount
Contents storage tank
Operating range outgoing water
Operating range outside temperature 3)
Nominal current consumption
per compressor 4)
Nominal current consumption. max.
Electrical connection
Power consumption. max.
Starting current
Supplied fuse protection (recommended)
Dimensions Width
Depth
Height
-
kg 5,0 4,1 8,0 2x7,4 2x7,6 2x20,5 2x21
l 45 45 108 - - - °C + 5 °C to + 15 °C
°C - 10 °C to + 43 °C
A 8.0 12.8 18.8 26.3 2x16.3 4x14.6 4x18.4
A 8.0 12.8 18.8 26.3 32.6 58.5 73.5
V/Ph/Hz
kW 4.4 7.1 11.2 15.7 19.4 36.0 45.2
A 49 101 167 2x90 2x120 2x116 2x127
A 20 20 25 35 50 80 100
mm 1150 1150
mm 460 460
mm 1300 1300
1 Scroll 2 Scroll 2 Tandem Scroll
1340 2370 2370 2990 2990
560 560 560 1280 1280
1770 1310 1310 1520 1520
R 407C
400/3~,N,PE/50
Weight
Ref. No. 1611600
(1) Capacities based on ISO R 859A; room temperature of TK 27°C/FK 19°C - outside temperature 35°C, supply 7 °C, discharge 12 °C
(2) Noise measurement DIN 45635 - 01 - KL3 in intervals of 10 meters
(3) Only when brine is used (water with 34% glycol)
(4) Power data per cooling cycle
kg 160
197 300 437 461 902 934
1611610 1611620 1611635 1611645 1611650 1611660
12
Dimensions
RKW 1000 INOX / 1600 INOX
K
B A
F
E
D
L
RKW 3600 INOX / 4500 INOX
RKW 2600 INOX
A B
C
A B F
K
F
E
D
L
K
E
C
D
C
RKW 8000 INOX / 9800 INOX
A B F
Model size
1000 INOX 1600 INOX 2600 INOX 3600 INOX 4500 INOX 8000 INOX 9800 INOX
K
G
E
L
D
A mm 1150 1150 1340 2370 2370 2990 2990
B mm 460 460 560 560 560 1280 1280
C mm 1300 1300 1770 1310 1310 1520 1520
D mm 625 625 90 715 715 900 900
E mm 615 615 1610 1180 1180 520 520
F mm 220 220 160 1100 1100 1300 1300
G mm - - - - - - - - - - - - - - - 290 290
K incoming water inch 1 ¼ ‘‘ inside 1 ¼ ‘‘ inside 1 ¼ ‘‘ inside 2 ‘‘ inside 2 ‘‘ inside 2 x 2 ‘‘ inside 2 x 2 ‘‘ inside
L outgoing water inch 1 ¼ ‘‘ inside 1 ¼ ‘‘ inside 1 ½ ‘‘ inside 2 ‘‘ inside 2 ‘‘ inside 2 x 2 ‘‘ inside 2 x 2 ‘‘ inside
M filling connection (water) inch ½ ‘‘ outside ½ ‘‘ outside
½ ‘‘ outside
- - - - - - - - - - - -
Fan / number Ø mm / - 450 / 2 450 / 2 630 / 1 630 / 2 630 / 2 800 / 2 800 / 2
C
Depending on the size of the unit, a certain number of vibration absorbers are supplied with the unit. These have a height of approx. 30 mm
up to the model size RKW 4500 I, and of approx. 45 mm for model size RKW 8000 I and higher which must be added to the heights above
(measurement C).
13
Assembly Instructions for
General information
Service Personnel
Prior to installation
The following must be checked and complied with before the unit is actually assembled:
◊ Ensure that the contents of the package are com-
plete and that the unit has no visible damage results
in from transport. Any problems must be communicated immediately to your contract partner and the
shipping company. Subsequent complaints will not
be acknowledged.
◊ Place the unit in its original packaging as close as
possible to the location where it will be assembled.
This will prevent damage resulting from transport.
◊ Ensure that the foundation for installing the chiller is
level, even, firm and resistant.
Pay attention to the load capacity of the foundation.
◊ Choose a place for installation which guarantees a
free air intake and air discharge of the unit and
where the unit is not exposed directly to the sun or
other heat sources.
◊ The air discharge of the unit should be in accor-
dance with the main direction of the wind.
◊ Keep all distances which are described in the chap-
ter “minimum distances”
◊ Prior to installation, the electrical connection values
must be checked for consistency with the data on
the type plate.
◊ All indoor units must have a separate electric supply.
◊ An electric control cable to the chiller is not neces-
sary.
◊ The chillers are units for outside setup.
◊ Wind protection devices must be set up if the air ex-
pelled from the unit does not flow in the same primary direction as the wind.
◊ You must ensure that the wind protection does not
adversely affect the air supply to the unit.
◊ When setting up the unit, ensure that adjacent
rooms or buildings are not exposed to adverse effects from noise emitted from the units. You should
avoid setting up the units on large, reverberant surfaces, such as between reflecting buildings, because
this can increase the noise level.
◊ The chillers must be mounted on vibration absorbers
or foundations which prevent vibrations (to be done
by the customer).
◊ If the chillers are also used during the winter months,
the unit must be assembled high enough so that it is
protected from snow. The minimum height is 20 cm
above the normal amount of snow expected.
◊ To ensure that the unit operates smoothly, adequate
safety distances to walls and other obstacles must
be maintained during setup.
Minimum distances
These safety zones ensure that air can flow freely in
and out of the unit, that maintenance and repair work
can be performed and to protect the unit from damage.
The figure below indicate the minimum distances that
must be maintained to ensure that the units operate
properly.
RKW 1000 / 1600 INOX
Unit Assembly
The REMKO RKW INOX chillers have been designed
and built for outside setup. Because a lot of heat is expelled to the surroundings, make sure that when you select a location for setup, air can flow freely in and out of
the unit.
It is generally not advisable to set up the unit in en-
closed rooms because adequate air exchange with the
outside air cannot be guaranteed and there must be an
equal amount of air intake and output.
An adequate air exchange can only be guaranteed if a
corresponding cross ventilation supplies fresh air to the
room at least at the air flow rate of the chiller. Otherwise
the room will heat up and the chiller will switch off due to
a malfunction. This occurs once the room temperature
exceeds the upper operating range of the set value of
the safety mechanism.
14
500
300
RKW 2600 INOX
500
300
1000
1000
300
300
500
600
RKW 3600 / 4500 INOX with storage module
Vibration absorbers
RKW 1000 - 4500 INOX RKW 8000 – 9800 INOX
500
1000
400
400 400
RKW 3600 / 4500 INOX without storage module
500
1000
400
400 400
RKW 8000 / 9800 INOX
8Ø
60
43 43
45
Attachment locations for chillers
RKW 1000 / 1600 INOX
735
RKW 2600 INOX
770
13Ø
66 66
M12 x 35
400
500
600
3000
1200
600
1200
Installation of the units
The units are supplied with vibration absorbers in this
series. These must be connected to statically permissible and level building or structural components.
The locations for attachment described below are for
fastening the vibration absorbers to the chillers. To establish an attachment to a subconstruction, the dimensions of the vibration absorbers must be observed.
RKW 3600 / 4500 INOX without storage module
950
417 950
RKW 3600 / 4500 INOX with storage module
770
430 770
RKW 8000 / 9800 INOX
933 998 998
500
500
1150
15
Hydraulic connections
The hydraulic connections are located on the back of
the units.
The RKW 1000 and 1600 INOX units are ready to be
connected upon shipment.
For the RKW 2600, 3600 and 4500 INOX units, it is
possible to separate the plate heat exchanger of the
chiller and the storage module mounted underneath this.
For the RKW 2600 INOX unit, the plate heat exchanger
and the storage module are connected hydraulically by
the pipe connection installed at the factory.
For the RKW 3600 and 4500 INOX units, the plate heat
exchanger and the separately ordered storage module
must be connected upon assembly with the supplied
pipe connection. If the module is set up separately, the
necessary connection line must be installed by the customer
The RKW 8000 and 9800 INOX units in this series are
supplied without hydraulics. The required components
are selected by the person who develops the system.
General information
◊ We recommend equipping the connections with
shut-off valves for service purposes.
◊ Additional, automatic ventilation valves must be
mounted at the highest location of the installation in
the supply and discharge pipes.
◊ To prevent vibrations from being transferred, com-
pensators (flexible lines) should be used between
the fixed pipe installation and the chiller.
◊ All pipe lines must be insulated to protect them from
condensation. According to the HeizAnlV (German
Heating Systems Ordinance), a 50% insulation diameter must be planned for cooling mode and a
100% insulation diameter for cooling and heating
mode.
◊ To prevent the unit from becoming dirty, a water filter
(approx. 16 meshes pro cm²) should be installed in
the discharge line.
◊ The water pipes may not exert any static strain on
the chiller.
◊ A second key or pliers must be used to mount the
pipe lines on the RKW so as not to create any strain
on the pipe lines in the inside of the unit.
◊ If the chiller is only initially operated with a single part
of the overall system, the flow rate of the missing
system parts must be stimulated by pipe regulating
valves.
◊ To increase the run time of the unit, we recommend
using a storage module or cold water pipes that are
slightly larger to increase the volume if the necessary
capacity of the inner units is considerably smaller
than the cooling capacity of the chiller.
◊ The hydraulics must be set up in such a way that the
predefined minimum flow rate is reached.
Connecting the water pipes
The RKW 1000, 1600 and 2600 INOX models in this
series are equipped with a cold water storage module
as a compact unit. The 3600, 4500, 8000 and 9800
INOX models are supplied in this series without hydraulics for technical reasons. The water components including the plate heat exchanger and the differential
pressure monitor are located in the chiller. The hydraulic
connections are found on the backs of all units.
For models RKW 3600 and 4500 INOX and higher, a
separate storage module can be mounted underneath
the chiller or somewhere else (e.g. inside the building).
So as not to transfer the vibrations of the chiller to the
system parts, the lines are connected to the unit by
compensators (flexible lines). We recommend equipping the connections with shut-off valves for service purposes.
Shut-off valve Compensator
Static attachment
Model
1000 INOX 1 ¼ ‘‘ inside 1 ¼ ‘‘ inside ½ ‘‘ outside
1600 INOX 1 ¼ ‘‘ inside 1 ¼ ‘‘ inside ½ ‘‘ outside
2600 INOX 1 ¼ ‘‘ inside 1 ½ ‘‘ inside ½ ‘‘ outside
3600 INOX 2 ‘‘ inside 2 ‘‘ inside 4500 INOX 2 ‘‘ inside 2 ‘‘ inside -
3600 INOX with
storage module
4500 INOX with
storage module
8000 INOX
9800 INOX
incoming outgoing
2 ‘‘ inside 2 ‘‘ inside ½ ‘‘ outside
2 ‘‘ inside 2 ‘‘ inside ½ ‘‘ outside
2 x 2 ‘‘inside
2 x 2 ‘‘inside
Water
RKW connection
2 x 2 ‘‘ in-
side
2 x 2 ‘‘ in-
side
Filling con-
nection
-
-
16
Hydraulic Connections
RKW 1000 / 1600 INOX
Hydraulic connection RKW 8000 / 9800 INOX
Incoming water
Incoming water
Outgoing water
RKW 2600 INOX
Incoming water
Outgoing water
RKW 3600 / 4500 INOX with separate storage module
Incoming water
Outgoing water
Incoming water
Outgoing water
RKW 3600 / 4500 INOX with the storage module below
Incoming water
Outgoing water
Outgoing water
Storage module for
RKW 3600 to 9800 INOX
For the RKW 3600, 4500, 8000 and 9800 INOX models,
it is not necessary to use a storage tank for certain
types of use
Other types of application absolutely require the volume
of water to be increased, for example, to extend the operating time of the chiller and prevent sporadic operation.
Five storage modules have been designed to meet
these practical requirements:
1. Storage module 1 for RKW 3600 and 4500 INOX,
216 l tank, safety component 3 kPa and MAG,
without pump,
Ref.No.: 1611530
2. Storage module 2 for RKW 3600 and 4500 INOX,
216 l tank, safety component 3 kPa and MAG,
including prompt, V
Ref.No.: 1611540
3. Storage module 3 for RKW 8000 and 9800 INOX,
2 x 216 l tanks, safety component 3 kPa and MAG,
without pump,
Ref.No.: 1611545
4. Storage module 4 for RKW 8000 and 9800 INOX,
2 x 216 l tanks, safety component 3 kPa and MAG,
including pump, V
Ref.No.: 1611550
5. Storage module 5 for RKW 8000 and 9800 INOX,
2 x 216 l tanks, safety component 3 kPa and MAG,
incl. 2 x pumps, V
Ref.No.: 1611555
The storage modules 1 and 2 are to be attached under
the RKW 3600 and 4500 INOX chillers by means of the
standard connection line. In Module 2, the circulation
pump is installed at the factory.
The storage modules 3, 4 and 5 can be set up on top of
one another to save space. The circulation pump(s) of
Modules 4 and 5 cannot be placed inside the modules
due to the design. They must be set up separately.
The hydraulic components which are to be placed in an
easily accessible location include the insulated storage
tank, a safety component, a manometer, a membrane
expansion vessel (MAG) and a filling connection with
ball stop valve.
: 6,2/7,6 m³/h, p
nenn
: 13,4/16,9 m³/h, p
rated
: 13,4/16,9 m³/h, p
rated
: 124/118 kPa
max
: 90/82 kPa
max
: 95/65 kPa
max
17
Storage Module Technical Data
3600 4500 8000 9800
Storage module for RKW INOX 1 2 1 2 3 4 5 3 4 5
Storage contents
Number of pumps
Incoming water / Outgoing
water
Filling connection
Operating pressure max.
Rated volume current water
Minimum volume current
water
Pump pressure max.
Storage pressure loss,
internal
Available external pressure
differential
Electrical connection
Power/Current consumption
Dimensions Width
Height
Depth
Weight when empty, storage
Weight pump
Ref.No.
l 216 2 x 216
-
1 - 1
-
1 2 - 1 2
inch 1½ 1½
inch 1/2 1/2
kPa
m³/h
m³/h
6.2 7.6
4.5 5.2
250
250
13.4 16.9
8.8 10.8
kPa - 124 - 118 - 90 95 - 82 65
kPa
5 8 6 10
8 11 10
11 15 13
kPa - 92 - 89 - 59 66 - 47 32
V - 3~,400 - 3~,400 - 3~,400 -
kW/A
mm
mm
mm
0.55/1.44
2370 2 x 2370
535 2 x 535
560 2 x 560
kg 123 126
kg - 3
1611530 1611540 1611530 1611540 1611545 1611550 1611555 1611545 1611550 1611555
123
-
0.55/1.44
126
3
0.75/1.86 1.1/2.88
-
-
246 246
- 4 6 - 4 6
3~,400
0.75/1.86 1.1/2.88
Storage module dimensions
Hydraulic operation of the storage module
Parallel operation Individual operation
18
Assembling the storage module
1. Remove the transport packaging and, if applicable,
assemble the vibration absorbers onto the bottom of
the storage module.
If the storage module is to be placed below the
chiller, the vibration absorbers do not need to be attached.
2. Attach the storage module horizontally using the
brackets of the vibration absorbers to a statically permissible attachment location.
If the modules are to be set up on top of one another
to save space, the vibration absorbers only need to
be attached to the bottom module.
3. For hydraulic parallel operation of the storage modules, the pipe line connections are to be connected
depending on the necessary hydraulics. When attaching the storage modules below the chiller for the
RKW 3600 and 4500 INOX modules, the supply connection line can be attached.
4. If the vibrations from the storage module are not to
be transferred to the pipe line network, compensators with the correct dimensions are to be selected.
Electrical connection
Characteristic curve of the pump RKW 3600 / 4500
INOX storage module 2
Characteristic curve of the pump RKW 8000 / 9800
INOX storage module 4
Prior to performing any work on the unit, it must be
unplugged from the power supply and secured
G
against being inadvertently switched on!
Follow these instructions to perform the electrical installation:
◊ These electrical installations may only be performed
by authorised service personnel in accordance with
the relevant regulations.
◊ The units must always be connected with low-ohm
protection conductor is with sufficient to dimensions.
In certain circumstances, the module must be
grounded as a measure to protect against lightning
in several places.
◊ The connection line of the pump is to be guided
through the respective cable penetration on the back
of the chillers into the housing in the switch box and
wired in accordance with the wiring diagram.
◊ All of the pumps to be installed in the storage mod-
ules are designed as three-phase alternating current
motors. The power supply of the pumps is performed
on the L1, L2, L3, N and PE terminal strips.
◊ The dimensions of the lines is based on the local
conditions. The connection capacity of the units can
be found in the table below:
Characteristic curve of the pump RKW 8000 / 9800
INOX storage module 4
Type
Electrical connection
Power consumption
Cur. consumption max.
RKW 3600 INOX /
RKW 4500 INOX
400 V, 50 Hz / 3~, N, PE
0.55 kW 0.55 kW 0.75 kW
1.44 A 1.44 A 1.86 A
RKW 8000 INOX /
RKW 9800 INOX
19
Antifreeze to prevent freezing
Electrical connection of the cable remote control
During cold seasons of the year, it is possible that the
water in the chiller will freeze at temperatures below 0°C
which can cause damage, for example, to the plate heat
exchanger. The same applies to installed connection
lines and system parts in rooms not susceptible to frost.
For this reason, we recommend mixing the water with
an adequate amount of antifreeze (e.g. antifreeze N).
If brine (a mixture of water and frost protection) is not
used in the hydraulic cycle, the water is to be drained
from the system parts in areas susceptible to frost during non-operation in the winter.
Appropriate shut-off and drainage mechanisms are to
be used. The amount of water drained out must be refilled before the next cooling season begins.
If the chiller is to be used throughout the whole year, e.
g. to air-condition a computer room) the hydraulic cycle
must be operated with brine.
When using brine, you must make sure that the pressure loss increases as a result of the changing density
in the hydraulic cycle. Whether or not to use brine must
be considered when the hydraulic cycle is being set up.
The variable technical data can be found in the table below:
The remote control comes with an operating module
TS-W, the additional regulation module CS-DIN/TTL
and an interface line.
CS-DIN/TTL
TS-W
The operating module is to be mounted in the desired
location. The operating module is connected to the
RKW with two, two-wire lines with a maximum length of
50 m. One line is used to transfer data and the other to
supply the current 12 V~ of the operating module. It is
not necessary to use an additional transformer.
The programmed data is transferred to the CH– DIN
regulation by an interface line.
Percent-
age of
ethylene
glycol
Vol. % °C K
20 -11 0.96 0.995 1.04 1.19
34 -20 0.95 0.990 1.09 1.35
40 -25 0.925 0.985 1.105 1.51
Anti-
freeze
0 0 1 1 1 1
Correction factors when using a brine
made of ethylene glycol * and water
L
Power
consump-
tion
K
PE
Flow rate
K
V
Pressure
Cooling
capacity
loss
K
D
* We recommend an ethylene glycol with inhibitors as
corrosion protection, e.g. antifreeze N or L.
Where the heat medium comes into contact with
drinking water or food, antifreeze L is to be given
preference because it contains the physiologically
harmless substance 1.2 propylene glycol.
The data provided in the table refers to antifreeze N.
Antifreeze L has other correction factors and thus a
different pressure loss!
Cable Remote Control
The cable remote control can be purchased as an accessory. It is used to query and program the chiller from
a remote location.
In the factory, all models are programmed using the remote control.
Install the remote control as follows:
1) Place the two, two wire connection lines between the
location where the remote control is to be assembled
and the switch box of the chiller. The minimum
cross-section is Cu 1.5 mm². The max. current may
not fall below 2 %.
2) Remove the assembly back panel of the operating
module and attach it to the setup location.
3) Clamp the lines to the terminal strips of the electronic board and make sure that the polarity is correct. Lock the operating module into place in the assembly back panel.
4) Insert the additional module into the switch box of
the chiller.
5) Clamp the lines to the terminal strips of the previously mounted additional regulation module in the
switch box of the chiller.
6) Using the interface line, you can connect the additional regulation module and the CH–DIN regulation.
7) Test the function of the remote control.
20
Electrical Connection
Electrical installations may only be performed by
authorised service personnel. Prior to performing
G
any work on the unit, it must be unplugged from
the power supply.
The following electrical connections must be made:
◊ Connecting the power supply
◊ Connecting the cable remote control if applicable
Please follow the instructions below to install the electrical connections:
◊ The inner units function independently of the chiller.
An electrical control line is hence not necessary.
◊ The electrical connections are to be performed as
fixed connections in accordance with the relevant
regulations.
◊ An all-polo separating switch is to be installed in the
power line in front of the unit.
◊ The power line must be insulated adequately by the
customer and the line drop may not fall below the
permissible values.
◊ Make sure that the electrical system is suitable to
supply the required operating current for operating
the unit and any other units that are already in operation.
◊ Prior to installation, if connections are made to exis t-
ing system parts, you must check that the line has
the right dimensions for unit consumption.
◊ The units must always be connected with low-ohm
protection conductors with sufficient dimensions. In
certain circumstances, the module must be grounded
as a measure to protect against lightning in several
places (especially when plastic pipes are used).
All electrical connections such as power input, cable remote control, etc., are to be made in the switch box of
the unit. The lines to be laid must be guided through the
appropriate cable penetrations on the back of the unit
into the housing.
All units require a three-phase alternating current connection. The power line is to be guided through the L1,
L2, L3, N and PE terminal strips.
The line dimensions are based on the local conditions.
The connection capacity of units can be found in the table below:
Type
1000 1600 2600 3600 4500 8000 9800
Electrical connection
Power consumption kW
Cur. Consumption max. A
Start-up current A
Fuse protection
customer-side
RKW INOX
400 V /3~, N. PE / 50 Hz
4.4 7.1 11.2 15.7 19.4 36.0 45.2
8 12.8 18.8 26.3 32.6 58.5 73.5
49 101 167 2x90 2x120 2x116 2x127
20 20 25 35 50 80 100
A
Warning! The units are equipped with a phase-sequencer relay that prevents the unit from operating if the rotational direction of the electrical connection is wrong. If the chiller remains neutral (i.e. no current) when be-
G
ing put into operation, the rotational field must be switched.
Description of the CH-DIN inputs and outputs
Terminal
strip
01 – 02
03 – 04
05 – 06
07 – 08
09 – 10
11 – 12
13 – 14
15 – 16
15 – 17
15 – 18
19 – 20
22 – 23
22 – 24
22 – 25
21 – 22
42 – 43
Normal status
ST 1 Incoming water - Sensor PTC - input
ST 2 Outgoing water – Sensor PTC - input
ST 5 Condenser – Sensor PTC - input
closed AT 1 High pressure switch Neutral contact
closed AT 3 Low pressure switch Neutral contact
closed AT 5 Not in use Neutral contact
12 V ~ Tr Current supply 12 V ~, 50 Hz
Closed when pump is in operation AT 9 Differential pressure monitor Neutral contact
AT 7 Heating-cooling removed Neutral contact
closed AT 10 On Off, remote control contact for heating pump Neutral contact
RL 1 Global shut-off Max. 48 V ~, 200 mA
RL 2 Defrost heating / Boiler signal 230 V ~, 50 Hz, 4,0 A
RL 4 Compressor 230 V ~, 50 Hz, 0,4 A
RL 8 Circulation valve (heating pump only) 230 V ~, 50 Hz, 0,4 A,
RL 10 Pump switch contact 230 V ~, 50 Hz, 4,0 A
TK 1 Fan regulation - output Phase regulation
Input /
Output
Function Connections
21
Wiring Diagram RKW 1000 INOX / 1600 INOX
ST 1: Temperature sensor
Incoming water
ST 2: Temperature sensor
Outgoing water
ST 5: Temperature sensor
Verflüssiger
HP Pressure absorber
High-pressure
LP Pressure absorber
Low pressure
Fan rotation
regulation board
(winter regula-
tion)
Microprocessor
regulation
Differential
pressure
monitor IN-
TERNAL
Condenser motor
Terminal strip M2
Relay condenser
Phase-sequence relay
fan 1
Verflüssiger
Verflüssiger
Wiring Diagram RKW 2600 INOX
ST 1: Temperature sensor
Incoming water
ST 2: Temperature sensor
Outgoing water
ST 5: Temperature sensor
Condenser
HP Pressure absorber
High pressure
LP Pressure absorber
Low pressure
Fan rotation
regulation board
(winter regulation)
Overheating
protection
compressor
Microprocessor
regulation
fan 2
Potentialfreier
Kontakt for
regulating cool-
ing
EXTERNAL
Flow switch
EXTERNAL
Circula-
tion pump
Compressor
motor
Terminal strip M1
Relay compressor
Input
400 V / 3 Ph ~ / 50 Hz
Phase-sequence relay
22
Neutral con-
tact for cooling
regulation
EXTERNAL
Differential
pressure
monitor
INTERN
Circulation
pump
Condenser
fan 1
400 V / 3 Ph ~ / 50 Hz
Terminal strip M2
Terminal strip M1
Input
L1
12V
12V
Pri
230V~
Electrical Wiring Diagram RKW 3600 INOX / 4500 INOX
sequence
ST 1: Temperature
Incoming water
ST 2: Temperature
sensor outgoing water
ST 5: Temperature
sensor
HP Pressure absorber
High pressure
LP Pressure absorber
Low pressure
Microprocessor
regulation
Frequency block
Frequency block
Compressor motor 1
Additional
module
Overheating protection condenser
Overheating protection condenser 1
Compressor motor 2
Neutral con-
tact for cooling
regulation
EXTERNAL
Differential
pressure
monitor
INTERNAL
Condenser
fan 1
Condenser
fan 2
Connecting the Remote Control RKW 1000 INOX to 9800 INOX
Terminal
strip
M2
Circulation pump
Fan rotation regulation
board
TK 1 and TK 2
(winter regulation)
400 V / 3 Ph ~, N, PE
Transformer 220 / 12 V~
L1 N
Phaserelay
Terminal strip M1
Input
50 Hz
in the switch box RKW
CH – DIN regulation /
C2 – DIN regulation
BUS
Assembly Instructions
1. Place the two connection lines with a minimum
cross-section of Cu 1.5 mm² between the RKW and
the operating module (max. 50 m).
2. Connect the operating module electrically.
3. Switch the RKW so that it is neutral (i.e. no current)
and connect the 250 mm long bus-interface line to
the additional module.
4. Connect the line of the data transfer to the terminal
strips 23 and 24 (pay attention to polarity) of the additional module and the terminal strips on the transformer for the current supply.
Additional module for
the remote control
CS-DIN/TTL
BUS
Operating module
TS-W
in
out
12V 12V
N
20
23
21 22
24
Maximum line length
50 meter
23
Electrical Wiring Diagram RKW 8000 INOX / 9800 INOX
ST 1: Temperature sensor
ST 2: Temperature sensor
ST 5: Temperature sensor
HP Pressure absorber
High pressure
LP Pressure absorber
Low-pressure
Microprocessor
regulation
Frequency
block
Additiona
module
Klemmleiste M2
Potentialfreier
Kontakt für die
Ansteuerung
Kühlen
EXTERN
Circulation pump
Overheating protection
Compressors 1 and 2
Winter regulation
Overheating protection
Compressors 3 and 4
Compressor 1
Compressor 3
Condenser fan
1 and 2
Winter
regulation
400 V / 3 Ph~, N PE
Input
50 Hz
Compressor 2
Compressor 4
Terminal strip M1
Phasesequence
relay
Hydraulic System
Hydraulic Diagram RKW 1000 / 1600 INOX
3
4
5
6
7
13
11
10
15
12
9
16
8
17
18
14
Hydraulic Diagram RKW 2600 to 4500 INOX
4
8
14
12
10
16
15
5
13
17
18 9
7
2
3
2
6
Hydraulic Diagram RKW 8000 / 9800 INOX
4
1
P
15
16
8
7
18
10
1
5
12
1 Shut-off element
2 Ventilation
3 Filling connection
4 Temperature display
5 Pressure display
6 Water filter
1
7 Static attachment
8 Compensator
9 Circulation pump
10 Differential pressure monitor
11 Ventilator
12 Storage
13 Safety valve
14 Expansion vessel
15 Stainless steel heat exchanger
16 Drainage unit connection
17 Filling connection / Drainage connection
18 Supply unit connection
19 Safety assembly
9
17
19
2
6
1
14
1
24
Summer Operation Cooling Only
Winter Operation Cooling and Heating
Initial Operation
Checks prior to operation:
◊ Prior to operation, the electrical connection values
and the data on the type plate must be checked for
consistency.
◊ You must ensure that all electrical connections have
been made in line with the requirements of the local
power supply company as well as national regulations.
◊ The water lines must be clean and free of impuri-
ties . For this purpose, the lines should be rinsed out
twice or three times to ensure that all foreign matter
has been removed from the lines.
◊ Make sure that all shut-off valves in the cold water
lines are opened.
◊ Make sure that the temperature sensors (condenser,
supply and discharge / protection against freezing)
are in the correct positions and that the water lines
are connected properly to the input and output.
◊ One important prerequisite is that all lines are filled,
ventilated and have been checked for leaks. The
system pressure can be read on the outside of the
unit on the manometer. The system pressure may
be a maximum of 2.5 bar. Initial pressure during
non-operation 1.5 – 2.0 bar.
◊ If the system is being operated with antifreeze, make
sure that the concentration is correct.
◊ The electrical lines of the system must be checked
that they are attached properly to the terminal strips.
◊ Prior to operation, all screws in the water system
must be checked to ensure that they are in the
proper position and do not leak.
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Operation
The unit must be put into operation by the manufacturer
or one of his appointed representatives. All regulation,
control and safety mechanisms must be checked to ensure that they are working properly and have the correct
settings.
Follow the instructions below to put the unit into operation:
1. Remove the housing cover.
2. Make sure that the shafts in the circulation pumps
can turn freely. To do this, remove the plug
(depending on the pump type) and turn the shaft or
remove the housing cover by taking off the four
screws and then rotate the shaft.
3. Make sure that there is no dirt.
4. Reassemble the pump in the opposite order and select the highest performance level for multi-phase
circulation pumps.
5. Make sure that the shut-off valves of the hydraulic
lines are open and set the pipe regulating valves to
the corresponding flow rate.
6. Make sure that all pipes and valves in the system
have been insulated correctly.
7. Fill the system with water or a pre-mixed water-glycol
mixture.
8. Ventilate the entire system and the pump.
9. Make sure that there is no air in the differential pressure monitor line. If there is, ventilate it at the connection.
10.Check the entire system for leaks.
11.Check the insulation of all components.
12.Check that the operating current is consistent with
the power current.
13.Before switching the unit on, make sure that the
power input and the condenser (s) have the correct
rotational field. If an incorrect rotational field has
been connected, the integrated phase-sequence relay interrupts the supplied current of the regulation.
14.Switch the chiller on by pressing ON / OFF / RESET
and select the cooling operating mode via MODE. If
the drainage temperature is warmer than the factory
setting of 12 °C, the COMP. display blinks and the
condenser begins to run in approx. three to five minutes.
15.If the factory setting has been changed, set the desired drainage temperature by setting the Parameter -02 to the target value, exit the parameter level
and press the ON / OFF / RESET button twice.
16.If the drainage target temperature falls below 8 °C in
the parameter level, both displays begin blinking.
You must then select a higher drainage temperature.
17.The supply temperature is approx. 5 Kelvin under the
drainage temperature for the rated flow rate.
18.If the supply temperature is below the factory setting
of 4°C, the unit registers a malfunction (E05/E25). In
this case, the drainage temperature must be set
higher. If the difference between the supply and return temperatures is too high or too low, check the
flow rate.
19.The circulation pump starts and the regulation
checks the volume current via the flow switch
(differential pressure monitor). If the amount of water
is too small, the unit registers a malfunction and the
cold cycle is not released.
20.In this case, the source of the error (pipe regulating
valve not set, all valve assemblies of the inner units
are still closed, pipe dimensions of the system are
not correct) must be identified and fixed.
21.The cold cycle switches on after a time delay of approx. 3 to 5 minutes.
22.Check the system pressure, system height between
chiller and the highest inner unit and the water volume and set, if necessary, the filling pressure of the
membrane expansion vessel to the system.
23.Reattach the covers.
24.Train the operator in system operation.
Environment and Recycling
Important information about recycling!
Only authorised personnel may come into contact with
the cold cycle. This ensures that refrigerant does not escape into the environment when the unit is being repaired.
Both the refrigerant and the system parts are subject to
special requirements for disposal.
The refrigerant in use is a safety refrigerant. This
means that, should damage occur, the quantities
released will not cause injury to the respiratory
G
systems of people and animals. Do not touch the
liquid refrigerant as it can freeze the skin!
Service and Guarantee
For the guarantee to be valid, the purchaser or his customer must completely fill out the "guarantee certificate"
enclosed with all units and send it back to REMKO GmbH
& Co. KG.
The units are repeatedly tested at the production site to
ensure that they are working properly. If a malfunction
occurs that cannot be eliminated by the operating personnel, please contact your dealer or contact person.
Operation/handling which does not comply with
these instructions is prohibited!
In cases of non-compliance, we assume no liability
G
and the guarantee becomes null and void.
26
REMKO GmbH & Co. KG
Klima- und Wärmetechnik
D-32791 Lage • Im Seelenkamp 12
D-32777 Lage • PO Box 1827
Phone +49 (5232) 606 - 0
Fax +49 (5232) 606260
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