Compact-Line - Operating Manual 83000102.Kf PDF

Compact-
Compact-Line
Operating Instructions
cBoxX 30
cBoxX 40
cBoxX 50
cBoxX 60
cBoxX 70
cBoxX 80
cBoxX 90
cBoxX 100
cBoxX 120
cBoxX 160
cBoxX 180
cBoxX 200
Table 1: Contact details
Manufacturer
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T +49 9228 9977 0
F +49 9228 9977 149
E [email protected]
W www.kkt-chillers.com
Service
ait-deutschland GmbH
Industriestraße 3
95359 Kasendorf
Germany
T +49 9228 9977 7190 *
F +49 9228 9977 7474
E [email protected]
W www.kkt-chillers.com *
Service USA
KKT chillers, Inc.
1280 Landmeier Road
Elk Grove Village
IL 60007
T +1 847 734 1600
F +1 847 734 1601
TF +1 866 517 6867 *
E [email protected] *
2 / 77 83000102.Kf
Introduction
These operating instructions have been drawn up by KKT chillers on the basis of the Machinery
Directive 2006/42/EC. They contain all important information and instructions for the installation
and safe operation of the refrigerating machine (chiller). It also contains advice on how to prevent
or correct faults.
Please allow yourself sufficient time to read through these instructions carefully and to digest all
the information this document contains. If you have any further questions, please contact the
KKT chillers Service Team using the contact details provided.
If properly used for its intended use and correctly maintained, the chiller ensures sustained, fault-
free operation. The methods and procedures described in these instructions should help you to
detect problems early and to take appropriate countermeasures.
If you keep to the maintenance programme described you ensure the reliability and safety of the
machine. You also keep the operating costs low and at the same time increase the life of the
components.
To ensure that the performance of your chiller is not impaired, we recommend that you only use
original spare parts purchased from KKT chillers. In this way you ensure the reliability and quality
of the machine.
ATTENTION! A black exclamation mark on a yellow background in a triangle indicates

important information and instructions to which you must pay particular attention and
must always follow.
KKT chillers reserves the right to change technical details without prior notice. The illustrations in
this document are not to scale!
As the Compact-Line units can be adapted to specific projects, this document only contains
information that is generally valid for all units in the series.
All project-specific data is enclosed with the unit in separate summary documentation.
Machine configuration
Parameter list
P&I diagram
Pump characteristic curve(s)
Circuit diagram
All other project specific details
3 / 77 83000102.Kf
Contents
Introduction............................................................................................................................................. 3
1. Product description ................................................................................................................... 8
1.1. Intended use ...................................................................................................................... 8
1.2. Technical data .................................................................................................................... 9
1.3. Elements........................................................................................................................... 11
1.4. Explanation of terms ........................................................................................................ 12
2. Function and main components ............................................................................................. 13
2.1. Compressor ...................................................................................................................... 13
2.2. Evaporator ........................................................................................................................ 14
2.3. Condenser ........................................................................................................................ 14
2.4. Expansion valve ............................................................................................................... 14
2.5. Refrigerant........................................................................................................................ 14
2.6. Oil ...................................................................................................................................... 15
2.7. Filter dryer ........................................................................................................................ 15
2.8. Pressure sensors ............................................................................................................. 15
2.9. Temperature sensors....................................................................................................... 15
2.10. Control unit/ main circuit board...................................................................................... 15
2.11. Display .............................................................................................................................. 15
2.12. Control cabinet ................................................................................................................. 16
2.13. Pump................................................................................................................................. 16
2.14. Fan .................................................................................................................................... 16
2.15. Cold water cycle ............................................................................................................... 16
2.16. Materials used in the water circuit ................................................................................. 17
2.17. Water quality .................................................................................................................... 19
2.18. Permitted cooling media ................................................................................................. 20
3. Options and accessories ......................................................................................................... 20
3.1. Version without tank, with pump .................................................................................... 20
3.2. Version without tank, without pump ............................................................................... 20
3.3. Version with water cooled condenser............................................................................. 21
3.4. Heater for compressor and control cabinet ................................................................... 21
3.5. Insulation of the cold pipes and the pump(s) ................................................................ 21
3.6. Tank heater with thermostatic pump start..................................................................... 22
3.7. Overflow valve for standby mode .................................................................................... 22
3.8. Higher pressure pump ..................................................................................................... 22
3.9. Second consumer circuit ................................................................................................. 23
3.10. Additional evaporator pump ............................................................................................ 23
3.11. Automatic water feed....................................................................................................... 23
3.12. Water circuit in non-ferrous metal-free version ............................................................. 23
3.13. DI package........................................................................................................................ 24
3.14. Special voltage ................................................................................................................. 24
3.15. Phase monitoring ............................................................................................................. 24
3.16. Hot gas bypass for output control <1K........................................................................... 24
3.17. High-temperature package.............................................................................................. 24
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3.18. Special paint finish .......................................................................................................... 24
3.19. Air filter mat (accessories)............................................................................................... 24
3.20. Levelling feet (accessories) ............................................................................................. 25
3.21. Level package (accessories) ........................................................................................... 25
3.22. Filter assembly group coolant circuit (accessories)....................................................... 25
3.23. Filter assembly group cooling water circuit (accessories) ............................................. 26
3.24. MultiplexX connection group (accessories) .................................................................... 26
3.25. Refill cartridge R410A (accessories) .............................................................................. 26
3.26. Anybus-Gateway (accessories) ........................................................................................ 26
3.27. Remote Control Panel (accessories).............................................................................. 27
3.28. Special languages (accessories)..................................................................................... 27
3.29. Wooden Crate (accessories) .......................................................................................... 27
3.30. Seaworthy crate packaging (accessories) ...................................................................... 27
3.31. Water Pump Redundancy ................................................................................................ 27
3.32. Closed Water Loop ........................................................................................................... 28
4. Safety........................................................................................................................................ 28
4.1. General information ......................................................................................................... 28
4.2. Hazard warnings .............................................................................................................. 28
4.3. Residual energy................................................................................................................ 30
4.4. Safety devices, guards and safeguards ......................................................................... 31
4.4.1. High-pressure limiter................................................................................................ 31
4.4.2. High-pressure monitoring ........................................................................................ 32
4.4.3. Low-pressure monitoring ......................................................................................... 32
4.4.4. Flow monitoring ........................................................................................................ 32
4.4.5. Personal protective equipment when operating the machine .............................. 32
4.5. Personal protective equipment for servicing work ........................................................ 32
4.6. Airborne sound emissions ............................................................................................... 33
4.7. Notes on reducing noise and vibration........................................................................... 34
4.7.1. Noise ......................................................................................................................... 34
4.7.2. Vibration.................................................................................................................... 34
4.8. Residual risks ................................................................................................................... 34
4.8.1. Electrical ................................................................................................................... 34
4.8.2. Mechanical ............................................................................................................... 34
4.8.3. Chemical ................................................................................................................... 34
4.8.4. Other ......................................................................................................................... 35
4.9. Dangerous substances .................................................................................................... 35
4.9.1. Refrigerant R410A ................................................................................................... 35
4.9.2. Oil POE 160SZ .......................................................................................................... 36
4.10. Reasonably foreseeable misuse ..................................................................................... 37
4.11. Information for emergencies ........................................................................................... 38
5. Handling and storage .............................................................................................................. 38
5.1. Dangerous goods ............................................................................................................. 38
5.2. Transport .......................................................................................................................... 38
5.2.1. Forklift truck ............................................................................................................. 39
5.2.2. Crane......................................................................................................................... 40
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5.3. Unpacking......................................................................................................................... 41
5.4. Storage ............................................................................................................................. 41
6. Installation ............................................................................................................................... 42
6.1. Overview ........................................................................................................................... 42
6.2. Installation site................................................................................................................. 42
6.2.1. General information ................................................................................................. 42
6.2.2. Minimum room volume ............................................................................................ 42
6.2.3. Ambient temperature ............................................................................................... 43
6.2.4. Effect of surrounding air flow .................................................................................. 43
6.2.5. Minimum clearances ............................................................................................... 43
6.2.6. External attachments ............................................................................................... 43
6.2.7. Process level............................................................................................................. 44
6.2.8. Surface and foundation ........................................................................................... 44
6.2.9. Stability ..................................................................................................................... 45
6.2.10. Levelling .................................................................................................................... 45
6.2.11. Vibration isolation .................................................................................................... 45
6.2.12. Installation ................................................................................................................ 46
6.2.13. Hydraulic installation ............................................................................................... 46
6.2.14. Frost protection measures ...................................................................................... 47
6.2.15. Flushing the cold water circuit ................................................................................ 47
6.2.16. Filling ......................................................................................................................... 47
6.2.17. Venting ...................................................................................................................... 49
6.2.18. Electrical installation ................................................................................................ 50
7. Commissioning ........................................................................................................................ 51
7.1. Installation checklist ........................................................................................................ 51
8. Operation.................................................................................................................................. 52
8.1. Switching on ..................................................................................................................... 52
8.2. Selecting the operating mode ......................................................................................... 52
8.3. External release ............................................................................................................... 52
8.4. Control .............................................................................................................................. 52
8.5. Control panel .................................................................................................................... 53
8.5.1. Start screen .............................................................................................................. 54
8.5.2. Main menu................................................................................................................ 55
8.5.3. Information ............................................................................................................... 55
8.5.4. Settings ..................................................................................................................... 57
8.5.5. Alarm menu .............................................................................................................. 58
8.6. Parameters ....................................................................................................................... 58
8.7. Controller description ...................................................................................................... 59
8.7.1. Electronic level monitoring ...................................................................................... 59
8.7.2. Switching the chiller On/off ..................................................................................... 59
8.7.3. Cold water flow temperature control ...................................................................... 60
8.7.4. Compressor control .................................................................................................. 61
8.7.5. Fan speed control .................................................................................................... 62
8.7.6. Electronic expansion valve control.......................................................................... 62
8.7.7. Temperature limit monitoring .................................................................................. 62
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8.7.8. Group fault alarm ..................................................................................................... 62
8.8. Operating modes.............................................................................................................. 62
8.8.1. ECO mode ................................................................................................................. 62
8.8.2. Comfort mode........................................................................................................... 63
9. Cleaning ................................................................................................................................... 63
9.1. Air filter mat ...................................................................................................................... 63
9.2. Condenser ........................................................................................................................ 63
9.3. Water filter ........................................................................................................................ 63
9.4. Complete cleaning of the cold water circuit ................................................................... 63
10. Service ...................................................................................................................................... 64
10.1. Maintenance .................................................................................................................... 64
10.2. Fault correction ................................................................................................................ 64
10.3. Spare parts ....................................................................................................................... 64
11. Taking out of service ............................................................................................................... 65
11.1. Draining ............................................................................................................................ 65
12. Recycling .................................................................................................................................. 66
13. Products, solutions and services ............................................................................................ 66
14. Lists .......................................................................................................................................... 67
14.1. List of illustrations............................................................................................................ 67
14.2. List of tables ..................................................................................................................... 68
I. Troubleshooting ....................................................................................................................... 69
II. Maintenance intervals in accordance with the VDMA........................................................... 73
III. Product Registration ................................................................................................................ 76
IV. EC Declaration of Conformity .................................................................................................. 77
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1. Product description
Please read all the points in these operating instructions before starting up the machine. You
should pay particular attention to the points on safety, commissioning/startup and operation. If
you have further questions about your machine, please contact the KKT chillers Service Team
(see
see Table 1:
1: Contact details).
details
1.1. Intended use

tested, fully automatic compressor chiller. The machine is solely for cooling
The cBoxX is a factory-tested,
liquids (fluids) in accordance with EN 378-1.1. An adequate supply of cooling air must be provided.
Only approved liquids may be used. The cBoxX corresponds to protection class IP 54 (when the
housing is closed) and is suitable for both indoor and outdoor installation (note the options
packages).
The operator is responsible for complying with the specified operating, servicing and maintenance
conditions according to these operating instructions.
The owner of the chiller, not the manufacturer, is responsible and liable for all personal injuries
and damage to property caused by improper use of the unit (misuse).
Table 2 shows the general safety instructions of the chiller. These are attached to the machine in
a clear and readily visible
sible position. A complete description of all hazard warnings is given in
Chapter 4.2 Hazard warnings.
warnings.
Table 2: Safety instructions
Note and follow the instructions for use!
Before opening the machine it must be disconnected from the power supply!
After disconnecting the machine from the power supply, always wait for at least
2 minutes before opening it.
Danger! High voltage! If the machine is only switched off at its main switch,
dangerous electrical
electrical voltage is still present at several terminals in the control
cabinet.
8 / 77 83000102.Kf
1.2. Technical data
Table 3: Technical data
Compact-Line - cBoxX 30 cBoxX 40 cBoxX 50 cBoxX 60 cBoxX 70 cBoxX 80 cBoxX 90 cBoxX 100
Refrigerating capacity @ tw2=20°C /
kW 34 43 55 68 78 87 95 105
tu=32°C
Refrigerant - R410A
Refrigerant capacity kg 6 6 6 7 8 8 8 8
Cooling medium (liquid/secondary
- Water or water / glycol
refrigerant)
Ambient temperature range °C +5 to +45 (optionally -25 to +50°C)
Liquid feed temperature °C +8 to +30 (optionally to -10)
Target constancy K +/-1
Tank volume l 300 500
Coolant circulation, nominal (dt = 5K) m³/h 5.5 7.2 9.2 11.1 12.4 14.3 16.1 18.2
Free pump pressure (standard) bar 3
Water connection, nominal size RP 11/2" 2"
Air flow rate (max.) m³/h 9350 9350 12600 20000 23270 23270 23270 23270
Sound pressure level at 5 m distance dBA 62 62 55 69 59 59 59 59
Operating voltage (standard) V/Ph/Hz 400/ 3/ 50
Protection class - IP54
Height mm 2030 2030
Width mm 830 830
Length mm 1240 1840
Net weight kg 540 540 550 620 650 650 700 720
Gross weight kg 840 840 850 920 1150 1150 1200 1220
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Compact-Line - cBoxX 120 cBoxX 160 cBoxX 180 cBoxX 200
Refrigerating capacity @ tw2=20°C /
kW 135 166 194 210
tu=32°C
Refrigerant - R410A
Refrigerant capacity kg 17 17 23,5 23,5
Cooling medium (liquid/secondary
- Wasser oder Wasser / Glykol
refrigerant)
Ambient temperature range °C +5 bis +45 (optional -25 bis +50°C)
Liquid feed temperature °C +8 bis +30 (optional bis -10)
Target constancy K +/-1
Tank volume l 700 900
Coolant circulation, nominal (dt = 5K) m³/h 21,5 27,2 32,2 35,4
Free pump pressure (standard) bar 3
Water connection, nominal size RP DN65 PN10 EN1092
Air flow rate (max.) m³/h 45550 49100
Sound pressure level at 5 m distance dBA 67 67 67 67
Operating voltage (standard) V/Ph/Hz 400/ 3/ 50
Protection class - IP54
Height mm 2030
Width mm 1200
Length mm 2665 3965
Net weight kg 1100 1200 1300 1400
Gross weight kg 1800 1900 2200 2300
10 / 77 83000102.Kf
1.3. Elements
5 1 3
e d
a b c 6 2 4
1 Metal cladding, top, operator side a Safety instructions
2 Metal cladding, bottom, operator side b Water connections
3 Metal cladding, top, service side c Rating plate
4 Metal cladding, bottom, service side d Display
5 Metal cladding, condenser protective grating e Main switch
6 Cladding, hydraulics
11 / 77 83000102.Kf
1.4. Explanation of terms
A few important terms which appear in this document are briefly explained here for improved
understanding.
Table 4: Explanation of terms

Term Explanation
Application The heat source connected hydraulically with the chiller.
Process circuit Application and piping to the chiller.
Cold water cycle The process circuit and chiller in hydraulic piping.
Cold water Cooling medium in the cold water circuit.
Cooling air Ambient air drawn through the machine, which absorbs the heat.
Net weight Ready to operate machine without cold water.
Gross weight Ready to operate machine including cold water.
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2. Function and main components
The chiller consists of the main components: compressor, condenser, expansion valve and
evaporator, which are arranged in a circuit (Figure
Figure 1).
1 Refrigerant circulates in this circuit (cycle).
It absorbs heat from the cold water in the evaporator and gives it up to the ambient air in the
condenser.
Heat
Condenser and fan
Expansion
Compressor
valve
Evaporator
Cold
Figure 1: C6848 refrigeration diagram
In addition, diverse pressure and temperature sensors, a control unit, a high-pressure switch, one
or more pumps and one or more fans are also installed for control and operation of the chiller.
2.1. Compressor
The compressor generates the pressure difference between the heat sink and heat source in the
refrigerant circuit needed for evaporation and condensing. Coolant vapor from the evaporator is
drawn in and compressed to the condensing pressure in the compressor.
The compressors used operate according to the scroll principle. Scroll compressors are
maintenance-free, quiet and have a very high efficiency.
The flow temperature is controlled by switching on or off one or more compressors (see 8.7.4
control). Sequential changeover ensures that all compressors are loaded uniformly.
Compressor control
13 / 77 83000102.Kf
2.2. Evaporator
The evaporator is a plate heat exchanger which transfers heat from the cold water to the
refrigerant. In order for the heat transfer to take place, the refrigerant in the evaporator has a
lower temperature than the cold water and when it absorbs heat it changes its physical state from
liquid to gaseous.
If the cold water is contaminated, deposits can form on the transfer surfaces of the evaporator.
These impair the heat transfer to the refrigerant and reduce the refrigerating capacity of the
machine. For this reason, always ensure the specified water quality and do not use any other
additives than those specified.
2.3. Condenser
The condenser is a microchannel heat exchanger which transfers heat from the refrigerant to the
ambient air. In order for the heat transfer to take place, the refrigerant in the condenser has a
higher temperature than the ambient air drawn in and when it gives off heat its physical state
changes from gaseous to liquid.
Contaminated cooling air can cause deposits to form on the surface of the condenser over time.
This impairs heat transfer to the refrigerant which restricts the operating limit of the machine and
reduces the machine's refrigerating capacity. Please refer to Chapter 9: Cleaning for a description
of how to clean the condenser. If you operate your chiller in an environment containing dust or oil
vapour, use the optionally available air filter mat (see 3.19 Air filter mat).
mat).
In case that there already is an existing house water system and the warm condensing air has to
be avoided, the chiller can also be specified with a water cooled condenser (see 3.3 Version with
water cooled condenser)
condenser
2.4. Expansion valve

The expansion valve controls the admission of liquid refrigerant to the evaporator and at the
same time restricts the pressure of the refrigerant before it enters the evaporator. With this
restriction the refrigerant cools to the evaporation temperature.
The expansion valve used in your machine is controlled electronically. The electronic control
ensures that the evaporator is always optimally supplied with refrigerant. This improves the COP
(Coefficient of Performance) and reduces pressure fluctuations in the refrigeration circuit.
2.5. Refrigerant
The refrigerant R410A circulates in the refrigeration circuit. It conveys heat from the evaporator to
the condenser and at the same time continuously changes its physical state.
R410A is a zeotropic mixture of 50% each R32 and R125 with virtually negligible temperature
glide. R410A has a very high volumetric refrigerating capacity and has no ozone depletion
potential (ODP=0). A corresponding safety data sheet can be obtained from our KKT chillers
Service Team (see
see Table
Table 1:
details
14 / 77 83000102.Kf
2.6. Oil
The components of the compressor subject to friction are lubricated by oil, which is added to the
refrigerant in the factory. The polyolester-160SZ is used for this. The oil is soluble in the
refrigerant and is distributed with it throughout the refrigeration circuit. The total oil quantity of
the respective unit is given in the technical data. A corresponding safety data sheet can be
obtained from our KKT chillers Service Team (see
see Table 1:
details
2.7. Filter dryer

The task of the filter dryer is to absorb any contamination or moisture from the refrigerant circuit.
Both refrigerant and oil are hygroscopic. When the refrigeration circuit is installed the oil can
absorb moisture. This moisture can cause corrosion and has a negative effect on the cooling
process. The filter dryer bonds this moisture and also has a mechanical filter effect. If work is
carried out on the refrigeration circuit requiring it to be opened, the filter dryer (cBoxX 30 –
cBoxX100) respectively the filter cartridge (cBoxX 120 – cBoxX 200) must be replaced.
2.8. Pressure sensors

The pressure sensors used are compact pressure transmitters with piezoresistive measuring cell.
The sensors register the system pressure continuously in different places within the refrigerant
and cold water circuit. The values are used to control the system and for visualisation at the
controller display.
2.9. Temperature sensors

The temperature sensors used are equipped with a platinum measuring cell. The sensors register
the temperature continuously in different places within the refrigerant and cold water circuit. The
values are used to control the system.
2.10. Control unit/ main circuit board

The control unit is programmed in the factory. All system readings and information come together
on it. In addition, the electrical components are controlled via algorithms.
2.11. Display
The display is used to visualise the information required by the operator and the system
processes. It is also possible to make entries at it. The display communicates with the control
unit. Further information on operation is given in Chapter 8.5 Control panel)
panel).
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2.12. Control cabinet
The control cabinet conforms to the requirements of EN 60204 and contains the electrical and
electronic components for controlling the chiller. After removing the operator control panel the
control cabinet is accessible and can be opened using a standard two-way key. In order to avoid a
damage of the main switch while demounting the side panel, the side panel has to be tipped
10cm on the bottom side. A circuit diagram is supplied with the unit.
Figure 2: Demounting the side panel of the switch

switch cabinet
2.13. Pump
The chiller's pump ensures the necessary circulation of the cold water. The water is drawn out of
the chiller's internal tank and is pumped through the process circuit. Optionally, the units can also
be designed as a continuous flow cooler without tank, with pump or without tank, without pump
(see Chapter 3.1 Version without tank, with pump,
pump, and Chapter 3.2 Version without tank, without
pump).
pump
2.14. Fan
The fan draws the cooling air from the surroundings through the condenser and blows out the
heated air upwards out of the chiller. To prevent injuries, the fan is protected against accidental
contact by protective grilles. The fan's speed is variable and is controlled by the main printed
board. The speed of the fan is essentially controlled by the condensing pressure. The fan is
protected against thermal overload. In units with two fans the speed of fan 1 is always the same
as the speed of fan 2.
2.15. Cold water cycle

The cold water is drawn out of the chiller's internal tank by the internal pump and is pumped
through the process circuit. Optionally, the units can also be designed as a continuous flow cooler
without tank, with pump or without tank, without pump (see Chapter 3.1 Version without tank,
16 / 77 83000102.Kf
with pump,
pump, and
and Chapter 3.2 Version without tank, without pump).
pump In the process circuit the cold
water absorbs heat. The circuit closes when the cold water is pumped back into the chiller. It
flows through the evaporator, in which it gives off heat. The cold water then passes back into the
tank. The cycle begins again.
2.16. Materials used in the water circuit

The material composition of the standard equipment is shown in Table 5:
5
Table 5: Materials used - standard version

Component Material (cBoxX 30 – cBoxX 100)
Unit connections V2A 1.4305
Hose Synthetic rubber
Evaporator V2A 1.4301 and copper (99.9%)
Tank V2A 1.4301
Tank ports/connection sockets V4A 1.4571
Pump Grey cast iron and V2A 1.4301
Mechanical seal EPDM
Sealing plugs, yellow Polyamide PA 6
Sealing plugs, black Polyoxymethylene (POM)
Filling and drain cock Nickel-plated brass
Bends, tees, couplings Gunmetal CC499K
Fittings V4A 1.4408
Hose nozzles Nickel-plated brass
Swivelling elbow threaded coupling PVC and nickel-plated brass
(level indicator)
Temperature sensor PT1000 V2A 1.4301
Pressure sensor XSK AC10I-U188 V2A 1.4301
Overflow valve (optional) Gunmetal
Tank heater (optional) Nickel-chrome-iron alloy 825
Unit connections ABS
Piping and fittings ABS
evaporator V2A 1.4301 and copper (99,9%)
Tank V2A 1.4301
Pump Grey cast iron and V2A 1.4301
Mechanical seals EPDM
Filling and drain cock Nickel-plated brass
Swivelling elbow threaded coupling PVC and nickel-plated brass
(level indicator)
17 / 77 83000102.Kf
If equipped with the optional Water circuit in non-
non-ferrous metal-
metal-free version the material
composition is as shown in Table 6:
Table 6: Materials used for the non-

non-ferrous metal-
metal-free version
Unit connections (rotating parts) V2A 1.4305
Hose Synthetic rubber
Evaporator V2A 1.4301
Tank V2A 1.4301
Pump V2A 1.4301
Mechanical seal EPDM
Filling and drain cock V4A 1.4401
Fittings V4A 1.4408
Hose nozzles V4A 1.4408
Elbow threaded couplings PVC and polyoxymethylene (POM)
(level indicator)
Hose (level indicator) PE natural
Pressure sensor XSK AC10I-U188 V2A 1.4301
Overflow valve (optional) V2A 1.4301
Tank heater (optional) Nickel-chrome-iron alloy 825
Unit connections ABS
Piping and fittings ABS
evaporator V2A 1.4301
Tank V2A 1.4301
Pump V2A 1.4301
Mechanical seals EPDM
Filling and drain cock V4A 1.4401
Swivelling elbow threaded coupling PVC und polyoxymethylen (POM)
(level indicator)
Hose for level indicator PE nature
18 / 77 83000102.Kf
2.17. Water quality
The following limits must be maintained for safe operation of the equipment:
Table 7: Water quality
Property / Unit Value range Value range
components Standard version Non-
Non-ferrous metal-
metal-free version
pH value (20 °C) - 7-9 6-9
Saturation index - -0.2 < 0 < +0.2 -0.2 < 0 < +0.2
Conductivity µS/cm 80-500 5-500
Water hardness °dH <5.6 <5.6
Carbonate hardness mol/m³ <0.5 <0.5
Total plate count K/ml <10,000 <10,000
Grain size µm < 250 < 250
Glycol fraction (AFN) % by vol 20-40 20-40
Oil fraction % by vol 0 0
Chloride (Cl-) mg/l <50 <50
Sulphate mg/l <50 <50
Nitrate mg/l <100 <100
Copper mg/l <0.1 <0.1
Iron mg/l <0.2 <0.2
Free carbonic acid mg/l <20 <20
Manganese mg/l <0.1 <0.1
Ammonia mg/l <2 <2
Free chloride mg/l <0.5 <0.5
Sulphide mg/l <0.03 <0.03
In order to avoid a restriction of the plate heat exchanger the above listed limit values have to be
guaranteed imperatively.
Furthermore mucilage bacteria are not allowed in the cooling water. If that is not possible, KKT
chillers can recommend an accordant inhibitor based on a biologic water analysis.
19 / 77 83000102.Kf
2.18. Permitted cooling media
Water and mixtures of water / Antifrogen N (AFN) or water / Antifrogen L (AFL) according to the
details given in Chapter 2.17 Water quality.
quality. The following table shows the requirements for the
mix ratio of water with the antifreezes AFN or AFL. To maintain the performance of your machine
and prevent damage to components, these values must be maintained as precisely as possible.
ATTENTION! Do not mix different antifreezes. This can cause unwanted chemical
reactions and silting up.
Table 8: AFN and AFL mix ratios (or equivalent)

Setting Frost--free to
Frost AFN mix ratio AFL mix ratio
Glycol 20 - 25 % -10°C 20-25 % 25-30 %
Glycol 30 - 35 % -15°C 30-35 % 32-37 %
Glycol 40 % -25 °C 40 % 42 %
3. Options and accessories

The chiller can be equipped in the factory with the options described in the following.
The items marked "accessories" are enclosed with the unit, unattached, and can be reordered at
any time using the appropriate product number. The installer of the machine is responsible for
installing the accessories. You can also ask our KKT chillers Service Team to arrange for this
installation (see Table 1 Contact details).
details
Details of your machine's equipment are given in the separate summary documentation.
3.1. Version without tank, with pump

The Compact-Line units are also optionally available as continuous flow chillers. In this case the
units are delivered without an internal tank. The temperature sensor is then located in the
chiller's return line. If a tank open to the atmosphere is integrated on site, it is necessary to
ensure that the tank is not installed at a lower level than the chiller. Additional pressure losses
between the tank on site and integrated pump must be avoided (dpmax=0.3bar)
3.2. Version without tank, without pump

The Compact-Line units are also optionally available as continuous flow chillers. In this case the
units are delivered without an internal tank and without pump. The temperature sensor is then
located in the chiller's return line. The cold water is then circulated via the evaporator by a pump
to be installed on site. This must at least be designed to the pressure loss of the overall system.
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3.3. Version with water cooled condenser
Whereas the basic versions of the Compact-Line is specified with an air cooled condenser, the
units are also available with an water cooled condenser.
Thereby the condenser is a plate heat exchanger with copper brazed stainless steel plates. The
3way valve is mounted in the cooling water outlet and is adjusted by an actuator depending on
the condensing pressure. The operation mode can be switched from the 3way operation to a
2way operation by closing the pre mounted bypass valve. The cooling water temperature is
measured by an additional temperature sensor in the cooling water inlet and is shown at the
controller display.
The water quality shown in Table

Table 7: Water quality has to be guaranteed imperatively –
the manufacturer does not assume liability for damages caused by other water
qualities.
The project specific data as well as the adapted hydraulic scheme and the dimension sketch can
be found in the additional short documentation.
3.4. Heater for compressor and control cabinet

The oil sump heater prevents refrigerant from becoming deposited in the oil of the compressor at
low ambient temperatures. When the compressor is started up this refrigerant would be liberated
from the oil as gas and make the oil foam up. Under these basic conditions the lubrication of
components in the compressor subject to friction would be poor and the compressor could be
damaged.
The control cabinet heating is controlled thermostatically and, at low ambient temperatures, it
prevents moisture from the ambient air drawn in condensing on the electrical and electronic
components of the cabinet thereby damaging them.
For both heaters to be active, the chiller must not be disconnected from the power supply (8.2
mode).
Selecting the operating mode
3.5. Insulation of the cold pipes and the pump(s)

To prevent condensation on cold chiller pipes, where high temperature differences exist between
the surroundings and cold water flow and taking into account the relative humidity the option of
insulation of the cold pipes must be specified.
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3.6. Tank heater with thermostatic pump start
The tank heater maintains a minimum temperature in the tank. The pump circulates the cold
water, while the tank heater controls the temperature in the system. We recommend a hydraulic
installation as shown in Figure 3.
3 Any bypass valves must therefore always be installed frost-free.
For the heater to be active, the chiller must not be disconnected from the power supply. Even if
the external release (8.3 External release
release) is deactivated, the pump remains active.
cBoxX Frost-free area
Application
Figure 3: C6856 thermostatic pump start with overflow valve (recommended installation)
3.7. Overflow valve for standby mode

The optional overflow valve should be installed if it is possible for the flow of the cold water to
reduce sharply or be completely prevented while the unit is running. The internal overflow valve
ensures the minimum volumetric flow through the chiller and therefore prevents the pump from
switching off. Figure 4 shows the position of the internal overflow valve.
cBoxX Application
Figure 4: C6863 overflow valve for standby mode
3.8. Higher pressure pump

The standard Compact-Line units have a 3 bar pump, which is designed for the nominal
volumetric flow of the respective unit. Optionally the units can also be built with higher pressure
pumps, within the limits of the minimum or maximum volumetric flow (1.2 Technical data). data The
pump characteristic curve of the pump(s) used in your unit is enclosed with the unit.
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3.9. Second consumer circuit
The standard Compact-Line Line units have a 3 bar pump, which is designed for the nominal
volumetric flow of the respective unit. If several consumers with different water specifications are
to be cooled with one unit, the unit can also be supplied with an optional second cold water
circuit. Ask your KKT chillers contact.
3.10. Additional evaporator pump

The evaporator is optimised for the nominal volumetric flow rate of cold water. The nominal
volumetric flow rate is given in Table 3 Technical data.
data
If the operating volumetric flow rate of the cold water is
i more than 50 % smaller, an evaporation
pump must be installed. The evaporator pump circulates the cold water internally and keeps the
storage water at feed temperature. A second pump supplies the process circuit with cold water.
3.11. Automatic water feed

Anyy leaks and evaporation can cause the quantity of cold water available for the chiller function to
reduce during the course of operation of the chiller. The Automatic water feed option provides the
possibility of topping up the cold water circuit automatically.
automatically. The tank contents are monitored
continuously and if necessary topped up until it has again reached the optimum level. In this case
the operator only has to connect the chiller to the building's water system via the feed connection
(see Figure 5)
5). The inlet pressure must lie between 1 bar and 10 bar.
Figure 5: Top-
Top-up connection
The initial unit fill by means of the top-up

top up connection is only possible if the corresponding
controller function is activated. Further details are given in Chapter 6.2.15 Flushing the cold
circuit..
water circuit
If you operate your chiller with a mixture of water / glycol and top up only with pure water, you
must check the glycol content of the circuit water at regular intervals and if necessary adjust it.
3.12. Water circuit in non-

non-ferrous metal-
metal-free version
If your machine is a non-ferrous
ferrous metal-free
metal free version, all parts of the chiller's cold water circuit in
contact with the media are free from non-ferrous
non ferrous metals. Certain components such as the
evaporator and pump are suitably modified.
dified. The materials used in the water circuit are listed in
Table 6.
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3.13. DI package
The DI package contains the non-ferrous metal-free option for the water circuit (see chapter,
3.12) and a replaceable DI cartridge with conductivity monitoring and control.
3.14. Special voltage

If you machine is equipped for a special voltage, electrical components such as the compressor
and pump have been adapted. Your machine must only be operated with the voltage noted on the
rating plate.
3.15. Phase monitoring

The Compact-Line units can be equipped with optional phase monitoring. This monitors the phase
sequence, phase failure, undervoltage and asymmetry and covers a voltage range of 200-690V. If
the respective predefined limits are exceeded the system switches off and protects the electrical
components installed in the unit.
3.16. Hot gas bypass for output control <1K

If a more precise target constant than ±1 Kelvin is required, the chiller can be equipped with an
output control. In this case the output of the refrigeration circuit is adjusted to the cooling
demand by an electronically controlled valve. Unlike the standard control by switching
compressors on or off, a higher target constant is achieved by the continuous regulation of the
valve.
3.17. High-
High-temperature package
In principle, the units must be operated within the given ambient temperature range (see see
Table 3). If the high-temperature package is selected, the unit can be operated at an ambient
temperature of up to 50 °C without high-pressure faults.
3.18. Special paint finish

While the condenser's protective grille is always painted in RAL 7015 anthracite black, the
cladding panels (1.3 Elements)
Elements can also be optionally finished in special colours.
3.19. Air filter mat (accessories)

If the chiller is operated in surroundings with dust or oil vapour the condenser should be
protected with the air filter mat. The filter is fixed using the Velcro tapes attached in the
condenser protective grille. The filter is cleaned by removing it and washing it with water or a
slightly alkaline solution. Heavily-contaminated filters must be replaced by new ones. Please
contact the KKT chillers Service Team (see Table 1 Contact details).
details
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3.20. Levelling feet (accessories)
The levelling feet are used for vibration isolation and for height adjustment. They consist of a
threaded rod and a grey cast iron shell with an elastic element attached. The threaded rod
enables the height to be adjusted and compensates for floors sloping by up to 5°. The elastic
element has a slip-resistant covering. Figure 6 and Figure 7 show the installed machine foot – the
technical drawing is given in the appendix.
Figure 6: Machine base (foot) – outside view
Figure 7: Machine base (foot) - mounting on the baseplate
3.21. Level package (accessories)

The level package is used if the application is to be installed more than 500 mm above the chiller
(see also Chapter 6.2.7 Process level).
level This option is delivered uninstalled and consists of an
electronically controlled valve and a non-return valve. The electronically controlled valve must be
installed at the unit inlet, the non-return valve at the unit outlet. The electronically controlled valve
is installed electrically in the control cabinet as shown in the circuit diagram.
3.22. Filter assembly group coolant circuit (accessories)

(accessories)
The water filter protects the coolant circuit against dirt. The set, consisting of a filter, fitting and
two shut off valves, is enclosed with the chiller in a separate pack and must be fitted onto the
cold water inlet of the chiller from the outside when the chiller is installed.
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3.23. Filter assembly group cooling water circuit (accessories)
The water filter protects the cooling water circuit against dirt. The set, consisting of a filter, fitting,
two shut off valves and two pressure gauges for displaying the cooling water inlet- and outlet
pressure is enclosed with the chiller in a separate pack. The installation can be either mounted
for shutting of the filter group or for shutting of the complete cooling water circuit.
3.24. MultiplexX connection group (accessories)

If the refrigerating capacity of a chiller is not sufficient, several units of the same type can be
combined in the version with tank and pump. A MutliplexX connection group can be ordered for
this purpose and consists of the level package (3.21 Level package) package and a corresponding
connection kit for the flow balance between the tanks. The refrigerating capacity of the individual
units can then be added together. Please contact your KKT chillers contact to arrange the
appropriate project planning for this option.
3.25. Refill cartridge R410A (accessories)

Chillers with refrigerant capacity >12kg must be declared as dangerous goods in accordance with
UN2857 (5.1 Dangerous goods).goods The optional R410A refill cartridge is available for units with
refrigerant capacities >12kg (cBoxX 120- CBoxX 200) so that you do not incur any additional
logistics costs. Following the performance check in the factory, a quantity of refrigerant is filled in
a certified refrigerant cylinder so that the 12kg limit is kept to in the unit. The refill cartridge is
then delivered together with the unit. The refrigerant quantity drained for transport can be
returned to the system as part of the commissioning using the summary description provided with
the refill cartridge.
3.26. Anybus-
Anybus-Gateway (accessories)
The Anybus-Gateway is ready mounted in the switch cabinet and can be used as an interface for
processing all chiller signals. Therefore the following processing protocols are available
depending on the customer specification:
Modbus
Profibus
CANopen
Profinet
Devicenet
EtherNet
EtherCAT
ControlNet
CC-Link
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3.27. Remote Control Panel (accessories)
For the case that the chiller shall be operated not from the machine itself but from a different
operating place the chiller can be delivered with a remote control panel. Thereby the same display
is mounted together with the operating voltage supply in one miniature housing. The remote
control panel can be connected to the chiller via the RS485 interface and takes over the
complete function of the controller in the main device. By setting the accordant bridge in the
switch cabinet of the main device, the required operating place can be chosen.
3.28. Special languages (accessories)

These instruction manuals are provided in German, English, French and Spanish. Other languages
are available on request.
3.29. Wooden Crate (accessories)

Whereas the chillers of the Compact-Line are delivered on a wooden palette with Styrofoam
corners stretched in the foil as a standard, the chillers can be also ordered in a wooden crate.
There the chillers are protected additionally by a wooden crate with IPPC-Label according
ISPM 15.
3.30. Seaworthy crate packaging (accessories)

Seaworthy crates for the Compact-Line are produced according to International Standards for
Phytosanitary Measures with packaging made of solid wood (ISPM 15). This means that the
crates are made of heat-treated solid wood which has been stripped of its bark. Only wood-based
materials, such as OSB boards, are used. In addition, all crates are marked with the IPPC logo
and registration number. The units are fixed in the crate with the help of coach bolts, ring nuts
and polyester straps and are packed in a sea air consistent foil with desiccant. The components
used to pack the units can be dismantled using a cross-head screwdriver.
3.31. Water Pump Redundancy

Depending on the optional configuration, the cboxX (water chiller) can be equipped with a dual
water pump for redundancy and increased life time of the pump itself. The operating hours of the
pumps are programmable and can be shared by both pumps (f. e. 24h switch on/off between
both pumps). In case of a pump defect, an automatic switch to the pump redundant, ensures the
continuation of the water chiller and the operation of the end customers application.
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3.32. Closed Water Loop
The water chiller is designed as a closed water loop system with an expansion tank. The
expansion tank is pressurized in accordance with the volume of the entire system volume
(including installation).The expansion tank balances temperature swings and related system
pressure of the water loop. In case the coolant temperature rises the expansion tank takes in the
expanded volume of the coolant and if the coolant temperature falls the stored volume will be
released back into the loop again.
Advantages of a closed water loop system are:

- No top up or refill required, due to no evaporation of the coolant
- No dirt or algues in the coolant
- No cleaning required of the tank
- Reduces weight of the chiller
4. Safety
Provided it is used as intended, the chiller is designed to operate safely, provided also that the
instructions concerning transport, installation, commissioning/startup and maintenance given in
these operating instructions are complied with. The machine conforms to the safety standards in
accordance with the EC Declaration of Conformity (see Appendix III).
4.1. General information

The chiller contains a high-pressure circuit. The maximum pressure that occurs is 45 bar. Even
when inactive or disconnected from the power supply the circuit is still under pressure.
4.2. Hazard warnings

A number of warning labels are applied to the machine. Keep these warnings clean at all times.
Damaged or missing warnings must be replaced.
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Table 9: Definition of the safety symbols
Note and follow the instructions for use!
Before opening the machine it must be disconnected from the power supply!
After disconnecting the machine from the power supply, always wait for at
least 2 minutes before opening it.
Danger! High voltage! If the machine is only switched off at its main switch,
dangerous electrical
electrical voltage is still present at several terminals in the control
cabinet.
Wear foot protection!
Wear hand protection!
Wear eye protection!
Wear protective clothing!
Warning! Hot surface!
Warning! Cold surface!
ATTENTION!
Contains pressurised gas!
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In particular, the following hazard warnings apply to the machine:
Table 10:
10: Hazard warnings
ATTENTION! Work on the chiller must be carried out by properly qualified,

competent personnel!
The surfaces of pipes and components of the refrigerant and cold water
circuit and electrical equipment can be very hot during operation and even
for a while after.
The surfaces of pipes and components of the refrigerant and cold water
circuit and electrical
electrical equipment can be very cold during operation and even
for a while after.
ATTENTION! Pipes and components of the refrigerant and cold water circuit
are pressurised.
ATTENTION! Do not undo the system parts. Risk of injury on contact.
ATTENTION! Only use the specified liquids!
4.3. Residual energy

Even if all the hazard warnings in the chapter above are taken into account, the following residual
energy situations can result in a hazard:
Rotational energy of the decelerating fan

o Despite the installed protective grille, hair or pieces of clothing can still be drawn
in and caught.
Hot surfaces on machine parts
o Especially the compressor head and the hot gas pipe and the condenser can still
be very hot for some time after the machine has been switched off.off Temperatures
within the range from 60°C to 90°C are possible.
Dangerous electrical voltage in the control cabinet despite the switched off main switch
o If the machine is only switched off at its main switch, dangerous electrical voltage
is nonetheless still present at several terminals in the control cabinet. In
particular, these are the main supply terminal and the input terminals of the main
switch.
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Refrigeration circuit is pressurised
o Provided it is not damaged the refrigeration circuit is closed. Therefore, a hazard
is not to be assumed.
Note:
After switching off the unit at the main switch, if you wait for 3 minutes before opening the unit
risks due to rotational energy and electrical power can be reduced. In this case only the residual
thermal energy must be considered.
4.4. Safety devices, guards and safeguards
4.4.1. High-
High-pressure limiter
The high-pressure
pressure limiter (PZH) is a pressure switch with manual reset. The PZH limits the
condensing pressure and switcheswitches off all compressors via their load contactors when the
maximum permitted system operating pressure is reached. It is part of the safety chain. The PZH
is installed on the refrigerant collector for the chiller types cBoxX 30 – cBoxX 200 and on the fluid
f
pipe for the chiller types cBoxX 120 – cBoxX 200 (see Figure 8: Position of the high- high-pressure
limiter (PZH))
(PZH)). If the PZH has triggered, a message appears at the operator control terminal. In
this case, please follow the instructions in the Troubleshoo
Troubleshooting
ting chapter (see Appendix 0).
).
High-pressure
pressure limiter (PZH)
High pressure limiter (PZH) High pressure limiter (PZH)

cBoxX 30 – cBoxX 100 cBoxX 100 – cBoxX 200
Figure 8: Position of the high-

high-pressure limiter (PZH)
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4.4.2. High-
High-pressure monitoring
If the high pressure in the refrigeration circuit of your machine increases to a maximum value, the
compressors are switched off via the High- High-pressure limiter (see Chapter 4.4.1 High-
High-pressure
limiter).
limiter A manual reset is required. The high-pressure monitoring on the other hand reduces the
compressor output before the PZH's switch-off value is reached. This is done by successive
switching off of one or more compressors. A message appears at the control panel. When the
high pressure has reduced to a minimum value of 31.5 bar, the compressors are released once
more. In most cases partial shutdown of the compressors enables operation of the chiller to be
maintained with reduced output. If the high-pressure monitor has triggered, please follow the
instructions in the Troubleshooting chapter (see Appendix 0). ).
4.4.3. Low-
Low-pressure monitoring
If the low-pressure in the refrigeration circuit of your system is too low for the specified cooling
medium there is a risk of freezing. For this reason the low pressure is monitored continuously and
if it falls below a minimum value, one or more compressors are switched off successively. A
message appears at the control panel. If the low pressure has increased to a minimum value the
compressors are released once more. In most cases partial shutdown of the compressors
enables operation of the chiller to be maintained with reduced output.
If the low-pressure monitor has triggered, please follow the instructions in the Troubleshooting
chapter (see Appendix 0).).
4.4.4. Flow monitoring

If the volumetric flow of the cold water which is pumped through the evaporator is too low, there
is a risk of freezing. For this reason the flow through the evaporator is monitored continuously. If
the volumetric flow rate is only around 50 % of the nominal volumetric flow rate, the message
"Flow warning" appears.
If the rate falls below the minimum value of 20 % the compressors are switched off and the
message "Flow stop“ appears. In this case, please follow the instructions in the Troubleshooting
chapter (see Appendix 0). ).
4.4.5. Personal protective equipment when operating the machine

Operating the machine involves making settings at the control panel. During operation of the
machine its cladding panels are installed, the machine is completely enclosed. No protective
equipment is needed.
We recommend ear protectors be worn by persons with jobs that require them to be continuously
in the immediate vicinity of the chiller. Please refer to the sound emission information included in
the technical data.
4.5. Personal protective equipment for servicing work

Servicing work on the machine includes all work for which the machine is opened and one or
more cladding panels are dismantled. In particular, this includes cleaning work in accordance
with Chapter 9 Cleaning and maintenance work in accordance with Chapter 10 Service.
Service Before
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work is carried out on the chiller the protective equipment described in Table 9: Definition of the
safety symbols must be used.
Table 11:
11: Personal protective equipment for servicing work
Wear foot protection!
Wear hand protection!
Wear eye protection!
Wear protective clothing!
4.6. Airborne sound emissions

The airborne sound emissions data is given as the sound pressure level, measured at a distance
of five metres without reflection. Its maximum value is shown in the technical data. This only
occurs at the highest fan speed at the air intake side of the chiller (Figure
(Figure 9,
9 measuring point [1]).
The emissions in [2] to [4] are generally around 10 % lower than [1].
3 1
2
Figure 9: Airborne sound emissions
In partial load mode or under favourable ambient conditions (see Chapter 4.7.1 Noise)
Noise) the fan
speed and therefore the sound emissions reduce automatically.
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4.7. Notes on reducing noise and vibration
4.7.1. Noise
Details of your chiller's airborne sound emissions are given in Chapter 4.6.
To reduce noise pollution caused by airborne sound emissions it is advisable to install the chiller
out of doors and out of the range of workplaces.
If this is not possible we recommend that when the unit is installed attention is paid to ensuring
that the air intake side is not pointed directly at a workplace/workstation.
High ambient temperatures mean high fan speeds and this increases the noise levels produced.
It is advisable not to expose the chiller to direct sunlight or to install it in rooms with high air
temperature. Further information is given in Chapter 6.2 Installation site.
site.
4.7.2. Vibration
The chiller is designed so that the vibrations caused by the compressor are largely isolated by the
chiller's frame.
To minimise the effect of vibration still further it is possible to install the chiller with optionally
available levelling feet (3.20 Levelling feet ). These are fitted with damping elastomers.
4.8. Residual risks
4.8.1. Electrical
If all safety provisions are complied with there is no risk.
4.8.2. Mechanical
If all safety provisions are complied with there is no risk.
Mechanical damage to components or pipes of the refrigerant circuit can cause refrigerant to
leak. Leaking refrigerant can cause cold burns.
4.8.3. Chemical
ATTENTION! Toxic and caustic products are produced by

by the thermal
decomposition of the R410A refrigerant.
ATTENTION! Do not install in rooms with naked flames or smoke.
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4.8.4. Other
ATTENTION! Risk of suffocation if the chiller is installed in a room that is too

small. Please note and follow Chapter 6.2.2..
ATTENTION! In the EU you must follow the provisions of EN378

EN378--3. Please also
note and follow the local installation regulations and provisions, especially the
Ordinance on handling water pollutant substances and BGR500 Chapter 2.35.
4.9. Dangerous substances
4.9.1. Refrigerant R410A

First aid measures:
After inhaling: remove victim to fresh air, ensuring your own safety, and keep the person
at rest in a comfortable position. Get medical attention. If the person stops breathing,
give artificial respiration.
Following skin contact: leave clothing that has fused with the skin. Rinse areas damaged
by cold with lukewarm water (never use hot water). Do not rub! Cover with sterile
dressing. Ensure medical treatment is provided.
Following eye contact: rinse the eyes with clean water or eyewash solution for at least 15
minutes with the eyelids open. Consult an eye specialist.
After swallowing: swallowing is not considered to be a likely risk as the refrigerant in the
surroundings is gaseous.
Notes for the doctor: do not give the patient catacholamine or adrenalin ephedrine preparations.
Fire-fighting measures:
Suitable extinguishing agents: The product itself does not burn. Match the extinguishing
measures to the surrounding fire. Cool containers with sprayed water.
Particular hazards due to the substance, its combustion products or gases formed:
forms toxic and caustic gases and fumes on decomposition.
Special protective equipment for fire-fighting: self-contained or air-line breathing
apparatus and acid-resistant protective suit for deployment in immediate vicinity.
Further information: The effect of fire can cause bursting or explosion of the container.
Ignitable gas-air mixtures possible under certain conditions.
Measures in case of accidental release:

Environmental protection measures: where possible do not allow the product to get into
the environment.
Cleaning procedure: leave the product to evaporate.
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Handling and storage:
Handling: fire and explosion protection: heating results in increased pressure and a risk
of bursting. Cool containers at risk with water. Open the containers slowly and carefully.
Personal protective equipment:

Respiratory protection: not necessary if adequate ventilation available. Self-contained or
air-line breathing apparatus within enclosed rooms, if insufficient oxygen supply
available, in case of substantial or uncontrollable release. Only use breathing apparatus
in accordance with the international / national standards. Only use breathing apparatus,
no filtering devices.
Hand protection: chemical-resistant protective gloves. Recommended material: Polyvinyl
alcohol.
Eye protection: close-fitting safety glasses/goggles.
General protection and hygiene measures:

Do not inhale fumes / aerosols.
Do not eat/drink or smoke during work.
4.9.2. Oil POE 160SZ

First aid measures:
After inhaling: remove victim to fresh air, ensuring your own safety, and keep the person
at rest in a comfortable position. Get medical attention.
Following skin contact: remove soiled, soaked clothing. Wash skin with water. If
symptoms develop, get medical advice.
Following eye contact: rinse the eyes with clean water or eyewash solution for at least 10
minutes with the eyelids open. Consult an eye specialist.
After swallowing: can cause vomiting. Have the mouth rinsed out with water and give the
patient two glasses of water to drink. Get medical advice.
Notes for the doctor: symptomatic treatment and assistive therapy as indicated.
Fire-fighting measures:
Low fire risk. Product only ignites in case of very large heat supply.
Suitable extinguishing agents: match to the surroundings. Carbon dioxide, powder and
foam extinguishing agents. Use water with caution to avoid possibly considerable steam
generation.
Particular hazards due to the substance, its combustion products or gases formed:
irritant fumes are released during thermal decomposition.
Special protective equipment for fire-fighting: self-contained or air-line breathing
apparatus and acid-resistant protective suit for deployment in immediate vicinity.
Further information: The effect of fire can cause bursting or explosion of the container.
Ignitable gas-air mixtures possible under certain conditions.
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Measures in case of accidental release:
Environmental protection measures: do not allow the product to get into the sewers or
bodies of water. Absorb with sand, soil or a similar absorbent material. Ensure proper
disposal in containers.
Cleaning procedure: Clean the contaminated area with water. Caution! Slipping hazard!
Further information: Inform the police or competent authorities in case of penetration in
the sewers or bodies of water.
Personal protective equipment:

Respiratory protection: Not necessary if adequate ventilation available. Self-contained or
air-line breathing apparatus within enclosed rooms, if insufficient oxygen supply
available, or in case of substantial or uncontrollable release. Only use breathing
apparatus in accordance with the international / national standards. Only use breathing
apparatus, no filtering devices.
Hand protection: protective gloves. Recommended material: nitrile rubber.
Eye protection: close-fitting safety glasses/goggles.
Handling and storage:

Handling: avoid lengthy skin contact. Avoid inhaling high concentrations of vapour or
fumes.
Storage: suitable material for containers: mild steel. Tightly close unused containers to
prevent the penetration of moisture. Store away from strong oxidants.
4.10. Reasonably foreseeable misuse

Reasonably foreseeable misuse, for the users of the chiller, means foreseeable use in a way not
intended according to the operating instructions. It is due to foreseeable human behaviour.
The following Dangerous situations can arise due to misuse which could reasonably be expected:
dangerous voltage of electrical components, if the machine is not disconnected from the
power supply before it is opened.
the fan and compressor can start up suddenly, without any visible change to the
machine's state.
even if the machine has been disconnected from the power supply, the surfaces of
components in the unit can still be very hot or cold.
risk of damage to external hydraulic components if the cold water feed is confused with
the cold water return.
danger caused by using media in the unit that have not been approved.
danger caused by connecting an incorrect source of power.
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4.11. Information for emergencies
If an emergency occurs during operation of the chiller the machine must be disconnected from
the mains at once using the master switch. Remove people from the danger zone immediately. An
emergency situation can among other things be:
o a leak and escape of refrigerant and/ or oil.
o a part of the machine becoming mechanically detached from it.
o the machine making unusual noises.
o the machine vibrating severely.
Then contact the KKT chillers Service Team. If you detect a refrigerant or oil leak, proceed as
described in Chapter 4.9 Dangerous substances.
substances.
5. Handling and storage

The chiller is fixed on a wooden pallet in the factory for delivery. The machine is additionally
protected against damage by polystyrene corner protectors and stretch film. Therefore you should
remove the packaging as late as possible.
5.1. Dangerous goods

Chillers with refrigerant capacity >12 kg must be declared as dangerous goods in accordance
with UN2857. The cBoxX 30 – cBoxX 100 chillers have been specified so that they contain <12
kg refrigerant. The cBoxX 120 – cBoxX 200 chillers basically have a refrigerant filling >12kg. In
order to avoid the declaration as dangerous goods also for these types, the option Refill cartridge
R410A (accessories) (see chapter 3.25) can be ordered. Following the performance check in the
factory, a quantity of refrigerant is filled in a certified refrigerant cylinder so that the 12kg limit is
kept to in the unit. The refill cartridge is then delivered together with the unit. The refrigerant
quantity drained for transport can be returned to the system as part of the commissioning using
the summary description provided with the refill cartridge.
5.2. Transport
The chiller may only be transported using a fork lift truck or crane with sufficient rated capacity.
The net weight of your machine is given in the technical data. Please note that if a machine has
already been in operation, it can contain residual fluids, which increase the transport weight.
ATTENTION! The chiller must not be tilted by more than 10° from the
perpendicular position.
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5.2.1. Forklift truck
It is possible to transport the machine both in a packed and an unpacked condition by means of
fork lift truck. In this case, please note the defined centre of gravity marking as shown in
Figure 10 and Figure 11.
11
Figure 10:
10: C6845-
C6845-0 centre of gravity cBoxX 30 - 60
Figure 11:
11: C6846-
C6846-0 centre of gravity cBoxX 70 – 100
Figure 12:
12: C6846-
Figure 13:
13: C6846-
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5.2.2. Crane
When it is unpacked the machine can be lifted by means of a crane and an adequately
dimensioned lifting beam. Figure 14 shows the regulations for transport by crane. Please also
refer to the Table 12 for the dimensions and descriptions of the Figure 14.
14
Figure 14:
14: C6841-
C6841-0 crane transport cBoxX 30 - 100
Table 12:
12: Description of figure C6841-
C6841-0
A Transport sling or rope (do not use chains)

B Locking bolt
C Split rivet
D Pipe diameter: 30 – 50 mm, Wall thickness: min. 3 mm, Length: ~ 1000 mm
E 1300 mm (cBoxX 30 – cBoxX 60)
1900 mm (cBoxX 70 – cBoxX 100)
1400 mm (cBoxX 120 – cBoxX 160)
1900 mm (cBoxX 180 – cBoxX 200)
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5.3. Unpacking
ATTENTION! Packing straps are mechanically stressed and can snap back when
cut. Risk of injuries!
Remove all straps, films, corner protectors and spacers carefully. Optional accessories may be
located under the film. Ensure that they are not damaged.
The packaging can be recycled according to the local regulations. Refer to the following table for
details of the packaging materials used:
Table 13:
13: Materials in the packaging
Element Material Recycling code

Polystyrene corner
Polystyrene
protectors
Stretch film Polyethylene
Edge protection / corner

Cardboard
protectors
Packaging tape Polypropylene
Strapping seals Zinc-plated steel
Untreated raw wood, spruce or pine

Wooden pallet
without bark
5.4. Storage
If the chiller is stored for more than one month, it should remain in the transport packaging or be
repacked.
The following conditions must be noted for storage:
Avoid direct sunlight and moisture

Ambient temperature - 30°C to + 50°C
To avoid frost damage the cold water

water circuit must be completely drained before the chiller is
placed in storage and then flushed with a mixture of water and anti-freeze
anti freeze (see 11.1 Draining).
Draining
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6. Installation
6.1. Overview
Several tasks are necessary to install the chiller. The following work schedule shows the order in
which they are carried out:
Prepare the installation site
Install the machine
Flush the cold water circuit
Hydraulic installation
Fill the whole system
Vent the whole system
Electrical installation
6.2. Installation site
6.2.1. General information

information
The chiller is suitable for both indoor and outdoor installation (note options packages). The
electrical degree of protection corresponds to IP54. If installed indoors, ensure sufficient air
exchange. An enclosed room will steadily heat up and the machine can switch off due to a lack of
cooling. The exhaust heat from the machine can be approximately calculated as 1.3 x net
refrigeration capacity. The air flow rate required for your machine is given in Table 3 Technical
data.
data. When choosing the installation site, ensure that waste heat from other processes cannot be
guided directly onto the air intake side of the chiller.
ATTENTION! Do not install in rooms with naked flames or smoke.
6.2.2. Minimum room volume

The refrigerant R410A contained in the system is classified in safety group A1 in accordance with
EN 378-1 Table E.2. I.e. the refrigerant is not flammable and has low toxicity. If the chiller is
installed in enclosed rooms without additional safety measures a minimum room volume is
required. This is due to the maximum concentration occurring in an area occupied by persons in
the event of release and depends on the refrigerant quantity in the chiller. Please refer to the
following table for the value to be complied with for your machine.
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Table 14:
14: Minimum volume of the installation room with regard to maximum refrigerant
concentration in case of a leakage if installed indoors
cBoxX chiller 30 40 50 60 70 80 90 100 120 160 180 200
Minimum 14 14 14 16 20 20 20 20 40 40 55 55
volume of the
installation room
(in m³)
6.2.3. Ambient temperature

The chiller is cooled by the ambient air and the lower the temperature of this cooling air the more
economically the chiller works. Direct sunshine or exhaust air from other machines heats up the
surrounding air and must be taken into account when installing the chiller. Preference is for a
shaded installation. The maximum ambient temperature is given in the technical data.
6.2.4. Effect
Effect of surrounding air flow
The chiller emits heat to the surrounding area, the machine also draws in cooling air. The
machine controls the quantity of cooling air automatically via the speed of the fan. Air currents
surrounding the machine, such as the wind, can affect this control and endanger operation of the
machine. If a constant direction of an air current is known at the installation site, this should not
be directed at the air intake side of the chiller.
6.2.5. Minimum clearances

The minimum clearances around the machine are made up of service clearances and clearances
to ensure optimum air supply. On the one hand accessibility must be ensured from all sides, in
addition, an unhindered, sufficient quantity of cooling air must be able to be drawn in and blown
out upwards. If the minimum clearances are not complied with there is a risk of an air short-circuit
between the air intake and discharge side. As regards to the minimum clearances please refer to
Annex III.
III.
6.2.6. External attachments

In general a free pressure (compressive force) of 5 Pa is available for external attachments.
Malfunctions can be caused if this is not adhered to. Figure 15 shows a layout with which you
can implement a system with rectangular ducts while complying with the free pressure. The duct
system consists of a straight piece of duct [1], a 90° elbow bend [2] and another straight piece
of duct [3].
The ducts are made of sheet steel, the duct cross-section must be adjusted to the machine base
area (footprint). The straight pieces of duct [1] and [3] are each no longer than 2 metres. The
90° elbow [2] has a pressure loss coefficient of ζ ≤ 0.2. The system designer is responsible for
the sealing and mechanical fixing of external attachments.
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2 3
Figure 15:
15: Exhaust air duct cBoxX 30-
30-200
Duct systems with a pressure loss higher than 5 Pa require external ventilation with a variable air
flow rate. Please contact our KKT chillers Service Team (see Table 1 Contact details).
details
6.2.7. Process level

The chiller must not be installed more than 500 mm below the process level. There is a risk, when
the chiller is not in operation, of the cold water draining via the internal tank of the chiller. If this
installation situation is nonetheless necessary the optional Level package (3.21 Level packagepackage))
must be installed.
6.2.8. Surface and foundation

The surface on which the machine is installed must be flat and horizontal. All the machine's feet
must have uniform contact with the ground. Ensure that the ground/subsoil has sufficient load
bearing capacity. According to the installation instructions (see
see annex III)
III a continuous concrete
foundation with the given minimum size is recommended. For details, the gross weight of your
machine is listed in the technical data (Table
Table 3: Technical data).
data In the case of chillers equipped
with a tank the net weight increases during operation by the quantity of liquid in the tank. This
gives the gross weight.
If it is not possible to lay a foundation, the machine can also be positioned on a baseframe made
of steel sections. Please also ensure here that all the unit feet have uniform contact with the
baseframe.
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6.2.9. Stability
The normal situation is for the machine and the baseplate to be stood firmly on the ground. It is
not necessary to anchor the machine to the ground. However, if this is necessary due to the
surrounding conditions, the machine can be equipped with the optionally available levelling feet
(3.20 Levelling feet . The levelling feet provide very good resistance to slipping. If this is not
sufficient for your application the machine can also be bolted to the ground. Holes are provided in
the machine baseplate for precisely this purpose. These are shown in Appendix III. III The system
designer is responsible for choosing suitable fixing elements.
6.2.10. Levelling
If it is necessary to level the chiller on the ground or floor, this can be done using the optionally
available levelling feet.
6.2.11. Vibration isolation

If it is necessary to isolate the chiller on the ground or floor, this can be done using the optionally
available levelling feet. The levelling feet are fitted with vibration-isolating elastomers.
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6.2.12. Installation
Filling and feed (topping up)
Draining
Unit outlet cold water circuit 1 (supply

supply line)
line
Unit outlet cold water circuit 1 (return

return line)
line
Unit outlet cold water circuit 2 (supply line)
Unit outlet cold water circuit 2 (return line)
6.2.13. Hydraulic installation

The system designer is responsible for choosing the material and the cross-section
cross of the
hydraulic connections between the chiller and the application. Other dependent factors include
the accepted pressure loss in the connection lines and the available pump
pump pressure. When
designing the connections attention must also be paid to the minimum flow rate to be maintained
and sufficient resistance to the maximum pump pressure.
In the case of chillers equipped with an internal tank the cold water cycle must be hydraulically
h
closed.
ATTENTION! Galvanised pipes must not be used if water-

water-glycol mixtures are
used! Formation of decomposition products, which result in silting up of the
system!
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6.2.14. Frost protection measures
The chiller is exposed to the risk of frost in two different situations. Both with an ambient
temperature < 0 °C and a feed temperature < 8 °C there is a risk of freezing of parts of the cold
water circuit system.
Installation in ambient temperature < 0 °C with anti-freeze

The machine is protected against freezing by antifreeze. Ensure that you always comply with the
requirements with regard to the operating fluid and the mix ratio. This is also valid for the version
with water cooled condenser (3.3 Version with water cooled condenser
condenser).
Feed temperature < 8 °C

The machine must be protected against freezing by antifreeze in accordance with the
specifications. Please note that the evaporation temperature is always significantly below die cold
water flow temperature. Even within the supposedly safe temperature range there can still be a
risk of freezing. Ensure that you comply with the requirements with regard to the operating fluid
and the mix ratio.
6.2.15. Flushing the cold water circuit

Contamination of external pipes and components can damage the chiller. Before the chiller is
connected hydraulically with the cold water circuit this must be flushed several times. If there are
dirt traps in the cold water circuit they must be cleaned after the flushing.
6.2.16. Filling
If the hydraulic installation of the overall system has been completed the chiller can be filled. All
shut-off valves in the cold water circuit must be opened.
ATTENTION! Only use approved refrigerants, see Chapter 2.15!! If there is a

risk of frost, note Chapter 6.2.14!!
All operating liquids must be mixed before they are added to the system!
Procedure for chillers with integrated tank:
Remove the cladding panels 3 and 4 (see Chapter 1.3 Elements)

Elements and fill your system via the
internal filling connection mounted on the tank or use a hose to fill directly into the internal tank.
Procedure for chillers without integrated tank:
In the standard installation a machine without integrated tank does not have a filling connection.
You must provide a filling connection in the process circuit for filling the system. If an external
tank is installed in the process circuit, fill your system directly in this tank.
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Procedure for chillers with automatic top-up:
top
If your machine is equipped with the optional 3.11 Automatic water feed, feed, the cold water circuit
can also be filled automatically. However, beforehand the tasks in 6.2.18 Electrical installation
must be completed. You must also install a hydraulic connection between your building water
system and the external filling connection of the machine.
machine. Please note that the inlet pressure
must not exceed 10 bar. The volumetric flow rate should be at least 0.75 m³/h. If this has been
done, activate the initial fill in the controller menu (→Main menu / Settings / First fill).. Note that
the first fill is controlled
ontrolled by the level in the internal tank. Before activating the first fill, always
ensure that the cold water circuit is free of leaks. The control adds fresh water until the operating
level is reached.
All filling and feed connections are identified with

w the following pictogram:
Figure 16:
16: Filling and feed connection
ATTENTION! In the EU you must follow the provisions of EN378

EN378--3. Please also
note and follow the local installation regulations and provisions, especially the
Ordinance on handling water
water pollutant substances and BGR500 Chapter 2.35.
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6.2.17. Venting
If your chiller contains a horizontal pump (standard for cBoxX 30 – cBoxX 100), the pump does
not have to be vented. If your chiller contains a vertical pump (standard for cBoxX 120 – cBoxX
200) the pump has to be vented. To do this, before switching on the pump the vent plug must be
opened and left open while the unit is running until all air has completely escaped from the pump
body (see Figure 17).
17
Pump venting
(here: open-ended spanner SW9)
Figure 17:
17: Position of the pump vent (vertical type)
If your chiller is equipped with an internal tank, further water circulation ensures that the residual
air in the overall system can escape into the atmosphere via the open tank.
For machines without a tank we recommend installing an automatic venting valve at the highest
point in the cold water circuit.
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6.2.18. Electrical installation
ATTENTION! The electrical installation, testing and commissioning may only be

carried out by qualified personnel. Note and follow the local regulations.
ATTENTION! Do not switch on the chiller until the hydraulic installation is

completed and the machine has been filled as specified in Chapter 6.2.15..
Otherwise the machine could be damaged.
The chiller is connected electrically to its main supply terminal in the control cabinet. (see Figure
18 Main supply)
supply). A circuit diagram is supplied with the unit.
Figure 18:
18: Main supply
The dimensioning of the load cable and the fusing must be in accordance with the machine's
technical data and the local regulations of the power supply company.
The supply cable must be routed into the machine. Cut-outs are provided for this purpose in the
baseplate and in the compressor mount (cBoxX 30 – cBoxX 100). Feed the supply cable,
protected by rubber grommets, through these openings (see Figure 18 Main supply).
supply).
Never switch on the chiller immediately if the machine is moved from a cold into a warm room.
The condensing moisture can damage electronic components. For the initial startup or following a
lengthy period out of use all the electronic components must have become acclimatised.
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Use an external control cable to set the chiller's release (see Chapter 8.3 External release)
release); this
cable is laid parallel with the supply cable and is wired at the corresponding terminals in the
control cabinet. The machine is bridged at the corresponding terminals on delivery.
If the electrical installation has been completed the phase sequence must be tested. This is done
by checking the rotational direction of the pump. This has a rotational direction arrow on it. If the
rotational direction does not match the arrow, the phase sequence can be corrected by swapping
two phases at the main supply.
7. Commissioning
Before commissioning the chiller the checklist must be used to check whether all the necessary
work in Chapter 6 Installation has been carried out properly.
The chiller must be installed for at least 12 hours at >+5 °C, so that the compressor oil can heat
up and the refrigerant can be liberated from the oil.
If your machine is equipped with oil sump heating and the machine has been completely
installed, it is permissible to switch on the machine at the main switch and to allow the
compressor to be preheated for at least 3 hours without enabling the cooling.
7.1. Installation checklist

Unit installed horizontal and stable?
Any vibration damping and floor anchors installed?
Spaces / clearances around the unit are adequate according to the requirements?
Air intake side free from packaging materials, etc. ?
Hydraulic connection OK?
Cold water circuit filled in accordance with the specifications? Water quality OK?
Whole system flushed? Dirt trap cleaned?
Cross-sections adequately dimensioned?
Electrical connection OK? Electrical power is available?
External pumps OK? Rotational direction?
Unit cover closed?
Overall system OK and ready for commissioning/startup?
Compressor "preheated" ?
External enable OK?
After checking the above list you can continue with Chapter 8 Operation.
Operation
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8. Operation
The chiller is designed for fully automatic operation.
8.1. Switching on
First, switch on the machine at the main switch (component 5 in Figure 19:
19: C6842 Display
elements and controls).
controls The Start screen appears on the display.
8.2. Selecting the operating mode

In the Start screen you can choose between the following three operating modes:
OFF
If you select "OFF" mode, all electrical components except the compressor heater are
switched off.
This operating mode is to be selected if the chiller was disconnected from the power
supply in ambient temperatures <5°C for longer than 6 h. In this case the compressors
must be preheated for 3 h, so that the refrigerant can escape from the oil.
AUTO
With the selection of "AUTO" operating mode the machine is ready for use. The fully
automatic operation only starts in this mode if the external release has been installed
beforehand as described in Chapter 8.3 External release.
release.
ON
Fully automatic operation (without external release) starts with the selection of "ON"
mode.
8.3. External release

In the delivered state the contact for the external release is bridged. An external control cable can
be wired up in place of the bridge. Please refer to Chapter 6.2.18 Electrical installation for
information on the external release. Fully automatic operation starts with this external release.
8.4. Control
The chiller's control consists of a control board and a control panel, which communicate with each
other via a BUS connection. The control board operates autonomously so that if the control panel
or communication fails, operation continues to be possible if no other fault prevents operation.
The program, target / setpoint values, parameters and times are stored in an Eprom in the
control and are therefore retained even in the event of a power failure. Therefore the control does
not require a buffer battery.
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8.5. Control panel
The following Figure 19 shows the chiller's display elements and controls.
5 2
Figure 19:
19: C6842 Display elements and controls
Table 15:
15: Description of C6842
Number Function
1 "UP" button
2 "OK" button
3 "DOWN" button
4 Display with plain text
5 Main switch
Use the "UP" and "DOWN" buttons to select the required menu item. The selected menu item is
displayed with inverse text. Press the "OK" button to return to or exit the selected menu. The data
is accepted at the end of the menu by selecting the box with the tick/checkmark. In the Start
screen the "right" arrow points towards the Main menu. The "left" arrow indicates return to the
previous menu.
The displays are divided into the three access levels
• Customer
• Service
• Factory
Detection occurs by means of a USB stick. Only the information that exists or is selected in the
configuration is displayed.
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8.5.1. Start screen
Figure 20:
20: Start screen without alarm
Figure 21:
21: Start screen with alarm
The general operating state of the chiller is displayed on the Start screen:
• Active alarm
• Top left-hand side: Number of pumps running
• Left-hand middle: Number of compressors running
• Bottom left-hand side: Number of fans running
• Middle: Actual value of the cold water feed
• Right-hand side: Tank level (if tank installed)
If an alarm is active the alarm symbol is displayed
Press the OK button to switch to the Main menu, the Time - Date setting and the Switching
Command setting. There are three switching commands:
• Off: the chiller is always switched off
• Auto: the chiller is switched on and off via the floating contact.
• On: the chiller is always switched on
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8.5.2. Main menu
Figure 22:
22: Main menu
From the Main menu you can move into the submenus or return to the Start screen.
8.5.3. Information
In the Information menu you can move into various submenus to obtain an overview of the state
of the chiller.
Figure 23: Information
In the Measured Value (Readings) menu you can call up the values of the analog inputs.
Figure 24:
24: Measured Value menu
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In the Status menu the states of the digital inputs and outputs and several internal control states
can be called up.
Figure 25:
25: Status menu
The alarms are listed in the Alarm menu. A detailed description is given in Chapter 8.5.5 Alarm
menu..
menu
The operating hours counter gives information on the operating hours of the individual
components and cannot be reset.
Figure 26:
26: Operating hours counter
The digital inputs shows the state at the terminals of the digital inputs.
Figure 27:
27: Digital inputs
The digital outputs show the state of the output relays.
Figure 28:
28: Digital outputs
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The analog inputs show the signal upstream of the analog digital converter. The value must be
between 0 and 4095. 0 means that no sensor is connected. 4095 means that the input is short-
circuited.
Figure 29:
29: Analog inputs
The analog outputs show the signal upstream of the digital - analog converter. The value 10000
corresponds to an output voltage of 10 volts.
Figure 30:
30: Analog outputs
8.5.4. Settings
All setpoint/target and parameter values and times are stored in the Settings menu.
Figure 31:
31: Setting
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8.5.5. Alarm menu
The alarm is acknowledged if the "OK" button is pressed for longer than five seconds.
Alarm messages can have three states:
• active: The alarm is still active. (e.g. DI MSS …) The motor protection switch has triggered.
• SH: The alarm is no longer queued. E.g. the motor protection switch has been unlocked on
the hardware side but has not yet been acknowledged at the control panel.
• OK: The alarm is no longer queued and has been acknowledged at the control panel. The
alarm entry no longer appears the next time the Alarm menu is opened.
Alarms that are preceded by the abbreviation DI refer directly to the digital input. All digital inputs
must be closed in a fault-free state. The abbreviation AI indicates a sensor error of an analog
input. The analog input must be checked for interruption and short circuit. Alarms without
abbreviations are formed internally in the control.
Figure 32:
32: Alarm menu
8.6. Parameters
The parameters are divided into the three display and access levels:
• Customer, user
• Service
• Factory setting
A parameter can have a lower display level than access level. I.e. not all the parameters displayed
can be changed.
The specific parameter list for your application is enclosed with the unit.
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8.7. Controller description
8.7.1. Electronic level monitoring

Before switching on the chiller the electronic level monitoring starts up.
The level is monitored for three states:
• Tank min level STOP; the chiller switches off immediately.
• Tank min level warning; the chiller continues running but does not switch back on in the
event of a stoppage. The water feed solenoid valve (only with optional automatic water
top-up) is opened.
• Tank max level message; the cold water feed, water feed solenoid valve (only with
optional automatic water feed) is closed.
The ideal state is if the level is above the warning level and below the maximum level. In this case
no message appears.
If the chiller is switched on and the min level warning is reached the chiller remains switched on
so that any cooling process that has been started is not interrupted. If the chiller is switched off,
the chiller does not start, to ensure that no cooling process is initiated that may not be able to be
ended.
8.7.2. Switching the chiller On/off

The following conditions must be fulfilled for the chiller Standby state:
• The control has finished its initialisation routine,
• Release of at least one primary pump,
• Release of at least one condenser fan,
• Release of the cold water feed or return sensor,
• No exceeding of the cold water feed temperature,
• Release through tank level monitoring,
• Release through cold water pressure monitoring at the evaporator inlet.
A primary pump is released if:

• It is selected in the system configuration of the software,
• No motor protection switch faults are queued,
• No flow monitoring faults are queued,
• No minimum or maximum pump pressure faults are queued.
A condenser fan is released if:

• No motor protection switch faults are queued,
• No fault is queued at the digital fault input (e.g. control unit group fault).
From the Standby state, a software switch in the display can be used to switch the chiller between
Manual-Off-Auto or Manual-On. In Automatic mode the floating contact for the remote control
must be closed.
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When the system is switched on the primary pumps are switched on with a 3.5 s delay. After a
further 3.5 s the fan control is released.
When the primary pump is switched on a timing element starts for each pump, which activates
the monitoring of the minimum and maximum cold water pressure at the pump outlet. When the
pump is switched on a timing element also starts for release of the compressor's temperature
control. The compressor's temperature control is released when the time of a pump has expired.
This time is also used for activation of the flow monitoring.
The pressure and flow monitoring takes place with two timing elements:
• Delay at start; the pressure or the flow monitoring does not trigger an alarm.
• Delay during operation; in order to ignore short-term fluctuations in pressure or flow, the
alarm is delayed.
When the system is switched off the temperature control is locked immediately and therefore the
compressor is switched off. The pump continues running to prevent uncontrolled continued
evaporation.
8.7.3. Cold water flow temperature control

In the normal case the sensor in the tank (system with tank, with pump) is used to control the
cold water feed temperature. If this sensor fails, the control switches internally to the sensor in
the cold water return and the target value (setpoint value) is increased by a defined value.
A purely proportional controller is used, which generates an output signal from -100 % to +
100 %. The switching on and switching off points of the cooling levels are set within this range. If
the setpoint is changed the switching ratio between the compressors is retained, it is shifted
overall. If the proportional range is changed the switching ratio is also retained. The range is
extended or reduced.
Heating =
Y electric Y- cooling
controller
Compressor 4 on
100 %
Compressor 3 on
75 %
Compressor 2 on
50 %
Compressor 1 on
25 %
Compressor 1 off
- 25 % Temperature
Compressor 2 off
- 50 %
Compressor 3 off
- 75 %
Compressor 4 off
- 100 %
Hy-heating P-Band
cooling
Set - heating Set - cooling
Figure 33:
33: Cooling and heating sequence
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Different operating states reduce the number of cooling levels required by one cooling level:
• High pressure warning
• Low pressure warning
• Difference between high and low pressure is too large.
8.7.4. Compressor control

The control is defined for a refrigeration circuit with a maximum of four compressors. The number
of compressors is selected by means of coding resistance. The number of compressors is
determined once when the control is restarted (switching on of the operating voltage) and is
compared with the number of the last restart. If these are not the same the "Coding resistance
changed" alarm is generated. When the alarm is acknowledged the new number of compressors
is stored in the E-EPROM and the factory setting is accepted as the new number of compressors.
The compressors are requested depending on the controller output signal. The compressor with
the least number of operating hours switches on first. If no more refrigerating capacity is required
the compressor that switched on first also switches off first. The compressors are switched on
with a time delay (comment: only applies if several compressors exist)
In the event of a fault in a compressor (motor protection switch) a fault changeover is activated.
The high pressure is monitored on the hardware side by means of the high-pressure limiter. If it is
triggered all compressors switch off immediately. In addition, the high pressure is controlled by
means of a pressure transmitter. This also switches off the compressors if the setpoint is
exceeded, but releases them again if the value falls below the release value. Before switching off
the, high-pressure transmitter signals a warning.
61 / 77 83000102.Kf
Low pressure is also monitored by pressure transmitters. If the value falls below the setpoint the
compressors switch off. If the switch-off value is exceeded by the hysteresis, the compressors are
released again. The triggering of the alarm is delayed by two timing elements. The first timing
element is started with the request for the compressor. If no intake pressure has built up by the
time the time expires the low-pressure fault alarm is triggered. After the start time has expired the
low pressure may exceed the switch-off value for a short time. If this occurs more than three
times within an hour the compressors are blocked. Before a low-pressure fault is triggered a low-
pressure warning is signalled.
8.7.5. Fan speed control

Due to the continuous adjustment in the number of fans, the condensing pressure is kept
constant depending on the ambient temperature by means of a PI controller. As the condensing
pressure at the moment in which the compressor is switched on rises very fast, the PI controller is
superimposed by a P controller with limiting setpoint. This only intervenes if the PI controller is too
slow.
8.7.6. Electronic expansion valve control

control
An electronic expansion valve with PI controller is used to keep the overheating constant. To
prevent the maximum operating pressure (MOP) from being exceeded, a P controller is used,
which counteracts when the MOP is approached and limits opening of the electronic expansion
valve.
8.7.7. Temperature limit monitoring

The temperature of the cold water feed is monitored for a minimum and maximum limit value if
the chiller is switched on (pump is running). If the limit value is exceeded or the minimum is not
reached, an alarm is triggered with time delay, which switches off the chiller.
8.7.8. Group fault alarm

A group fault alarm is triggered if an alarm occurs. All alarms are included in the group fault, but
not the warnings. The group fault signalling relay has a floating changeover contact and is
energised in fault-free operation, in order to ensure wire break monitoring.
8.8. Operating modes

It is possible to choose between two operating modes:
8.8.1. ECO mode

The default setting of the Compact-Line provides for operation in ECO mode ("Run" parameter is
set to "0"). As a result, the increase in fan speed reduces the condensing pressure to the
minimum necessary value in the respective operating point – the electrical power consumption of
the overall system is limited to a minimum.
62 / 77 83000102.Kf
8.8.2. Comfort mode
In case of strict sound emission requirements the fan speed can be reduced to the minimum
necessary value in the respective operating point and sound power level limited to a minimum. To
do this the "Run" parameter must be set to "1". As a result of the lower air flow rate a reduced
output of around 3% is to be expected.
The optimised parameter list for your application is enclosed with the unit.
9. Cleaning
9.1. Air filter mat

To maintain high performance the optional air filter mat (3.19 Air filter mat)
mat must be checked for
contamination at least once a month. The correct air filter mats can be ordered at any time as an
original spare part – please contact our KKT chillers Service Team (Table
Table 1 Contact details).
details
9.2. Condenser
To maintain high performance the microchannel heat exchanger must be cleaned if there is any
visible contamination, but at least annually. To do this, disconnect the unit from the power supply
and remove the service panels and the condenser protective grille (panels 3 and 5, see Chapter
Elements). First of all, remove coarse dirt particles from the outside using a standard vacuum
1.3 Elements
cleaner. Then flush the microchannel heat exchanger carefully, in the opposite direction to the air
flow, from inside with warm tap water. Then clean with a wet vacuum cleaner until the surface is
dry again. For versions with water cooled condensers see complete cleaning of the cold water
circuit.
9.3. Water filter

To ensure the required water quality and the required water circulation quantity, the optional
water filter (3.22 Filter assembly group coolant ) must be checked for contamination at least
once a month. The correct filter unit can be ordered at any time as an original spare part – please
contact our KKT chillers Service Team (Table
details
9.4. Complete cleaning of the cold water circuit

Due to the complexity and diversity of the possible external materials, we recommend that the
complete cleaning of the cold water circuit only be carried out by qualified personnel – please
contact our KKT chillers Service Team (Table
details
63 / 77 83000102.Kf
10. Service
All service work may only be carried out by properly trained, competent personnel.
10.1. Maintenance
Reliable operation and a long service life for the entire system can be guaranteed by proper
maintenance.
The purpose of the maintenance is:

• to ensure that the machine operates reliably and without unexpected
un failures
• to plan further service work in order to minimise downtimes
An overview of the maintenance intervals as recommended by the VDMA is given in Appendix II. In
addition, the national regulations of the respective installation site must be followed.
Please note that the points listed

list represent the minimum maintenance required. By increased
in
monitoring, system reliability can be rnhanced.. Please contact our service department at any time
about maintenance quotations / service agreements.
10.2. Fault correction

Troubleshooting and fault correction
ection instructions are given in Appendix 0.
Our technical customer service can be reached around the clock and will assist you with all
service matters (maintenance, repairs, spare parts, etc.):
Europe Service Team

T +49 9228 9977 7190
E [email protected]
W www.kkt-chillers.com
USA Service Team

TF +1 866 517 6867
E [email protected]
chillersusa.com
W www.kkt-chillersusa.com
10.3. Spare parts

To ensure that the performance of your chiller is not impaired, we recommend that you only use
original spare parts purchased from KKT chillers. In this way you ensure the reliability and quality
of the machine. If you have any questions about spare parts, please contact our KKT chillers
Service Team (Table
details
64 / 77 83000102.Kf
11. Taking out of service
ATTENTION! Decommissioning must only be carried out by professional and

qualified technicians.
They must also be familiar with the local regulations.
For safety-relevant
relevant instructions regarding possible residual energy, please refer to Chapter 4.3
Residual energy.
energy.
11.1. Draining
If the system is filled and there is a risk of frost, suitable measures must be taken to protect the
liquid from frost. The complete cold water circuit must be fully drained before any a lengthy
stoppage of the unit. Do this as follows:
1. Drain the tank via the drain cock provided

2. Drain the evaporator via the drain cock provided
3. Drain the pump using the drain plug provided
The drain cock is marked on the unit by the symbol in Figure 34.
34
Figure 34:
34: Labelling of the drain cock
The position of the drain plug is shown

show in Figure 35.
35
Drain plug
(Allen key 10 mm)
Figure 35:
35: Position of the pump drainage (horizontal type)
65 / 77 83000102.Kf
To prevent frost damage the cold water circuit must then be flushed with a mixture of water and
40 % by vol Antifrogen-N (or equivalent).
12. Recycling
ATTENTION! Dismantling must be carried out by professional and qualified

technicians.
Water and refrigerant pipes are pressurised!
They must also be familiar with the local regulations.
All parts (e.g. refrigerant, oil, glycol, metal, electronics, battery etc.) must be recycled, reused or
disposed of. Please note and follow all local and national regulations and if necessary contact
your local waste management agency.
A specialised disposal company must be contracted to dispose of these wastes. They issue a
proof of disposal which must be archived. The chiller can be returned to KKT chillers for disposal.
Please contact our KKT chillers Service Team for details (Table
details
13. Products, solutions and services

Apart from the Compact-Line, KKT chillers also offers other products, solutions and services
which are not described in this document. For more information, visit our homepage
http://www.kkt-
http://www.kkt-chillers.com or contact your KKT chillers contact (Table
Table 1: Contact details)–
details we
look forward to hearing from you!
66 / 77 83000102.Kf
14. Lists
14.1. List of illustrations

Figure 1: C6848 refrigeration diagram ............................................................................................... 13
Figure 2: Demounting the side panel of the switch cabinet .............................................................. 16
Figure 3: C6856 thermostatic pump start with overflow valve (recommended installation) .......... 22
Figure 4: C6863 overflow valve for standby mode ............................................................................ 22
Figure 5: Top-up connection ................................................................................................................ 23
Figure 6: Machine base (foot) – outside view .................................................................................... 25
Figure 7: Machine base (foot) - mounting on the baseplate ............................................................. 25
Figure 8: Position of the high-pressure limiter (PZH) ......................................................................... 31
Figure 9: Airborne sound emissions.................................................................................................... 33
Figure 10: C6845-0 centre of gravity cBoxX 30 - 60 ......................................................................... 39
Figure 11: C6846-0 centre of gravity cBoxX 70 – 100 ...................................................................... 39
Figure 12: C6846-0 centre of gravity cBoxX 120 – 160 ................................................................... 39
Figure 13: C6846-0 centre of gravity cBoxX 180 – 200 ................................................................... 39
Figure 14: C6841-0 crane transport cBoxX 30 - 100 ........................................................................ 40
Figure 15: Exhaust air duct cBoxX 30-200 ......................................................................................... 44
Figure 16: Filling and feed connection ............................................................................................... 48
Figure 17: Position of the pump vent (vertical type) .......................................................................... 49
Figure 18: Main supply......................................................................................................................... 50
Figure 19: C6842 Display elements and controls ............................................................................. 53
Figure 20: Start screen without alarm ................................................................................................ 54
Figure 21: Start screen with alarm ...................................................................................................... 54
Figure 22: Main menu .......................................................................................................................... 55
Figure 23: Information ......................................................................................................................... 55
Figure 24: Measured Value menu ....................................................................................................... 55
Figure 25: Status menu ....................................................................................................................... 56
Figure 26: Operating hours counter .................................................................................................... 56
Figure 27: Digital inputs ....................................................................................................................... 56
Figure 28: Digital outputs .................................................................................................................... 56
Figure 29: Analog inputs ...................................................................................................................... 57
Figure 30: Analog outputs.................................................................................................................... 57
Figure 31: Setting ................................................................................................................................. 57
Figure 32: Alarm menu ........................................................................................................................ 58
Figure 33: Cooling and heating sequence .......................................................................................... 60
Figure 34: Labelling of the drain cock ................................................................................................ 65
Figure 35: Position of the pump drainage (horizontal type) .............................................................. 65
67 / 77 83000102.Kf
14.2. List of tables
Table 1: Contact details ......................................................................................................................... 2
Table 2: Safety instructions ................................................................................................................... 8
Table 3: Technical data .......................................................................................................................... 9
Table 4: Explanation of terms .............................................................................................................. 12
Table 5: Materials used - standard version ........................................................................................ 17
Table 6: Materials used for the non-ferrous metal-free version........................................................ 18
Table 7: Water quality .......................................................................................................................... 19
Table 8: AFN and AFL mix ratios (or equivalent) ................................................................................ 20
Table 9: Definition of the safety symbols............................................................................................ 29
Table 10: Hazard warnings .................................................................................................................. 30
Table 11: Personal protective equipment for servicing work ............................................................ 33
Table 12: Description of figure C6841-0 ............................................................................................ 40
Table 13: Materials in the packaging.................................................................................................. 41
Table 14: Minimum volume of the installation room with regard to maximum refrigerant
concentration in case of a leakage if installed indoors ..................................................................... 43
Table 15: Description of C6842 .......................................................................................................... 53
68 / 77 83000102.Kf
I. Troubleshooting
Fault description and

Fault Fault correction
cause
Sensor break, AI pump Testing the supply cable / connector /
AI pump pressure 1
pressure 1 sensor
Sensor break, AI pump Testing the supply cable / connector /
AI pump pressure 2
pressure 2 sensor
Sensor break, AI water inlet Testing the supply cable / connector /
AI water inlet pressure
pressure sensor
Sensor break, AI tank Testing the supply cable / connector /
AI tank pressure
pressure sensor
Sensor break, AI inlet Testing the supply cable / connector /
AI inlet temperature
temperature sensor
Sensor break, AI outlet Testing the supply cable / connector /
AI outlet temperature
temperature sensor
Sensor break, AI high Testing the supply cable / connector /
AI high pressure
pressure sensor
Sensor break, AI low Testing the supply cable / connector /
AI low pressure
pressure sensor
AI suction vapour Sensor break, AI suction Testing the supply cable / connector /
temperature vapour temperature sensor
Sensor break, AI ambient Testing the supply cable / connector /
AI ambient temperature
temperature sensor
Testing the supply cable / connector /
AI ESS inlet Sensor break, AI ESS inlet
sensor
AI ESS outlet Sensor break, AI ESS outlet
sensor
AI air flow Sensor break, AI air flow
sensor
AI conductivity Sensor break, AI conductivity
sensor
Pump 1 motor protection has Check pump 1, short-circuit in the
triggered. Motor current is supply cable? Internal short-circuit in
DI MSS pump 1
outside the permitted range, the motor windings? Motor blocked?
pump is possibly blocked Load contactor is not working correctly
Check external piping: Gate valves
Pump 1 flow is insufficient,
Flow, operation of pump 1 closed? Water filter blocked? System
pressure loss too high
leaking?
Pump 2 motor protection has Check pump 2, short-circuit in the
triggered. Motor current is supply cable? Internal short-circuit in
DI MSS pump 2
outside the permitted range, the motor windings? Motor blocked?
pump is possibly blocked Load contactor is not working correctly
Check external piping: Gate valves
Pump 2 flow is insufficient,
Flow, operation of pump 2 closed? Water filter blocked? System
pressure loss too high
leaking?
Check compressor 1: Check supply
Compressor 1 motor cable! Compressor blocked? Current
protection has triggered. measurement of individual phases?
DI MSS compressor 1
Motor current is outside the Continuity measurement of the
permitted range. windings? Load contactor is not
working correctly
69 / 77 83000102.Kf
DI MSS compressor 2
working correctly
DI MSS compressor 3
working correctly
DI MSS compressor 4
working correctly
High-pressure pressostat has
triggered, the pressure on See also: "High-pressure stop". The
the high-pressure side of the high-pressure pressostat is reset after
DI high-pressure limitation
refrigerant cycle has risen lowering the pressure to 35 bar by
very quickly above the max. pressing the Reset button.
value of 45 bar.
Check fan 1: Check supply cable! Fan
Fan 1 motor protection has
blocked? Current measurement of
DI MSS fan 1 triggered. Motor current is
individual phases? Load contactor is
outside the permitted range.
not working correctly
Internal monitoring of the fan Check the fan wiring. Fan blocked?
DI fault fan 1
has output fault. Missing phase? Fan overload?
Check fan 2: Check supply cable! Fan

Fan 2 motor protection has
blocked? Current measurement of
DI MSS fan 2 triggered. Motor current is
individual phases? Load contactor is
outside the permitted range.
not working correctly
Internal monitoring of the fan Check the fan wiring. Fan blocked?
DI fault fan 2
has output fault. Missing phase? Fan overload?
Check the tank heating wiring, short-

The tank heating protection circuit? Internal short-circuit in the
DI MSS tank heating
has triggered. heater? Load contactor is not working
correctly
ESS pump motor protection
Check ESS pump, short-circuit in the
has triggered. Motor current
supply cable? Internal short-circuit in
DI MSS pump ESS is outside the permitted
the motor windings? Motor blocked?
range, pump is possibly
Load contactor is not working correctly
blocked
Fan motor protection ESS Check fan ESS: Check supply cable!
has triggered. Motor current Fan blocked? Current measurement of
DI MSS fan ESS
is outside the permitted individual phases? Load contactor is
range. not working correctly
Maximum outlet temperature
will be reached soon, the unit Reduce the thermal load on the cold
Outlet temp. max warning
will switch off soon! Thermal water side!
overload!
70 / 77 83000102.Kf
Maximum outlet temperature
has been reached, the unit Reduce the thermal load on the cold
Outlet temp. Max STOP
switches off! Thermal water side!
overload!
The machine's ambient temperature
Minimum outlet temperature
may have to be increased. Cold water
Outlet temp. Min STOP has been reached, the unit
temperature may have to be
switches off! Risk of frost!
increased.
Level in the tank is no longer
Top up tank with fresh water as
Tank min level warning optimal - unit continues
described in the specification
functioning
Level in the tank is no longer
Top up tank with fresh water as
Tank min level STOP sufficient - unit stops
described in the specification
functioning
Water inlet pressure Excessive pressure at unit
Reduce pressure!
warning inlet!
Pressure at the unit inlet is
Water inlet pressure STOP Reduce pressure!
too high!
Pump pressure 1 min Pressure at the pump outlet Increase pressure loss downstream of
warning 1 is low! pump 1!
Pump runs out of the characteristic
Pump pressure 1 min Pressure at the pump outlet
curve, increase pressure loss
STOP 1 is too low!
downstream of pump 1!
Reduce pressure loss downstream of
Pump pressure 1 max Pressure at the pump outlet pump 1! Gate valves in the external
STOP 1 is too high! piping may need opening or filters
must be cleaned.
Pump pressure 2 min Pressure at the pump outlet Increase pressure loss downstream of
warning 2 is low! pump 2!
Pump runs out of the characteristic
Pump pressure 2 min Pressure at the pump outlet
curve, increase pressure loss
STOP 2 is too low!
downstream of pump 2!
Reduce pressure loss downstream of
Pump pressure 2 max Pressure at the pump outlet pump 2! Gate valves in the external
STOP 2 is too high! piping may need opening or filters
must be cleaned.
Overheating cannot be
permanently adjusted to the
Overheating defined value. There is a Contact the KKT chillers Service.
problem in the refrigeration
circuit.
The low-pressure of the
refrigeration circuit is
approaching the critical
Low pressure warning Check the flow through the evaporator.
range for the system
configuration. Evaporator
may be contaiminated
refrigeration circuit is within
the critical range for the Check the flow through the evaporator.
Low pressure STOP
system configuration. The Contact the KKT chillers Service.
evaporator may be
contaminated
71 / 77 83000102.Kf
refrigeration circuit lies
Low pressure STOP 3x continuously within the Contact the KKT chillers Service.
critical range for the system
configuration.
The high-pressure of the
High pressure warning refrigeration circuit is See also: "High-pressure stop".
approaching critical range.
Are all metal cladding panels in place?

Check condenser for external
contamination! Is the ambient
The high-pressure of the
temperature within specification? Can
High-pressure STOP refrigeration circuit lies within
you exclude an air short-circuit? Can
the critical range.
you exclude strong sunlight rediation?
Can the cooling air flow unhindered
into / out of the machine?
Coding resistance outside Coding resistor is defective / not

Coding
measuring range connected
72 / 77 83000102.Kf
II. Maintenance intervals in accordance with the VDMA
Explanation Annual Six-

Six- as Remark
monthly required
Compressor
1 Optical check for dirt, damage and corrosion x x
2 Check fixing, check running noises x
3 Measure the intake pressure x
4 Measure the suction gas temperature upstream x
of the compressor
5 Measure the compression end temperature at x
the discharge port
6 Check the oil level x
7 Check the acid content of the oil (acid test) x
8 Oil change x
9 Check that the crankcase heater is working x
10 Check that the output control is working x
11 Check the refrigerant side for leaks x
12 Check high/low pressure switching equipment x
Air-
Air-cooled condenser
21 Measure the condensing temperature x
22 Measure the refrigerant side supercooling x
temperature at the condenser outlet
23 Measure the medium temperature at condenser x
inlet and outlet
24 Check that the condensation pressure control is x
functioning properly
25 Check the refrigerant side for leaks x
Evaporator
30 Optical check for dirt, damage and corrosion x
31 Measure refrigerant overheating temperature x

32 Measure the medium temperature at the x
evaporator inlet and outlet
33 Measure the anti-freeze temperature (freezing x
point) of the heat transfer media
34 Check the water and refrigerant side for leaks x
73 / 77 83000102.Kf
Explanation Annual Six-
Six- as Remark
monthly required
Parts in the refrigeration circuit/water circuit
41 Check insulation for damage x
42 Check filter dryer for blockage x
43 Replace filter dryer X If com-
ponents
in the
refrig-
eration
circuit
are
replaced
45 Check all pipes carrying refrigerant for corrosion x
and damage
Fans
51 Check fixings and bearings x
52 Check flexible connection for tightness x
(electrical connection)
Pump and piping
61 Check fixing parts and bearings x
62 Check the safety function of the safety switching x
devices
63 Check pump/mechanical seal for leaks x x
Water filters
filters
71 Clean filters x x
72 Check filters for damage x
74 / 77 83000102.Kf
No.: Explanation Annual Six-
Six- as Remark
monthly required
Tank / water tank
81 Check fixing x
82 Check level x
Control cabinet
91 Check fixing x
92 Check all threaded connections x
93 Check all indicator lights and error messages x
94 Check the temperature and pressure sensors x
are functioning properly
95 Check the function of the motor protection x
switches
96 Check 24 VDC and supply voltage x x
97 Check control cabinet heater x
99 Check control cabinet filter and if necessary x
replace/clean
Documents and labelling
110 All documents such as operating instructions, x x
diagrams, circuit plans, system log are present
111 Rating plate and labels are clearly legible x x
Battery - time/date
120 Battery x Every 5
years
Refrigeration circuit leak check x
75 / 77 83000102.Kf
III. Product Registration
PDF download: http://www.kkt-chillers.com/en/downloads/product-registration/
76 / 77 83000102.Kf
IV. EC Declaration of Conformity
77 / 77 83000102.Kf

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Compact-

ATTENTION! A black exclamation mark on a yellow background in a triangle indicates

1.1. Intended use

Table 2: Safety instructions

Note and follow the instructions for use!

Table 3: Technical data

Table 4: Explanation of terms

Condenser and fan

Figure 1: C6848 refrigeration diagram

2.4. Expansion valve

2.7. Filter dryer

2.8. Pressure sensors

2.9. Temperature sensors

2.10. Control unit/ main circuit board

Figure 2: Demounting the side panel of the switch

2.15. Cold water cycle

2.16. Materials used in the water circuit

Table 5: Materials used - standard version

Table 6: Materials used for the non-

Table 8: AFN and AFL mix ratios (or equivalent)

3. Options and accessories

3.1. Version without tank, with pump

3.2. Version without tank, without pump

The water quality shown in Table

3.4. Heater for compressor and control cabinet

3.5. Insulation of the cold pipes and the pump(s)

cBoxX Frost-free area

3.7. Overflow valve for standby mode

Figure 4: C6863 overflow valve for standby mode

3.8. Higher pressure pump

3.10. Additional evaporator pump

3.11. Automatic water feed

The initial unit fill by means of the top-up

3.12. Water circuit in non-

3.14. Special voltage

3.15. Phase monitoring

3.16. Hot gas bypass for output control <1K

3.18. Special paint finish

3.19. Air filter mat (accessories)

Figure 6: Machine base (foot) – outside view

Figure 7: Machine base (foot) - mounting on the baseplate

3.21. Level package (accessories)

3.22. Filter assembly group coolant circuit (accessories)

3.24. MultiplexX connection group (accessories)

3.25. Refill cartridge R410A (accessories)

3.28. Special languages (accessories)

3.29. Wooden Crate (accessories)

3.30. Seaworthy crate packaging (accessories)

3.31. Water Pump Redundancy

Advantages of a closed water loop system are:

4.1. General information

4.2. Hazard warnings

Note and follow the instructions for use!

Wear foot protection!

Wear hand protection!

Wear eye protection!

Wear protective clothing!

Warning! Hot surface!

Warning! Cold surface!