REMKO RKW 1000 – 9800 INOX Stainless Steel Chiller Operation ...

remko

REMKO RKW 1000 – 9800 INOX Stainless Steel Chiller Operation ...

REMKO RKW 10009800 INOX

Stainless Steel Chiller

Operation

Technology

Spare Parts

Edition GB – M11

REMKO – powerful like a bear


Operating Instructions

Read these instructions carefully before setting up/operating the unit!

Our guarantee becomes null and void if the unit is used, set up

REMKO Stainless Steel Chiller

RKW 1000 INOX / 1600 INOX / 2600 INOX

3600 INOX / RKW 4500 INOX / 8000 INOX / 9800 INOX

Contents Page

Unit Description 4

Safety Hints 4

Transport and Packaging 5

Operation 5

Maintenance and Service 9

Shutting Down the Unit 10

Alarm Description 10

Troubleshooting 11

Technical Data 12

Dimensions 13

or maintained improperly,

or if modifications are made to the supplied unit without our prior consent.

Subject to alterations!

Contents Page

Assembly Instructions for Service Personnel 14

Unit Assembly 14

Storage Modules for RKW 3600 to 9800 I 17

Cable Remote Control 20

Electrical Connection 21

Hydraulic System 24

Initial Operation 25

Environment and Recycling 26

Service and Guarantee 26

� Always keep these operating instructions near or on the unit! �

3


Unit Description

REMKO chilled water air-conditioning systems consist

of an outer part ready which is ready to be connected,

the air-cooled chiller (REMKO RKW INOX) and one or

more inner units (cold water consumers: REMKO KLT,

WLT, DKT and FLG). All components required for cooling

are located in the outer part.

A hermetically closed cooling cycle in the chiller cools

the water (or a brine made of water and antifreeze) to

up to 5 °C via a plate heat exchanger.

A circulation pump integrated either into the unit or in

the storage module transports the cold water to the inner

unit(s). To expand the water volume and extend the

operating time, there is also a cold water tank with

safety assembly either in the unit or located in the separate

storage module.

In the inner units, the air in the room is guided through

the heat exchanger of the inner units by means of a

quiet fan. When the air in the room leaves the unit, it is

cooled, demoisturized and filtered. The water warms up

and transports the heat absorbed from the room back to

the outer part where it is passed along to the cooling cycle

and the surroundings.

The RKW 1000, 1600 and 2600 INOX chillers all have a

hydraulic system that is ready to be connected with a:

◊ Buffer tank

◊ Expansion vessel

◊ Safety valve

◊ Flow switch (differential pressure monitor)

◊ Manometer

◊ Ventilation

◊ Ventilation valve

◊ Drain valve

The RKW 3600 INOX chiller models and higher can be

easily equipped with a storage module that has an integrated

hydraulic system, even at a later time.

The system is regulated by means of a self-sufficient

microprocessor that monitors system safety parameters

and displays any malfunctions and monitors the set cold

water temperature. A connection between the chiller

and the cold water consumers is not required.

To air condition rooms, an outer part is usually used in

connection with the appropriate inner units (consumers).

Here, there are various options available depending on

how the unit is being used. In addition to standalone

units, wall and ceiling chests, ceiling cassettes with various

capacities can also be selected for mounting on intermediate

walls.

REMKO chillers are suitable for almost every type of application

when used with the right consumers if the priority

is cooling according to needs.

Thanks to modern technology, the chillers require up to

80 % less coolant than other cooling and airconditioning

systems.

4

The coolant is only necessary to cool the transport medium

(water or brine). In conventional systems, the coolant

is also required to transport the heat from the inner

units (consumers) to the outer part.

This makes another advantage of the REMKO chillers

evident; they do not require coolant lines to the inner

units (cold water consumers). All connection lines are

designed to be water lines with the correct dimensions

and heat insulation.

Ideally, lines of an existing heating network can be integrated

into the overall system.

Proper use

The outdoor parts have been designed and fitted exclusively

for operation with REMKO indoor units belonging

to the RKV series.

The manufacturer assumes no liability for damage resulting

from non-compliance with manufacturer specifications

and legal requirements, or if modifications are

made to the units.

Safety Hints

Extensive tests have been conducted on the material,

functionality and quality of these units before they were

shipped. These units may only be used in accordance

with their intended purpose. Hazards may arise if the

units are used improperly.

Please make sure to follow these safety instructions.

◊ Make sure that personnel trained in the operation of

the chiller check the unit for visible defects on the operating

and safety mechanisms each time before

putting it into operation.

◊ Before any work on the unit is performed, it must be

disconnected from the power supply and secured

against switching on!

◊ The unit may only be filled up and operated with water

or a mixture of water and glycol (brine)!

◊ Ensure that the air intake and outlet openings are always

clear of foreign objects.

◊ Do not insert any objects into the air intake and outlet

openings.

◊ Do not install the unit close to heat sources.

◊ Make sure to maintain the safety zones described

later in this manual!

◊ Do not use flammable gases such as spray paint in

the direct vicinity of the units.

◊ Make sure that the unit is kept at a safe distance

from flammable materials.

◊ Do not operate the unit if the atmosphere is contaminated

by oil, sulfur or salt.

◊ If there is a cable remote control installed, make sure

to protect it against moisture and direct or indirect

sunlight!


◊ Operate the units exclusively within the permissible

operating ranges.

◊ Do not expose the unit to direct streams of water

High-pressure cleaners, etc.

◊ Protect the connection lines from being damaged, for

example, by animals.

◊ The unit may only be connected to a correctly installed

and grounded power supply.

◊ Never open the unit housing.

There may cause an electric shock.

◊ Operate the unit only when assembled and for their

intended purpose. Keep in mind that it is dangerous

to remove covers protective grilles, etc., during operation;

this can lead to uncontrolled operating situations.

◊ Never operate the unit in rooms susceptible to explosions.

The units are also not suitable for operation in

rooms containing large amounts of dust or aggressive

air.

◊ Installation and repair work may only be performed by

authorised personnel.

◊ Cleaning and minor maintenance work made only be

performed by the operator or an authorised person

designated by him in accordance with the instructions

contained in the section "Maintenance and Service".

◊ If the unit is set up outside and is susceptible to being

hit by lightning, the appropriate countermeasures

must be implemented by an authorised company.

Transport and Packaging

The unit is shipped in a stable transport box made of

wood and cardboard. Please examine the unit when it is

delivered

Make note of any damage or missing parts on the shipping

bill and notify the shipping company and your contract

partner.

We do not assume any liability for subsequent complaints.

Instructions:

◊ When shipped, the units are packaged in a box and

mounted on a palette.

◊ The units must remain upright and be transported

with suitable means. They must also be adequately

secured from falling over.

◊ If the units are transported to a setup location that is

higher up, such as platforms or roofs, they must be

transported in an upright position as shown below.

Operation

The chiller is operated fully-automatically by an internal

regulation or by an external cable remote control installed

by the customer.

Both types of unit operation allow some parameters to

be changed as well as the water return temperature to

be displayed.

Internal and external regulation

Pulling point

Wooden boards to protect

from pressure

CH-DIN regulation Cable remote control

5


Regulation

CH–DIN regulation of all RKW INOX units

The CH–DIN microprocessor regulates the chiller for all

INOX units. It is located in the electrical switch box of

the unit and monitors all control and safety functions:

◊ Controls and displays incoming and outgoing cold

water temperatures

◊ Displays the time delay of the compressor and fan

◊ Checks that the outgoing water temperature is not

too low (frost monitoring)

◊ Displays and controls all safety mechanisms that

have been stopped due to a malfunction

◊ Displays the operating mode

◊ Regulates the condensation temperature

The regulator consists of the basic unit to control unit

operation. A fan board is connected to the basic unit

that controls the rotation of the fan motors by regulating

the output current depending on the liquefaction temperature.

Models RKW 3600 INOX and higher have two cold cycles.

The second cycle cannot be regulated by the CH–

DIN basic unit because there are not enough inputs and

outputs. For this reason, the extra C2-DIN regulator

controls the second cycle. Programming is, however,

still performed using the CH–DIN basic unit.

CH– DIN panel

6

Value display Arrow keys Code display

CH-DIN

8

Heat

Cool


8. 8

MODE

MENU

Comp

SET

8

STATUS

MENU button STATUS button

MODE button SET button

8

Alarm

Line

ON/OFF

RESET

ON/OFF

RESET button

The panel has two displays: the value display (three

numbers on the left) and the code display (two numbers

on the right).

MENU

STATUS

MODE

The buttons allow operating

processes (parameters) and their associated values to

be changed.

SET

ON/OFF

RESET

Value Display

The value display shows the target value in degrees

with one decimal place in Celsius. It can also display:

◊ All parameter settings

◊ The codes for all alarms

◊ The status of the functions

◊ The operating hours

◊ The shut-off status

8 8. 8

◊ The current delays

A square LED displays minus temperatures and an LED

in the top left-hand corner shows the multiplier of the

displayed value with 100.

Code Display

The code display indicates the number of the parameter

(or the function) whose value or status appears in the

value display. If a parameter is shown in the code display,

the setting appears in the value display.

Arrow Keys

8

8

The set value for each parameter can be changed with

the arrow keys.

When the parameter programming operating mode is

accessed (via the MENU button), both displays show a

value (continuous display). After the SET button has

been pressed, the code display (parameters) starts

blinking. The displayed values can be increased or decreased

using the arrow keys. If the SET is pressed a

second time, the value display blinks. The new values

are saved by pressing the SET button again. Both displays

switch from a blinking display to a continuous display.

MODE Button with two LEDs

The regulation mechanism was designed for use of a

chiller in the cooling operating mode Cool ❅ and as a

heat pump in the cooling and heating operating

modes. Heat

Only the summer operating mode (cooling mode) Cool ❅

may be used for all INOX units.

MENU Button with one LED MENU

The MENU button provides access to the parameter list

and displays the parameters on the code display and

the associated value on the value display.

STATUS Button with one LED

MODE

STATUS

The STATUS button provides access to the status list

and displays the status settings by pressing the arrow

keys.

The code display shows the function number of the

function list and the value display shows the corresponding

setting. The codes and their descriptions are

described in the table on page 8.


ON/OFF/RESET Button

ON/OFF

RESET

This button is used to switch the unit on and off. If the

alarm has been set off and the unit has to be manually

reset, this button is pressed to prevent further alarms

from being acknowledged. At the same time, the normal

operating function of the unit is restored.

Alarm LED

Alarm

If this LED is lit up, the unit’s alarm has gone off and operation

has been interrupted.

SET Button

SET

The parameters settings can be changed by pressing

the SET button together with the arrow keys.

Compressor LED

This LED is not lit up when the compressor is not in operation.

If this LED is blinking, the compressor is currently

in start-up time delay and will begin operation after

this time has elapsed. If this LED is continuously lit

up, the compressor is in operation. The time delay is no

longer active.

Line LED

Fan Board

Line

Comp

This LED is continuously lit up when the regulation is

connected to the power supply.

The fan board is connected to the CH–DIN regulation.

The CH-DIN (C2-DIN) regulation registers the current

condensation temperature via the sensor input ST 5 (ST

6) and passes along the corresponding programmed

output current to the CTK 1 (CTK 2) output of the TK 1

(TK 2) fan board.

The fan motor rotation can be controlled by the modulating

output current.

Fan board TK 1 Fan board TK 2

C2–DIN Additional Regulations for Models RKW 3600

and higher

For chillers with cooling capacities higher than 26 kW,

the cooling capacity is divided among two cooling cycles.

The second cycle cannot be regulated using the

CH-DIN regulation because there are not enough inputs

and outputs and requires an additional C2-DIN regulation.

The C2-DIN regulation controls the same functions

together with the CH-DIN regulation. These functions

are only displayed by LEDs. An alarm from the second

cycle is displayed on the CH-DIN regulation display as a

code, e.g. “E 01”.

The CH-DIN regulation is still used to program the settings

of the second cycle.

C2– DIN Additional Regulation

Operating display Compressor 2

Malfunction display

High pressure 2

C2-DIN

Compr.

High press.

C2- DIN additional regulation

Operating Display Compressor 2

Compr.

This display lights up when the compressor of the second

cycle is in operation.

Malfunction Display Compressor 2

Err. compr.

This display lights up when there is a malfunction in the

compressor of the second cycle.

Malfunction Display Fan 2

Err. fan

Malfunction display

Fan 2

Err. compr.

Low press.

Err. fan

This display lights up when there is a malfunction in the

fan of the second cycle.

High Pressure MalfunctionCycle 2

High press.

This display lights up when pressures that are too high

have been set in the second cycle.

Low Pressure MalfunctionCycle 2

Malfunction display Compressor 2

Malfunction display

Low pressure

CH- DIN regulation

Low press.

This display lights up when pressures that are too low

have been set in the second cycle.

7


Determining the Operating Mode (Status)

The Status menu is used to determine the current operating mode of the various system components such as operating

hours, outputs currently set, the current actual values of the sensor inputs and any current malfunctions.

Pressing the STATUS button takes you to the Status menu (Status LED is lit up). The left-hand value display now

indicates the current operating mode of the statuses in the right-hand code display using the index described in the

table below. These can be listed by pressing the arrow keys in sequence:

Programming process

8

Status Status Description Index Meaning

01 Compressor 1 01

02

03

04

06

Compressor 1 in cooling mode

Compressor 1 in heating mode (not in use)

Compressor 1 in defrost cycle (not in use)

Compressor 1 in time delay ON

Compressor 1 OFF

02 Run time Compressor 1 # (value in hours) Operating hours of Compressor 1

03 Fan(s) Cycle 1 01

02

04

06

In operation

Off (defrost for heating pump)

Time delay ON

OFF

05 Rotations condenser fan(s) Cycle 1 # (value as a %) Fan rotation as a percentage

21 Compressor 2 - - -

01

02

03

04

06

22 Run time Compressor 2 - - -

# (value in hours)

23 Fan(s) Cycle 2 - - -

01

02

04

06

25 Rotations condenser fan(s) Cycle 2 - - -

%

40

Sensor incoming water temperature

ST 1 (Cycle 1)

41 Remote control ON/OFF - - -

ON

OFF

42

43

44

45

Sensor outgoing water temperature

ST 2 (Cycle 1)

Sensor outgoing water temperature

ST 3 (Cycle 2)

Sensor condenser temperature

ST 5 (Cycle 1)

Sensor condenser temperature

ST 6 (Cycle 2)

- - -

# (value in °C)

ON

OFF

ERR

- - -

# (value in °C)

ON

OFF

ERR

- - -

# (value in °C)

ON

OFF

ERR

- - -

# (value in °C)

ERR

- - -

# (value in °C)

ERR

46 Cold water pump - - -

01

06

47 Run time cold water pump - - -

# (value in hours)

48

1

8

Defrost heating

(not in use)

STATUS 0 4 0 1

- - -

01

06

0 6

Not installed

Compressor 2 in cooling mode

Compressor 2 in heating mode (not in use)

Compressor 2 in defrost cycle (not in use)

Compressor 2 in time delay ON

Compressor 2 OFF

Not installed

Operating hours of Compressor 2

Not installed

Fans in operation

Off (not in use)

Time delay ON

OFF

Not installed

Fan rotation as a percentage

Not installed

Actual value in 0.1°C intervals

Sensor activated

Sensor not activated

Sensor malfunction or failure

Remote control not installed

Remote control active

Remote control locked

Not installed

Actual value Cycle 1

Sensor activated

Sensor not activated

Sensor malfunction or failure

Not installed

Actual value Cycle 2

Sensor activated

Sensor not activated

Sensor malfunction or failure

Not installed

Actual value condenser Cycle 1

Sensor malfunction or failure

Not installed

Actual value condenser Cycle 2

Sensor malfunction or failure

Not installed

Pump in operation

Pump not in operation

Not installed

Operating hours of the pump

Not installed

Heating in operation

Heating not in operation

0

2

STATUS


Changing the Target Values (Parameters)

A parameter is a modifiable value that can be set by the

operator/installer to adjust the chiller to the specific conditions

and guarantee optimum operation.

For example, the return temperature, the frost protection

alarm temperature and the new switch-on differential

can be changed after the target temperature has

been reached.

Access rights for system operators and qualified maintenance

and service personnel is divided into two parameter

levels. The operator can only change basic parameters

on the first level and the service personnel can

change system-specific parameters on the second level

after entering a password.

A technical data sheet which explains the second parameter

level can be requested separately by a qualified

company from REMKO GmbH &Co. KG.

Programming process

MENU

1

8

Table of the first parameter level

1

0

MENU

Parameter Function Unit

First Parameter Level for the System Operator

The first parameter level is accessed by pressing the

ON/OFF/RESET button. The current return temperature

is displayed.

After pressing the MENU button, the programmed value

of Parameter 02 (right-hand code display) appears in

the left-hand display. The right-hand parameter display

begins to blink when the SET

button is pressed. This mode displays the options for

changing the parameters to the programmer.

If one of the arrow keys is now pressed, the parameter

jumps to the next higher or lower parameter.

Once the correct value has been reached for the parameter,

the value display begins to blink after the SET

button has been pressed. The displayed value can now

also be changed using the arrow keys. The programming

level can be exited by pressing the SET button a

third time. The settings are saved and the return temperature

is displayed again.

RKW INOX factory setting

1000 1600 2600 3600 4500 8000 9800

02 Target value regulation, cooling °C 12,0 12.0 12.0 12.0 12.0 12.0 12.0

03 Target value regulation, heating °C 45.0 45.0 45.0 45.0 45.0 45.0 45.0

04 Cooling hysteresis °C 1.0 1.0 1.0 0.8 0.8 0.8 0.8

05 Heating hysteresis °C 1.0 1.0 1.0 0.8 0.8 0.8 0.8

26 Frost protection alarm target value °C 4.0 4.0 4.0 4.0 4.0 4.0 4.0

92 Password entry - Technical data sheet

Maintenance and Service

The unit almost never requires maintenance. Regular

care and the observation of a number of basic rules will

ensure the unit’s long service life and reliable operation.

◊ We recommend concluding a maintenance agreement

with a company who specialises in this type of

work. This will guarantee that the system operates

safely at all times!

◊ Keep the unit free of dirt, plants and other deposits

and only clean the units with a damp cloth.

Do not expose the units to a direct stream water.

◊ Do not use an abrasive cleaning agent or one that

contains solvent; if the units are extremely dirty, only

use suitable cleaning materials.

SET

0

2

1

0

SET 0 2 0 3

◊ Before taking the unit out of operation for a longer

period of time, clean the plate fins of the unit while

the ventilator is in operation and cover the unit with a

plastic sheet to prevent dirt from entering the unit.

◊ For systems with brine, check the ratio of water to

Antifreeze N or Antifreeze L before taking the unit out

of operation in winter to protect the system from

frost.

◊ We recommend having the unit checked at regular

intervals (once or twice a year) to ensure that it is

functioning properly and there are no leaks.

1

1

SET

9


Shutting Down the Unit

Temporary shutdown

If the unit is to be taken out of operation for a longer period

of time, for example, over the winter, proceed as

follows:

1. Use the remote control to shut down all of the inner

units.

2. Switch off the internal regulation in the chiller (or the

remote control).

3. Have the percentage of glycol is checked by an

authorised company.

4. If only water was used in the hydraulic cycle and no

brine (water and antifreeze), this water must be

drained from system components in areas susceptible

to frost during the period of non-operation. When

the unit is put back into operation, the amount of water

that has been drained must be refilled!

5. Check the inner units and the chiller for any visible

damage.

6. Clean the inner units and outer parts as described in

section 5 “Maintenance” and cover the chiller, if possible,

with a plastic sheet to protect it from weather

conditions.

When the unit is put back into operation after a long period

of non-operation, it must first be checked for external

damage before operation.

List of the alarm codes

10

Alarm Description

Code Alarm Type AUTO MANUAL

E00 Remote control defective (open contact)

E01 High pressure alarm Cycle 1

E02 Low pressure alarm Cycle 1

E03 Condenser overheating Cycle 1

E04 Condenser temperature too high

E05 Frost protection Cycle 1 activated

E06 Sensor defective ST 2 outgoing water Cycle 1

E07 Sensor defective ST 5 condenser Cycle 1

E21 High pressure alarm Cycle 1

E22 Lobe pressure alarm Cycle 1

E23 Condenser overheating Cycle 2

E24 Condenser temperature too high

E25 Frost protection Cycle 2 activated

E26 Sensor defective ST 3 outgoing water Cycle 2

E27 Sensor defective ST 6 condenser Cycle 2

E40 Sensor defective ST 1 incoming water

E41 Flow switch (differential pressure monitor) activated

E42 Hardware defective

To protect the unit, the CH-DIN regulation and the C2-

DIN additional regulation use sensors to check the unit’s

safety mechanisms for temperature, pressure, internal

configuration, etc.

The value display of the CH-DIN regulation indicates the

alarm code by displaying the letter E followed by two

numbers. The cause of the alarm can be determined by

finding the code in the table below. The C2-DIN additional

module also displays the alarm with a corresponding

LED.

On the second parameter level, resetting the alarm can

be programmed after the malfunction has been fixed

The alarms are pre-programmed to automatically reset

at the factory.

If the alarms have been reprogrammed to be reset

manually, the alarm must be reset after the problem has

been fixed by switching the CH-DIN and then on again

with the ON/OFF/RESET button (see programming example

below).

Resetting the alarms after the problem has been fixed

The alarms can be reset by following the programming process below. As an example, the compressor switched off

due to a malfunction caused by dirt in the condenser fins.

Programming process

Overheating of the

condenser as a

result of dirt in the

fins

E

Alarm

2 1

Temperature of the

condenser is lowered

and the fins of

the heat exchanger

are cleaned

0

2

Permanent shutdown

For environmental safety reasons, the chiller may only

be disassembled by authorised service centres.

REMKO GmbH & Co. KG or your contract partner would

be happy to provide you with the name of a service centre

in your area.

ON/OFF

RESET

Alarm

ON/OFF

RESET

3

The second parameter level can be

programmed to reset the alarms.

Enter the changed resets in the lefthand

column.

All settings made at the factory

have been pre-programmed to

AUTOMATIC.

1


Troubleshooting

This unit has been designed based on state-of-the-art manufacturing methods and it has been tested repeatedly to

ensure that it is working properly. However, should problems occur, refer to the following list.

Problem Alarm Possible cause Check Remedy

The unit

does not

start or it

switches

itself off

automatically.

The unit is

either not

cooling at

all or only

a little bit

Water

leaks out

of the unit

E01/E02

E21/E22

E00/E21

Power failure

Power fuse / power supply defective

Are all other electrical components

working?

Are all other electrical components

working?

Check voltage and wait for the

unit to start again.

Maintenance by authorised

personnel

Waiting period too short Is the COMP LED blinking? Schedule longer waiting periods

Regulation is not working

Incorrect discharge temperature

or parameter setting

High-low pressure alarm

Remote control / Connection

to C2-DIN defective

E03/E23 Compressor overheating

E04/E24

Liquefaction temperature too

high

E05/E25 Frost protection activated

E06/E07/

E26/E27/

E40

E41

Incorrect electrical rotational

direction

Sensors defective ST1 to ST6

Flow switch (differential pressure

monitor) activated

E42 Hardware defective

Compressor contact defective

Heating capacity was increased

Supply temperature too high

Air in the system

Liquefaction temperature too

hot

Is the LINE LED and to the

COOL LED lit up?

Connect current and select the

COOL operating mode

Check setting Change setting

Are the fans rotating?

Is the pressure in the cold cycle OK?

Is the display working?

Is the connection OK?

Is the temperature of the compressor

above approx. 100 °C?

Are the fins clean and have the operating

ranges been maintained?

Is the supply temperature 4°C or

lower?

It is the alarm activated when the

sensor is replaced?

Are the following values OK:

◊ Volume of current (too large/small)

◊ No air in the monitoring pipes

◊ Circulation pump

◊ Does the monitor switch on and off

◊ Stop mechanisms are open

◊ Water pressure too high/low

Does the regulation function

smoothly?

Is the COMP LED lit up and is there

current on the contact?

Have checked by authorised

company

Replace remote control or reestablish

connection between

CH-DIN and C2-DIN

Maintain operating ranges, clean

fins

Clean fins, place unit in the

shade

Increase discharge temperature

Replace defective sensors

Have checked by authorised

company

Have regulation replaced by

authorised company

Have the contact or compressor

replaced by an authorised company

Has there been a structural change? Maintain safety zones

Is the supply temperature approx.

5 ... 10 °C?

Have automatic ventilators been

mounted on the highest possible position?

Are the fins clean and have the operating

ranges been maintained?

Reduce discharge temperature

Ventilate manually or integrate

ventilators

Incorrect parameter settings Check settings Change settings

Sporadic operation because

cooling requirements are too

low

Leaks in pipes or defective insulation

Did the phase-sequence relay switch

through?

Has the system been designed for

smaller measurements?

Are there leaks and have all lines

been insulated?

Change the rotational direction

Clean fins, place unit in the

shade, maintain operating ranges

Increase the quantity of water by

installing a storage module

Seal and insulate

11


Technical Data

Type RKW INOX

Cooling capacity 1)

(1) Capacities based on ISO R 859A; room temperature of TK 27°C/FK 19°C - outside temperature 35°C, supply 7 °C, discharge 12 °C

(2) Noise measurement DIN 45635 - 01 - KL3 in intervals of 10 meters

(3) Only when brine is used (water with 34% glycol)

(4) Power data per cooling cycle

12

1000 1600 2600 3600 4500 8000 9800

kW 10,0 16,0 25,6 35,9 44,3 78,0 98,0

Air performance max. m³/h 3000 6200 10000 17000 19000 35000 39000

Number of fans / diameters -/mm 2/450 2/450 1/630 2/630 2/630 2/800 2/800

Rated flow rate water m³/h 1,8 2,8 4,4 6,2 7,6 13,4 16,9

Minimum flow rate water m³/h 1,3 1,9 3,0 4,5 5,2 8,8 10,8

Pump pressure max. kPa 70 90 74 - - - -

Internal pressure losses for rated flow rate kPa 25 37 40 32 29 19 20

Available external pressure differential kPa 45 53 34 - - - -

Operating pressure max. kPa 250

Incoming water chiller inch 1¼ 1 2 2 x 2

Outgoing water chiller inch 1¼ 1½ 2 2 x 2

Filling connection inch 1/2 -

Sound pressure level 2)

dB(A) 43 44 49 48 48 53 54

Refrigerant R 407C

Cold cycles/Compressor type - 1 Scroll 2 Scroll 2 Tandem Scroll

Refrigerant amount kg 5,0 4,1 8,0 2x7,4 2x7,6 2x20,5 2x21

Contents storage tank l 45 45 108 - - - -

Operating range outgoing water °C + 5 °C to + 15 °C

Operating range outside temperature 3) °C - 10 °C to + 43 °C

Nominal current consumption

per compressor 4)

A 8.0 12.8 18.8 26.3 2x16.3 4x14.6 4x18.4

Nominal current consumption. max. A 8.0 12.8 18.8 26.3 32.6 58.5 73.5

Electrical connection V/Ph/Hz 400/3~,N,PE/50

Power consumption. max. kW 4.4 7.1 11.2 15.7 19.4 36.0 45.2

Starting current A 49 101 167 2x90 2x120 2x116 2x127

Supplied fuse protection (recommended) A 20 20 25 35 50 80 100

Dimensions Width mm 1150 1150 1340 2370 2370 2990 2990

Depth mm 460 460 560 560 560 1280 1280

Height mm 1300 1300 1770 1310 1310 1520 1520

Weight kg 160 197 300 437 461 902 934

Ref. No. 1611600 1611610 1611620 1611635 1611645 1611650 1611660


Dimensions

RKW 1000 INOX / 1600 INOX

F

E

D

K

L

A

RKW 3600 INOX / 4500 INOX

RKW 8000 INOX / 9800 INOX

B

C

RKW 2600 INOX

A B F

A B

A B F

Model size 1000 INOX 1600 INOX 2600 INOX 3600 INOX 4500 INOX 8000 INOX 9800 INOX

A mm 1150 1150 1340 2370 2370 2990 2990

B mm 460 460 560 560 560 1280 1280

C mm 1300 1300 1770 1310 1310 1520 1520

D mm 625 625 90 715 715 900 900

E mm 615 615 1610 1180 1180 520 520

F mm 220 220 160 1100 1100 1300 1300

G mm - - - - - - - - - - - - - - - 290 290

K incoming water inch 1 ¼ ‘‘ inside 1 ¼ ‘‘ inside 1 ¼ ‘‘ inside 2 ‘‘ inside 2 ‘‘ inside 2 x 2 ‘‘ inside 2 x 2 ‘‘ inside

L outgoing water inch 1 ¼ ‘‘ inside 1 ¼ ‘‘ inside 1 ½ ‘‘ inside 2 ‘‘ inside 2 ‘‘ inside 2 x 2 ‘‘ inside 2 x 2 ‘‘ inside

M filling connection (water) inch ½ ‘‘ outside ½ ‘‘ outside ½ ‘‘ outside - - - - - - - - - - - -

Fan / number Ø mm / - 450 / 2 450 / 2 630 / 1 630 / 2 630 / 2 800 / 2 800 / 2

Depending on the size of the unit, a certain number of vibration absorbers are supplied with the unit. These have a height of approx. 30 mm

up to the model size RKW 4500 I, and of approx. 45 mm for model size RKW 8000 I and higher which must be added to the heights above

(measurement C).

K

D

L

E

K

G

E

D

L

F

D

E

K

C

13

C

C


Assembly Instructions for

Service Personnel

Prior to installation

The following must be checked and complied with before

the unit is actually assembled:

◊ Ensure that the contents of the package are complete

and that the unit has no visible damage results

in from transport. Any problems must be communicated

immediately to your contract partner and the

shipping company. Subsequent complaints will not

be acknowledged.

◊ Place the unit in its original packaging as close as

possible to the location where it will be assembled.

This will prevent damage resulting from transport.

◊ Ensure that the foundation for installing the chiller is

level, even, firm and resistant.

Pay attention to the load capacity of the foundation.

◊ Choose a place for installation which guarantees a

free air intake and air discharge of the unit and

where the unit is not exposed directly to the sun or

other heat sources.

◊ The air discharge of the unit should be in accordance

with the main direction of the wind.

◊ Keep all distances which are described in the chapter

“minimum distances”

◊ Prior to installation, the electrical connection values

must be checked for consistency with the data on

the type plate.

◊ All indoor units must have a separate electric supply.

◊ An electric control cable to the chiller is not necessary.

Unit Assembly

The REMKO RKW INOX chillers have been designed

and built for outside setup. Because a lot of heat is expelled

to the surroundings, make sure that when you select

a location for setup, air can flow freely in and out of

the unit.

It is generally not advisable to set up the unit in enclosed

rooms because adequate air exchange with the

outside air cannot be guaranteed and there must be an

equal amount of air intake and output.

An adequate air exchange can only be guaranteed if a

corresponding cross ventilation supplies fresh air to the

room at least at the air flow rate of the chiller. Otherwise

the room will heat up and the chiller will switch off due to

a malfunction. This occurs once the room temperature

exceeds the upper operating range of the set value of

the safety mechanism.

14

General information

◊ The chillers are units for outside setup.

◊ Wind protection devices must be set up if the air expelled

from the unit does not flow in the same primary

direction as the wind.

◊ You must ensure that the wind protection does not

adversely affect the air supply to the unit.

◊ When setting up the unit, ensure that adjacent

rooms or buildings are not exposed to adverse effects

from noise emitted from the units. You should

avoid setting up the units on large, reverberant surfaces,

such as between reflecting buildings, because

this can increase the noise level.

◊ The chillers must be mounted on vibration absorbers

or foundations which prevent vibrations (to be done

by the customer).

◊ If the chillers are also used during the winter months,

the unit must be assembled high enough so that it is

protected from snow. The minimum height is 20 cm

above the normal amount of snow expected.

◊ To ensure that the unit operates smoothly, adequate

safety distances to walls and other obstacles must

be maintained during setup.

Minimum distances

These safety zones ensure that air can flow freely in

and out of the unit, that maintenance and repair work

can be performed and to protect the unit from damage.

The figure below indicate the minimum distances that

must be maintained to ensure that the units operate

properly.

RKW 1000 / 1600 INOX

500

300 1000

300 500

RKW 2600 INOX

500

1000

300 300 600


RKW 3600 / 4500 INOX with storage module

400

RKW 8000 / 9800 INOX

1200

500

600

600

1000

1200

Installation of the units

400 400

RKW 3600 / 4500 INOX without storage module

400

500

1000

400 400

The units are supplied with vibration absorbers in this

series. These must be connected to statically permissible

and level building or structural components.

The locations for attachment described below are for

fastening the vibration absorbers to the chillers. To establish

an attachment to a subconstruction, the dimensions

of the vibration absorbers must be observed.

3000

Vibration absorbers

RKW 1000 - 4500 INOX RKW 8000 – 9800 INOX

43 43

Attachment locations for chillers

RKW 1000 / 1600 INOX

RKW 2600 INOX

RKW 3600 / 4500 INOX with storage module

770

RKW 8000 / 9800 INOX

998

735

770

400

500

RKW 3600 / 4500 INOX without storage module

950


60

45

66 66

417 950

430 770

933 998

M12 x 35

500

500

13Ø

1150

15


Hydraulic connections

The hydraulic connections are located on the back of

the units.

The RKW 1000 and 1600 INOX units are ready to be

connected upon shipment.

For the RKW 2600, 3600 and 4500 INOX units, it is

possible to separate the plate heat exchanger of the

chiller and the storage module mounted underneath this.

For the RKW 2600 INOX unit, the plate heat exchanger

and the storage module are connected hydraulically by

the pipe connection installed at the factory.

For the RKW 3600 and 4500 INOX units, the plate heat

exchanger and the separately ordered storage module

must be connected upon assembly with the supplied

pipe connection. If the module is set up separately, the

necessary connection line must be installed by the customer

The RKW 8000 and 9800 INOX units in this series are

supplied without hydraulics. The required components

are selected by the person who develops the system.

General information

◊ We recommend equipping the connections with

shut-off valves for service purposes.

◊ Additional, automatic ventilation valves must be

mounted at the highest location of the installation in

the supply and discharge pipes.

◊ To prevent vibrations from being transferred, compensators

(flexible lines) should be used between

the fixed pipe installation and the chiller.

◊ All pipe lines must be insulated to protect them from

condensation. According to the HeizAnlV (German

Heating Systems Ordinance), a 50% insulation diameter

must be planned for cooling mode and a

100% insulation diameter for cooling and heating

mode.

◊ To prevent the unit from becoming dirty, a water filter

(approx. 16 meshes pro cm²) should be installed in

the discharge line.

◊ The water pipes may not exert any static strain on

the chiller.

◊ A second key or pliers must be used to mount the

pipe lines on the RKW so as not to create any strain

on the pipe lines in the inside of the unit.

◊ If the chiller is only initially operated with a single part

of the overall system, the flow rate of the missing

system parts must be stimulated by pipe regulating

valves.

◊ To increase the run time of the unit, we recommend

using a storage module or cold water pipes that are

slightly larger to increase the volume if the necessary

capacity of the inner units is considerably smaller

than the cooling capacity of the chiller.

◊ The hydraulics must be set up in such a way that the

predefined minimum flow rate is reached.

16

Connecting the water pipes

The RKW 1000, 1600 and 2600 INOX models in this

series are equipped with a cold water storage module

as a compact unit. The 3600, 4500, 8000 and 9800

INOX models are supplied in this series without hydraulics

for technical reasons. The water components including

the plate heat exchanger and the differential

pressure monitor are located in the chiller. The hydraulic

connections are found on the backs of all units.

For models RKW 3600 and 4500 INOX and higher, a

separate storage module can be mounted underneath

the chiller or somewhere else (e.g. inside the building).

So as not to transfer the vibrations of the chiller to the

system parts, the lines are connected to the unit by

compensators (flexible lines). We recommend equipping

the connections with shut-off valves for service purposes.

Shut-off valve Compensator

Model

Water

incoming outgoing

1000 INOX 1 ¼ ‘‘ inside 1 ¼ ‘‘ inside ½ ‘‘ outside

1600 INOX 1 ¼ ‘‘ inside 1 ¼ ‘‘ inside ½ ‘‘ outside

2600 INOX 1 ¼ ‘‘ inside 1 ½ ‘‘ inside ½ ‘‘ outside

3600 INOX 2 ‘‘ inside 2 ‘‘ inside -

4500 INOX 2 ‘‘ inside 2 ‘‘ inside -

3600 INOX with

storage module

4500 INOX with

storage module

Static attachment RKW connection

8000 INOX 2 x 2 ‘‘inside

9800 INOX 2 x 2 ‘‘inside

2 ‘‘ inside 2 ‘‘ inside ½ ‘‘ outside

2 ‘‘ inside 2 ‘‘ inside ½ ‘‘ outside

2 x 2 ‘‘ inside

2 x 2 ‘‘ inside

Filling connection

-

-


Hydraulic Connections

RKW 1000 / 1600 INOX

RKW 2600 INOX

Incoming water

Outgoing water

Incoming water

Outgoing water

RKW 3600 / 4500 INOX with separate storage module

Incoming water

Outgoing water

Incoming water

Outgoing water

RKW 3600 / 4500 INOX with the storage module below

Incoming water

Outgoing water

Hydraulic connection RKW 8000 / 9800 INOX

Incoming water

Outgoing water

Storage module for

RKW 3600 to 9800 INOX

For the RKW 3600, 4500, 8000 and 9800 INOX models,

it is not necessary to use a storage tank for certain

types of use

Other types of application absolutely require the volume

of water to be increased, for example, to extend the operating

time of the chiller and prevent sporadic operation.

Five storage modules have been designed to meet

these practical requirements:

1. Storage module 1 for RKW 3600 and 4500 INOX,

216 l tank, safety component 3 kPa and MAG,

without pump,

Ref.No.: 1611530

2. Storage module 2 for RKW 3600 and 4500 INOX,

216 l tank, safety component 3 kPa and MAG,

including prompt, Vnenn: 6,2/7,6 m³/h, pmax: 124/118 kPa

Ref.No.: 1611540

3. Storage module 3 for RKW 8000 and 9800 INOX,

2 x 216 l tanks, safety component 3 kPa and MAG,

without pump,

Ref.No.: 1611545

4. Storage module 4 for RKW 8000 and 9800 INOX,

2 x 216 l tanks, safety component 3 kPa and MAG,

including pump, Vrated: 13,4/16,9 m³/h, pmax: 90/82 kPa

Ref.No.: 1611550

5. Storage module 5 for RKW 8000 and 9800 INOX,

2 x 216 l tanks, safety component 3 kPa and MAG,

incl. 2 x pumps, Vrated: 13,4/16,9 m³/h, pmax: 95/65 kPa

Ref.No.: 1611555

The storage modules 1 and 2 are to be attached under

the RKW 3600 and 4500 INOX chillers by means of the

standard connection line. In Module 2, the circulation

pump is installed at the factory.

The storage modules 3, 4 and 5 can be set up on top of

one another to save space. The circulation pump(s) of

Modules 4 and 5 cannot be placed inside the modules

due to the design. They must be set up separately.

The hydraulic components which are to be placed in an

easily accessible location include the insulated storage

tank, a safety component, a manometer, a membrane

expansion vessel (MAG) and a filling connection with

ball stop valve.

17


Storage Module Technical Data

18

3600 4500 8000 9800

Storage module for RKW INOX 1 2 1 2 3 4 5 3 4 5

Storage contents l 216 2 x 216

Number of pumps - 1 - 1 - 1 2 - 1 2

Incoming water / Outgoing

water

inch 1½ 1½

Filling connection inch 1/2 1/2

Operating pressure max. kPa 250 250

Rated volume current water m³/h 6.2 7.6 13.4 16.9

Minimum volume current

water

m³/h 4.5 5.2 8.8 10.8

Pump pressure max. kPa - 124 - 118 - 90 95 - 82 65

Storage pressure loss,

internal

Available external pressure

differential

kPa 5 8 6 10 8 11 10 11 15 13

kPa - 92 - 89 - 59 66 - 47 32

Electrical connection V - 3~,400 - 3~,400 - 3~,400 -

Power/Current consumption kW/A 0.55/1.44 0.55/1.44 - 0.75/1.86 1.1/2.88 - 0.75/1.86 1.1/2.88

Dimensions Width mm 2370 2 x 2370

Height mm 535 2 x 535

Depth mm 560 2 x 560

Weight when empty, storage kg 123 126 123 126 246 246

3~,400

Weight pump kg - 3 - 3 - 4 6 - 4 6

Ref.No. 1611530 1611540 1611530 1611540 1611545 1611550 1611555 1611545 1611550 1611555

Storage module dimensions

Hydraulic operation of the storage module

Parallel operation Individual operation


Assembling the storage module

1. Remove the transport packaging and, if applicable,

assemble the vibration absorbers onto the bottom of

the storage module.

If the storage module is to be placed below the

chiller, the vibration absorbers do not need to be attached.

2. Attach the storage module horizontally using the

brackets of the vibration absorbers to a statically permissible

attachment location.

If the modules are to be set up on top of one another

to save space, the vibration absorbers only need to

be attached to the bottom module.

3. For hydraulic parallel operation of the storage modules,

the pipe line connections are to be connected

depending on the necessary hydraulics. When attaching

the storage modules below the chiller for the

RKW 3600 and 4500 INOX modules, the supply connection

line can be attached.

4. If the vibrations from the storage module are not to

be transferred to the pipe line network, compensators

with the correct dimensions are to be selected.

Electrical connection


Type

Prior to performing any work on the unit, it must be

unplugged from the power supply and secured

against being inadvertently switched on!

Follow these instructions to perform the electrical installation:

◊ These electrical installations may only be performed

by authorised service personnel in accordance with

the relevant regulations.

◊ The units must always be connected with low-ohm

protection conductor is with sufficient to dimensions.

In certain circumstances, the module must be

grounded as a measure to protect against lightning

in several places.

◊ The connection line of the pump is to be guided

through the respective cable penetration on the back

of the chillers into the housing in the switch box and

wired in accordance with the wiring diagram.

◊ All of the pumps to be installed in the storage modules

are designed as three-phase alternating current

motors. The power supply of the pumps is performed

on the L1, L2, L3, N and PE terminal strips.

◊ The dimensions of the lines is based on the local

conditions. The connection capacity of the units can

be found in the table below:

Electrical connection

RKW 3600 INOX /

RKW 4500 INOX

RKW 8000 INOX /

RKW 9800 INOX

400 V, 50 Hz / 3~, N, PE

Power consumption 0.55 kW 0.55 kW 0.75 kW

Cur. consumption max. 1.44 A 1.44 A 1.86 A

Characteristic curve of the pump RKW 3600 / 4500

INOX storage module 2

Characteristic curve of the pump RKW 8000 / 9800

INOX storage module 4

Characteristic curve of the pump RKW 8000 / 9800

INOX storage module 4

19


Antifreeze to prevent freezing

During cold seasons of the year, it is possible that the

water in the chiller will freeze at temperatures below 0°C

which can cause damage, for example, to the plate heat

exchanger. The same applies to installed connection

lines and system parts in rooms not susceptible to frost.

For this reason, we recommend mixing the water with

an adequate amount of antifreeze (e.g. antifreeze N).

If brine (a mixture of water and frost protection) is not

used in the hydraulic cycle, the water is to be drained

from the system parts in areas susceptible to frost during

non-operation in the winter.

Appropriate shut-off and drainage mechanisms are to

be used. The amount of water drained out must be refilled

before the next cooling season begins.

If the chiller is to be used throughout the whole year, e.

g. to air-condition a computer room) the hydraulic cycle

must be operated with brine.

When using brine, you must make sure that the pressure

loss increases as a result of the changing density

in the hydraulic cycle. Whether or not to use brine must

be considered when the hydraulic cycle is being set up.

The variable technical data can be found in the table below:

Percentage

of

ethylene

glycol

Cable Remote Control

The cable remote control can be purchased as an accessory.

It is used to query and program the chiller from

a remote location.

In the factory, all models are programmed using the remote

control.

20

Antifreeze

Correction factors when using a brine

made of ethylene glycol * and water

Power

Cooling

consump- Flow rate

capacity

tion

Pressure

loss

Vol. % °C KL KPE KV KD

0 0 1 1 1 1

20 -11 0.96 0.995 1.04 1.19

34 -20 0.95 0.990 1.09 1.35

40 -25 0.925 0.985 1.105 1.51

* We recommend an ethylene glycol with inhibitors as

corrosion protection, e.g. antifreeze N or L.

Where the heat medium comes into contact with

drinking water or food, antifreeze L is to be given

preference because it contains the physiologically

harmless substance 1.2 propylene glycol.

The data provided in the table refers to antifreeze N.

Antifreeze L has other correction factors and thus a

different pressure loss!

Electrical connection of the cable remote control

The remote control comes with an operating module

TS-W, the additional regulation module CS-DIN/TTL

and an interface line.

CS-DIN/TTL

Install the remote control as follows:

TS-W

The operating module is to be mounted in the desired

location. The operating module is connected to the

RKW with two, two-wire lines with a maximum length of

50 m. One line is used to transfer data and the other to

supply the current 12 V~ of the operating module. It is

not necessary to use an additional transformer.

The programmed data is transferred to the CH– DIN

regulation by an interface line.

1) Place the two, two wire connection lines between the

location where the remote control is to be assembled

and the switch box of the chiller. The minimum

cross-section is Cu 1.5 mm². The max. current may

not fall below 2 %.

2) Remove the assembly back panel of the operating

module and attach it to the setup location.

3) Clamp the lines to the terminal strips of the electronic

board and make sure that the polarity is correct.

Lock the operating module into place in the assembly

back panel.

4) Insert the additional module into the switch box of

the chiller.

5) Clamp the lines to the terminal strips of the previously

mounted additional regulation module in the

switch box of the chiller.

6) Using the interface line, you can connect the additional

regulation module and the CH–DIN regulation.

7) Test the function of the remote control.


Electrical Connection


The following electrical connections must be made:

◊ Connecting the power supply

◊ Connecting the cable remote control if applicable

Please follow the instructions below to install the electrical

connections:

◊ The inner units function independently of the chiller.

An electrical control line is hence not necessary.

◊ The electrical connections are to be performed as

fixed connections in accordance with the relevant

regulations.

◊ An all-polo separating switch is to be installed in the

power line in front of the unit.

◊ The power line must be insulated adequately by the

customer and the line drop may not fall below the

permissible values.

◊ Make sure that the electrical system is suitable to

supply the required operating current for operating

the unit and any other units that are already in operation.

◊ Prior to installation, if connections are made to existing

system parts, you must check that the line has

the right dimensions for unit consumption.

◊ The units must always be connected with low-ohm

protection conductors with sufficient dimensions. In

certain circumstances, the module must be grounded

as a measure to protect against lightning in several

places (especially when plastic pipes are used).


Electrical installations may only be performed by

authorised service personnel. Prior to performing

any work on the unit, it must be unplugged from

the power supply.

Description of the CH-DIN inputs and outputs

All electrical connections such as power input, cable remote

control, etc., are to be made in the switch box of

the unit. The lines to be laid must be guided through the

appropriate cable penetrations on the back of the unit

into the housing.

All units require a three-phase alternating current connection.

The power line is to be guided through the L1,

L2, L3, N and PE terminal strips.

The line dimensions are based on the local conditions.

The connection capacity of units can be found in the table

below:

Type RKW INOX

1000 1600 2600 3600 4500 8000 9800

Electrical connection 400 V /3~, N. PE / 50 Hz

Power consumption kW 4.4 7.1 11.2 15.7 19.4 36.0 45.2

Cur. Consumption max. A 8 12.8 18.8 26.3 32.6 58.5 73.5

Start-up current A 49 101 167 2x90 2x120 2x116 2x127

Fuse protection

customer-side

A 20 20 25 35 50 80 100

Warning! The units are equipped with a phase-sequencer relay that prevents the unit from operating if the rotational

direction of the electrical connection is wrong. If the chiller remains neutral (i.e. no current) when being

put into operation, the rotational field must be switched.

Terminal

strip

Normal status

Input /

Output

Function Connections

01 – 02 ST 1 Incoming water - Sensor PTC - input

03 – 04 ST 2 Outgoing water – Sensor PTC - input

05 – 06 ST 5 Condenser – Sensor PTC - input

07 – 08 closed AT 1 High pressure switch Neutral contact

09 – 10 closed AT 3 Low pressure switch Neutral contact

11 – 12 closed AT 5 Not in use Neutral contact

13 – 14 12 V ~ Tr Current supply 12 V ~, 50 Hz

15 – 16 Closed when pump is in operation AT 9 Differential pressure monitor Neutral contact

15 – 17 AT 7 Heating-cooling removed Neutral contact

15 – 18 closed AT 10 On Off, remote control contact for heating pump Neutral contact

19 – 20 RL 1 Global shut-off Max. 48 V ~, 200 mA

22 – 23 RL 2 Defrost heating / Boiler signal 230 V ~, 50 Hz, 4,0 A

22 – 24 RL 4 Compressor 230 V ~, 50 Hz, 0,4 A

22 – 25 RL 8 Circulation valve (heating pump only) 230 V ~, 50 Hz, 0,4 A,

21 – 22 RL 10 Pump switch contact 230 V ~, 50 Hz, 4,0 A

42 – 43 TK 1 Fan regulation - output Phase regulation

21


Wiring Diagram RKW 1000 INOX / 1600 INOX

22

ST 1: Temperature sensor

Incoming water

ST 2: Temperature sensor

Outgoing water

ST 5: Temperature sensor

Verflüssiger

HP Pressure absorber

High-pressure

LP Pressure absorber

Low pressure

Fan rotation

regulation board

(winter regulation)

Verflüssiger

fan 1

Microprocessor

regulation

Wiring Diagram RKW 2600 INOX

ST 1: Temperature sensor

Incoming water

ST 2: Temperature sensor

Outgoing water

ST 5: Temperature sensor

Condenser

HP Pressure absorber

High pressure

LP Pressure absorber

Low pressure

Fan rotation

regulation board

(winter regulation)

Overheating

protection

compressor

Verflüssiger

fan 2

Microprocessor

regulation

Potentialfreier

Kontakt for

regulating cooling

EXTERNAL

Neutral contact

for cooling

regulation

EXTERNAL

Differential

pressure

monitor

INTERN

Flow switch

EXTERNAL

Circulation

pump

Differential

pressure

monitor IN-

TERNAL

Condenser motor

Circulation

pump

Terminal strip M2

Compressor

motor

Condenser

fan 1

Relay condenser

Terminal strip M1

Relay compressor

Input

400 V / 3 Ph ~ / 50 Hz

Input

400 V / 3 Ph ~ / 50 Hz

Terminal strip M2

Terminal strip M1

Phase-sequence relay

Phase-sequence relay


Electrical Wiring Diagram RKW 3600 INOX / 4500 INOX

ST 1: Temperature

Incoming water

ST 2: Temperature

sensor outgoing water

ST 5: Temperature

sensor

HP Pressure absorber

High pressure

LP Pressure absorber

Low pressure

Microprocessor

regulation

Additional

module

Overheating protection condenser

Overheating protection condenser 1

Neutral contact

for cooling

regulation

EXTERNAL

Differential

pressure

monitor

INTERNAL

Condenser

fan 1

Connecting the Remote Control RKW 1000 INOX to 9800 INOX

Assembly Instructions

CH – DIN regulation /

C2 – DIN regulation

1. Place the two connection lines with a minimum

cross-section of Cu 1.5 mm² between the RKW and

the operating module (max. 50 m).

BUS

2. Connect the operating module electrically.

3. Switch the RKW so that it is neutral (i.e. no current)

and connect the 250 mm long bus-interface line to

the additional module.

4. Connect the line of the data transfer to the terminal

strips 23 and 24 (pay attention to polarity) of the additional

module and the terminal strips on the transformer

for the current supply.

12V 12V in out

BUS

Compressor motor 1

Compressor motor 2

Terminal

strip

M2

Condenser

fan 2

Frequency block

Frequency block

Circulation pump

Fan rotation regulation

board

TK 1 and TK 2

(winter regulation)

L1 N

Additional module for

the remote control

Operating module

TS-W

CS-DIN/TTL

20 21 22 23 24

Input

400 V / 3 Ph ~, N, PE

50 Hz

12V

12V

Pri L1

230V~ N

Terminal strip M1

Transformer 220 / 12 V~

in the switch box RKW

Maximum line length

50 meter

23

Phase-

sequence

relay


Electrical Wiring Diagram RKW 8000 INOX / 9800 INOX

Hydraulic System

Hydraulic Diagram RKW 1000 / 1600 INOX

Hydraulic Diagram RKW 2600 to 4500 INOX

24

ST 1: Temperature sensor

ST 2: Temperature sensor

ST 5: Temperature sensor

HP Pressure absorber

High pressure

LP Pressure absorber

Low-pressure

13

14

11

10

12

15

12

14

10

9

5

Microprocessor

regulation

15

9

Additiona

module

Klemmleiste M2

16

17

18

16

13

17

18

Potentialfreier

Kontakt für die

Ansteuerung

Kühlen

EXTERN

8

8

7

7

Circulation pump

6 5

4

6

4

Overheating protection

Compressors 1 and 2

3

3

2

2

1

1

Winter regulation

Overheating protection

Compressors 3 and 4

Hydraulic Diagram RKW 8000 / 9800 INOX

10

P

15

Frequency

block

Compressor 1

Condenser fan

1 and 2

16

18

Compressor 3

1 Shut-off element

2 Ventilation

3 Filling connection

4 Temperature display

5 Pressure display

6 Water filter

7 Static attachment

8 Compensator

9 Circulation pump

10 Differential pressure monitor

11 Ventilator

12 Storage

13 Safety valve

14 Expansion vessel

15 Stainless steel heat exchanger

16 Drainage unit connection

17 Filling connection / Drainage connection

18 Supply unit connection

19 Safety assembly

8

1

7

Winter

regulation

Input

400 V / 3 Ph~, N PE

50 Hz

4

12

5

9 6

17

19

Terminal strip M1

2

Compressor 2

Compressor 4

1

14

1

Phase-

sequence

relay


Summer Operation Cooling Only

Winter Operation Cooling and Heating

Initial Operation

Checks prior to operation:

◊ Prior to operation, the electrical connection values

and the data on the type plate must be checked for

consistency.

◊ You must ensure that all electrical connections have

been made in line with the requirements of the local

power supply company as well as national regulations.

◊ The water lines must be clean and free of impurities

. For this purpose, the lines should be rinsed out

twice or three times to ensure that all foreign matter

has been removed from the lines.

◊ Make sure that all shut-off valves in the cold water

lines are opened.

◊ Make sure that the temperature sensors (condenser,

supply and discharge / protection against freezing)

are in the correct positions and that the water lines

are connected properly to the input and output.

◊ One important prerequisite is that all lines are filled,

ventilated and have been checked for leaks. The

system pressure can be read on the outside of the

unit on the manometer. The system pressure may

be a maximum of 2.5 bar. Initial pressure during

non-operation 1.5 – 2.0 bar.

◊ If the system is being operated with antifreeze, make

sure that the concentration is correct.

◊ The electrical lines of the system must be checked

that they are attached properly to the terminal strips.

◊ Prior to operation, all screws in the water system

must be checked to ensure that they are in the

proper position and do not leak.

25


Operation

The unit must be put into operation by the manufacturer

or one of his appointed representatives. All regulation,

control and safety mechanisms must be checked to ensure

that they are working properly and have the correct

settings.

Follow the instructions below to put the unit into operation:

1. Remove the housing cover.

2. Make sure that the shafts in the circulation pumps

can turn freely. To do this, remove the plug

(depending on the pump type) and turn the shaft or

remove the housing cover by taking off the four

screws and then rotate the shaft.

3. Make sure that there is no dirt.

4. Reassemble the pump in the opposite order and select

the highest performance level for multi-phase

circulation pumps.

5. Make sure that the shut-off valves of the hydraulic

lines are open and set the pipe regulating valves to

the corresponding flow rate.

6. Make sure that all pipes and valves in the system

have been insulated correctly.

7. Fill the system with water or a pre-mixed water-glycol

mixture.

8. Ventilate the entire system and the pump.

9. Make sure that there is no air in the differential pressure

monitor line. If there is, ventilate it at the connection.

10.Check the entire system for leaks.

11.Check the insulation of all components.

12.Check that the operating current is consistent with

the power current.

13.Before switching the unit on, make sure that the

power input and the condenser (s) have the correct

rotational field. If an incorrect rotational field has

been connected, the integrated phase-sequence relay

interrupts the supplied current of the regulation.

14.Switch the chiller on by pressing ON / OFF / RESET

and select the cooling operating mode via MODE. If

the drainage temperature is warmer than the factory

setting of 12 °C, the COMP. display blinks and the

condenser begins to run in approx. three to five minutes.

15.If the factory setting has been changed, set the desired

drainage temperature by setting the Parameter

-02 to the target value, exit the parameter level

and press the ON / OFF / RESET button twice.

16.If the drainage target temperature falls below 8 °C in

the parameter level, both displays begin blinking.

You must then select a higher drainage temperature.

17.The supply temperature is approx. 5 Kelvin under the

drainage temperature for the rated flow rate.

26

18.If the supply temperature is below the factory setting

of 4°C, the unit registers a malfunction (E05/E25). In

this case, the drainage temperature must be set

higher. If the difference between the supply and return

temperatures is too high or too low, check the

flow rate.

19.The circulation pump starts and the regulation

checks the volume current via the flow switch

(differential pressure monitor). If the amount of water

is too small, the unit registers a malfunction and the

cold cycle is not released.

20.In this case, the source of the error (pipe regulating

valve not set, all valve assemblies of the inner units

are still closed, pipe dimensions of the system are

not correct) must be identified and fixed.

21.The cold cycle switches on after a time delay of approx.

3 to 5 minutes.

22.Check the system pressure, system height between

chiller and the highest inner unit and the water volume

and set, if necessary, the filling pressure of the

membrane expansion vessel to the system.

23.Reattach the covers.

24.Train the operator in system operation.

Environment and Recycling

Important information about recycling!

Only authorised personnel may come into contact with

the cold cycle. This ensures that refrigerant does not escape

into the environment when the unit is being repaired.

Both the refrigerant and the system parts are subject to

special requirements for disposal.


The refrigerant in use is a safety refrigerant. This

means that, should damage occur, the quantities

released will not cause injury to the respiratory

systems of people and animals. Do not touch the

liquid refrigerant as it can freeze the skin!

Service and Guarantee

For the guarantee to be valid, the purchaser or his customer

must completely fill out the "guarantee certificate"

enclosed with all units and send it back to REMKO GmbH

& Co. KG.

The units are repeatedly tested at the production site to

ensure that they are working properly. If a malfunction

occurs that cannot be eliminated by the operating personnel,

please contact your dealer or contact person.

Operation/handling which does not comply with

these instructions is prohibited!

� In cases of non-compliance, we assume no liability

and the guarantee becomes null and void.


REMKO GmbH & Co. KG

Klima- und Wärmetechnik

D-32791 Lage • Im Seelenkamp 12

D-32777 Lage • PO Box 1827

Phone +49 (5232) 606 - 0

Fax +49 (5232) 606260

More magazines by this user
Similar magazines