KKT chillers cBoxX 100 Operating Instructions Manual Download Page 1

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Compact-Line Healthcare

Operating instructions

cBoxX 40
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Summary of Contents for cBoxX 100

Page 1: ...Compact Line Healthcare Operating instructions cBoxX 40 cBoxX 60 cBoxX 70 cBoxX 80 cBoxX 100 cBoxX 120 cBoxX 160 cBoxX 180...

Page 2: ...977 7474 E service kkt chillers com W www kkt chillers com Service USA KKT chillers Inc 765 Dillon Drive Wood Dale IL 60191 TF 1 833 558 4357 F 1 847 734 1601 E techsupport kkt chillersusa com Service...

Page 3: ...ow and increases the service life of the components To ensure that the performance of your chiller is not impaired we recommend that you only use original spare parts from KKT chillers By doing so you...

Page 4: ...water circuit 21 2 17 Water quality 22 2 18 Permitted coolant media 23 3 Options and accessories 23 3 1 Heater for the compressor and control cabinet 23 3 2 Insulating cold pipes 24 3 3 Pump redundan...

Page 5: ...7 Temperature limit monitoring 36 4 5 8 Group fault alarm 36 4 6 Execution types 36 4 6 1 ECO mode 36 4 6 2 Comfort mode 36 4 7 Airborne sound emissions 37 4 8 Notes on reducing noise and vibration 38...

Page 6: ...8 4 Control 52 8 5 Control panel 52 8 5 1 Start screen 53 8 5 2 Main menu 54 8 5 3 Information 54 8 5 4 Settings 54 8 5 5 Alarm menu 55 8 5 6 Control panel 55 8 5 7 Software update 55 8 5 8 Datalog e...

Page 7: ...10 Service 60 10 1 Maintenance 60 10 2 Fault correction 60 10 3 Spare parts 60 11 Taking out of service 61 11 1 Draining 61 12 Recycling 62 13 Products solutions and services 62 I Menu navigation 63 I...

Page 8: ...esponsible 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 li...

Page 9: ...r with 35Vol AFN Water with 50Vol AFN Water with 35Vol AFN Liquid feed temperature 7 C 25 C 9 C 25 C Target constancy at full load 1 K 2K Flow rate 1 at free pump pressure min 4 1 m3 h at 3 0bar 4 0 m...

Page 10: ...ter with 35Vol AFN Water with 35Vol AFN Water with 50Vol AFN Water with 35Vol AFN Water with 35Vol AFN Liquid feed temperature 13 C Target constancy 2K Coolant circulation 5 0 m h Free pump pressure m...

Page 11: ...5Vol AFN Water with 35Vol AFN Water with 35Vol AFN Water with 35Vol AFN Water with 35Vol AFN Liquid feed temperature 13 C Target constancy 2K Coolant circulation 5 0 m h Free pump pressure min 2 8bar...

Page 12: ...ium Water with 40Vol AFN Water with 40Vol AFN Liquid feed temperature 9 Target constancy 2K Coolant circulation 7 8 m h 7 2 m h Free pump pressure min 4 5 bar 5 5 bar Operating voltage 10 400V 3 50Hz...

Page 13: ...ater with 50Vol AFN Water with 40Vol AFN Water with 40Vol AFN Liquid feed temperature 9 C Target constancy 2K Coolant circulation 6 0 m h 6 0 m h 6 0 m h 7 8 m h 9 1 m h Free pump pressure min 5 0 bar...

Page 14: ...ol AFN Water with 35Vol AFN Water with 50Vol AFN Liquid feed temperature 9 C Target constancy 2K Coolant circulation 7 8 m h 7 8 m h 7 8 m h 7 8 m h Free pump pressure min 5 5 bar 5 5 bar 5 5 bar 5 5...

Page 15: ...r with 40Vol AFN Water with 40Vol AFN Liquid feed temperature 9 Target constancy 2K Coolant circulation 7 4 m h 7 4 m h Free pump pressure min 5 bar 5 bar Operating voltage 10 400V 3 60Hz 400V 3 50Hz...

Page 16: ...e top a Safety instructions 2 Cover panel operating side bottom b Water connections 3 Cover panel service side top c Nameplate 4 Cover panel service side bottom d Display 5 Cover panel condenser prote...

Page 17: ...ight Machine ready for operation without cooling water Gross weight Machine ready for operation with cooling water 2 Function and main components The chiller consists of the main components compressor...

Page 18: ...ing air can cause deposits to accumulate on the condenser surface This impairs the transfer of the heat to the refrigerant This restricts the operating limit of the machine and reduces the refrigerati...

Page 19: ...ped with a platinum measurement cell The sensors continuously record the temperature at various locations in the refrigerant and cold water circuits The values are used to control the system 2 10 Cont...

Page 20: ...old water circuit Cold water is conveyed through the process circuit by means of the internal pump In the process circuit the cold water absorbs heat The circuit closes when the cold water is conveyed...

Page 21: ...on Component Material cBoxX 40 cBoxX180 Unit connections V2A 1 4305 Evaporator V2A 1 4301 and copper 99 9 Pump Mechanical seal Grey cast iron and V2A 1 4301 EPDM Sealing plugs yellow Polyamide PA 6 Se...

Page 22: ...on Vol 0 0 Chloride Cl mg l 200 200 Sulphate mg l 70 300 Nitrate mg l 100 100 Copper mg l 0 1 0 1 Iron mg l 0 2 0 2 Free carbonic acid mg l 5 20 Manganese mg l 0 1 0 1 Ammonia mg l 0 5 20 Free chlorid...

Page 23: ...cabinet The oil sump heater prevents the deposit of refrigerant in the oil when the temperature is low When the compressor is started up this refrigerant would be liberated from the oil as gas and ma...

Page 24: ...ng compressors on or off a higher target constant is achieved by the continuous regulation of the valve 3 6 Low temperature package ambient temperature 25 C If the chiller is operated at ambient tempe...

Page 25: ...e An Anybus gateway is not required 3 10 Remote control panel accessories In the event that the chiller shall be operated not from the machine itself but from a different operating location the chille...

Page 26: ...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 Please note the change...

Page 27: ...The chiller within the sense of its intentional use is designed to operate safely provided also that the instructions concerning transport installation commissioning startup and maintenance given in...

Page 28: ...om the power supply Beware of dangerous electrical voltage If the machine is only turned off by means of the main switch some of the terminals in the control cabinet will still be under dangerous volt...

Page 29: ...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 equipment can be very hot during ope...

Page 30: ...o 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 no...

Page 31: ...PZH is installed on the refrigerant collector for the chiller types cBoxX 40 cBoxX 180 see Figure 10 Position of the high pressure limiter PZH If the PZH has been activated a message is output at the...

Page 32: ...ol 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...

Page 33: ...after activating the pump circulation process the tank heater or compressor is released The pump switches off when the runtime has elapsed and the tank heater and compressor are no longer required by...

Page 34: ...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...

Page 35: ...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 pres...

Page 36: ...gered with time delay which switches off the chiller 4 5 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 gro...

Page 37: ...ured 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 11 measurin...

Page 38: ...le to install the chiller with optionally available levelling feet see Chapter 3 7 Levelling feet accessories These are fitted with damping elastomers 4 9 Residual risks 4 9 1 Electrical If all safety...

Page 39: ...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 equipmen...

Page 40: ...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 m...

Page 41: ...sible 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 hydr...

Page 42: ...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 t...

Page 43: ...an unpacked condition by means of fork lift truck Please note that the centre of gravity may vary depending on the model Figure 12 center of gravity cBoxX 40 cBoxX 60 Figure 12 center of gravity cBoxX...

Page 44: ...following conditions must be noted for storage Avoid direct sunlight and moisture Ambient temperatures 30 C to 50 C To avoid frost damage the cold water circuit must be completely drained before the c...

Page 45: ...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 gi...

Page 46: ...from the power supply at ambient temperatures 25 C If necessary set the chiller to standby mode 6 2 4 Effect of surrounding air flow The chiller emits heat to the surrounding area the machine also dra...

Page 47: ...ty 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 surroundin...

Page 48: ...ailable on the refrigeration machine do not provide a fixed point In order to avoid damage to the piping and refrigeration machine the hydraulic connections must be supported close to the device conne...

Page 49: ...gulations and provisions especially the ordinance on handling water pollutant substances and BGR500 Chapter 2 35 ATTENTION The electrical installation testing and commissioning may only be carried out...

Page 50: ...Chapter 8 3 External release of the Chiller This must be laid separately from the supply line and wired to the appropriate terminals in the switch cabinet see wiring diagram included in the unit Once...

Page 51: ...ine at the main switch component 5 in Figure 17 C6842 Display and operating modes A start screen appears on the display 8 2 Selecting the operating mode In the Start screen you can choose between the...

Page 52: ...continues to be possible if no other fault prevents operation The program setpoints parameters and times are stored in an EEprom in the controller and are therefore retained even in the event of a po...

Page 53: ...tart screen with tank and without alarm Figure 19 Example 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...

Page 54: ...ts and outputs as well as some controller internal states Energy meter Operating hours Operating hours of the individual components of the system Digital inputs Status at the terminals of the digital...

Page 55: ...ates 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 8 5 6 Control panel Custome...

Page 56: ...no longer required by the temperature If the interval time is 0 min the thermostatic pump start is only activated by the temperature However the runtime is effective 8 7 2 Electronic level monitoring...

Page 57: ...s 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...

Page 58: ...re switching off the high pressure transmitter signals a warning Low pressure is also monitored by pressure transmitters If the value falls below the setpoint the compressors switch off If the switch...

Page 59: ...mats can be ordered at any time as an original spare part please contact our KKT chillers Service Team Contact details 9 2 Condenser To maintain high performance the Microchannel heat exchanger should...

Page 60: ...service department at any time about maintenance quotations service agreements 10 2 Fault correction Troubleshooting and fault correction instructions are given in Appendix II Our technical customer...

Page 61: ...lose the shut off valve leading the level sensor Drain the evaporator via the drain cock provided Drain the pump using the drain plug provided The drain cock is marked on the unit by the symbol in Fig...

Page 62: ...be returned to KKT chillers for disposal Please contact our KKT chillers Service Team for details Contact details 13 Products solutions and services Apart from the Compact Line KKT chillers also offer...

Page 63: ...mp 2 bar Datalog export Digital outputs Y pump 2 Datalog stop Analogue inputs Pressure KW VP bar Analogue outputs Press exp tank bar Software status Tank pressure bar Test point 1 Tank pressure Error...

Page 64: ...pcb Pump 2 Test point 1 DI flow pump 2 Error memory DI mpcb compressor 1 DI mpcb compressor 2 DI mpcb compressor 3 DI mpcb compressor 4 DI high pr limiter DI mpcb fan 1 DI fault fan 1 DI mpcb fan 2 DI...

Page 65: ...port Digital inputs U L2 N V Datalog stop Digital outputs U L3 N V Analogue inputs I L1 A Analogue outputs P L1 N kW Software status Total real energy kWh Test point 1 Operating hours h Error memory F...

Page 66: ...stop Digital outputs DI1 clip 1 2 Analogue inputs DI1 clip 3 4 Analogue outputs DI1 clip 5 6 Software status DI1 clip 7 8 Test point 1 DI1 clip 9 10 Error memory DI2 clip 1 2 DI2 clip 3 4 DI2 clip 5...

Page 67: ...ip 1 10 Inc AI1 clip 1 12 Inc AI1 clip 1 14 Inc AI1 clip 1 16 Inc AIO1 clip 1 2 Inc AIO2 clip 1 2 Inc AIO2 clip 5 6 Inc IFPAI1 clip 1 2 Inc IFPAI2 clip 3 4 Inc IFPAI3 clip 5 6 Inc AI1 clip 1 3 Inc AI1...

Page 68: ...op Digital outputs Analogue inputs Analogue outputs Software status Software status Test point 1 Display 3 24 Error memory Controller ES910 3 24 Test point 1 Test point 1 Analogue Test point 2 Analogu...

Page 69: ...utlet max warning 32 0 C Outlet min STOP 15 0 C Limit tank pressure Tank max level 125 mbar Tank min level warning 105 mbar Tank min level STOP 80 mbar Hysteresis 2 mbar Pressure exp vessel Min warnin...

Page 70: ...rheating Maximum Control condensation Setpoint 28 0 C Control cooling water Hysteresis 1 0 K Control ESS free cooling Control tank refill Control pump 1 pressure Control conductivity Mode VFD Auto Man...

Page 71: ...trol tank refill Proportional band 2 0 K Ti integration time 50 sec Td diff time 0 sec Temp min 35 0 C Opening temp min 0 Temp max 40 0 C Opening temp max 100 Cold water high temp start ass Temp inlet...

Page 72: ...ESS free cooling Model Eco Control tank refill Setpoint eco mode 31 5 bar Control conductivity Setpoint comfort mode 35 0 bar P band 10 0 bar Ti Int time 100 sec Td diff time 0 sec HP max limit Applic...

Page 73: ...temperature Sensor configuration Control hot gas bypass Control cold water valve Control tank heating Control condensation Control cooling water Control ESS free cooling Control tank refill Control t...

Page 74: ...ware update Control pump Control pump Datalog export Control compressor Delay control 15 sec Datalog stop Basics After run time 15 sec Chiller configuration Pump after run time 15 sec Sensor configura...

Page 75: ...TOP dP 0 2 bar Time delay 30 sec LP STOP 7 3 bar Delay start 60 sec Delay running 3 sec LP ON STOP dP 1 5 bar Number of alarms per hour 3 Time delay 10 sec High pressure HP HP warning ON 42 5 bar HP w...

Page 76: ...Pump 1 Consumer Pump 1 VFD No Pump 1 flow No Pump 2 No Pump 2 VFD No Pump 2 flow No Control pressure Outlet Cooling medium Water Condenser valve 2 No Control hot gas bypass No Tank present Yes Tank h...

Page 77: ...water evaporator Measuring 4 mA 0 5 bar Measuring 20 mA 10 0 bar AI tank pressure Measuring 4 mA 0 mbar Measuring 20 mA 200 mbar AI press exp vess Measuring 4 mA 0 0 bar Measuring 20 mA 10 0 bar AI h...

Page 78: ...mpcb fan 1 AI temp system return DI fan 1 fault AI coding resistor DI mpcb fan 2 AI conductivity DI fan 2 fault AI air flow DI mpcb tank heating DI emergency stop DI STP tank heating DI phase monitor...

Page 79: ...atalog stop IP address English Serial number Fran ais Save parameters Rom n Load parameters e tina Password Magyarul Dansk Eesti Portugu s Lietuviskai Polski Sloven ina Svenska Suomi T rk e Espa ol Hr...

Page 80: ...r Serial number Save parameters Entry of serial number Load parameters 9000 0000 Password Result Saving to controller OK Saving to USB OK Load parameters XXXXXXXX par Password Enter digits 0 0 0 0 Dat...

Page 81: ...frigerant level A compressor is switched off if the number of compressors is 1 delayed from v 2 60 After pressure increase the compressor switches on again All other components continue to run Warning...

Page 82: ...ure side was 3 times lower S h LP STOP S h LP STOP Compressor no longer starts automatically after the 3rd low pressure STOP AL161 All other components continue to run Alarm is saved Manual reset 163...

Page 83: ...k refill Open the shut off devices integrated in the supply line Check the supply line for leakage Solenoid valve for tank refill closes All other components continue to run Alarm is saved Manual rese...

Page 84: ...valve closes All other components continue to run Alarm is saved Manual reset 351 Outlettemp 1 max STOP Group fault alarm Maximum outlet temperature cold water circuit 1 exceeded No refrigeration Ther...

Page 85: ...ump 2 Evaporator pump Pump 1 continues to run Pump 2 switches off Pump 1 Consumer pump Pump 2 Redundant The required pump continues to run Alarm is saved manual reset 379 Pr exp vess min Stop Group fa...

Page 86: ...hed to this sensor and the setpoint is increased by 6K Alarm is saved From V 2 60 Manual reset 503 AI temp outlet 2 Group fault alarm from Version 2 60 Sensor defective sensor break or sensor short ci...

Page 87: ...sensor check sensor using the characteristic curve Alarm is saved From V 2 60 Manual reset 512 AI press exp vess Group fault alarm from Version 2 60 Measured value of the analogue input outside the v...

Page 88: ...lue of the analogue input outside the valid measuring range Sensor defective sensor break or sensor short circuit Check electrical connections of the sensor check sensor using the characteristic curve...

Page 89: ...31 AI conductivity Group fault alarm from Version 2 60 Measured value of the analogue input is outside the valid measuring range Sensor defective sensor break or sensor short circuit Check the electri...

Page 90: ...t 613 Flow start pump 1 Group fault alarm Flow switch did not switch through after the pump start up phase Flow too low Check flow check shut off valves check pump check the setting of the reed contac...

Page 91: ...Consumer pump Pump 2 Evaporator pump Pump 2 and compressor switch off Pump 1 runs up to outlet temperature Max Stop continues Pump 2 Consumer pump Pump 1 Redundant Pump 2 switches off Pump 1 switches...

Page 92: ...or blocked Check the motor power consumption check the operating point check the electrical connection of the components all components continue to run Free cooling is stopped Fault is stored and must...

Page 93: ...f rotation poor contact at terminals short circuit of windings earth fault rotor blocked Check the motor current consumption check the electrical connection of the components check for mechanical bloc...

Page 94: ...poor contact at clip points due to soiling or corrosion Short circuit between the heating rods earth fault Check the electrical connection to the components test for short to earth all components cont...

Page 95: ...the refrigerant side for leaks x 12 Check high low pressure switching equipment x Air cooled condenser 20 Optical check for dirt damage and corrosion x x 21 Measure the condensing temperature x 22 Me...

Page 96: ...pipes carrying refrigerant for corrosion and damage x Fans 50 Optical check for dirt damage and corrosion x x 51 Check fixings and bearings x 52 Check flexible connection for tightness electrical con...

Page 97: ...ning properly x 95 Check the function of the motor protection switches x 96 Check 24 VDC and supply voltage x x 97 Check control cabinet heater x 99 Check control cabinet filter and if necessary repla...

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KKT chillers cBoxX 100, Operating Instructions Manual

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