Service training top therm chiller 1 6 k w-eng_01.10.2014

1
Service Training Top Therm Chiller 1-6 kW
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Rittal - A powerful alliance with the Friedhelm Loh Group
Family- owned business
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Top Therm Chiller 1-6 kW
Processes
 Introduction and general information
 Device description
 Assembly & connection
 Control / controller
 Inspection & maintenance
 Application

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Processes
Production, process and
machine cooling
Cooling of liquid media such as water
and emulsion
Enclosure climate control with air/water
heat exchangers
Vorlauftemperatur 18°C
Rücklauf-
temperatur 23°C
Return
temperatur
23°C
Flow temperatur 18°C

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Process chain
Production, process and
machine cooling
Cooling of liquid media such as water
and emulsion
Vorlauftemperatur 18°C
Rücklauf-
temperatur 23°C
Spindle
Return
temperatur 23°C
Flow temperatur 18°C

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Recooling system line Cooling output at
Tw 18°C / Tu 30°C
Product image Use
3318.600 (pressure-closed) 960 W
-Spindle cooling
-Enclosure cooling
-Frequency converter
-Welding machines
-Printing industry
-Plant engineering
3318.610 960 W
3319.610 1500 W
3320.600 3000 W
3334.600 4500 W
3334.660 6000 W
Floor-standing enclosure: 1 – 6 kW

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Tw 18°C / Tu 30°C
Product image Use
-Spindle cooling
-Enclosure cooling
-Welding machines
-Printing industry
-Plant engineering
3318.710 960 W
3320.700 3000 W
3334.700 4500 W
3334.800 6000 W
Floor-standing enclosure: 1 – 6 kW

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Tw 18°C / Tu 30°C
Product image Use
3360.100 1000 W
-Spindle cooling
-Enclosure cooling
-Welding machines
-Printing industry
-Plant engineering
3360.250 2500 W
3360.470 4000 W
Wall mounting: 1 – 4 kW

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CHILLER
Water circuit
Cooling
circuit
Intake
Outlet
20°C +/- 1 K
Pump
Water tank
Air-cooled condenser
Compressor
Evaporator
Expansion valve
Liquid diagram

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SK3318.600-610 / SK3319.600-610
Legend
1 Rating plate
2 Display
3 Louvred grille for air inlet
4 Louvred grille for air outlet
5 Cable entry
6 Cooling medium inlet
7 Tank drain nozzle
8 Cooling medium return
Operating instructions
Device description

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SK3320.600-3334.600
Legend
2 Display
3 Liquid level display of cooling medium
4 Tank filling nozzle for cooling medium
5 Rating plate
6 Louvred grille for air intake
7 Tank drain nozzle for
cooling medium
8 Cable entry
Device description

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6
4
10
9
7
11
5
SK3334.660
Legend
2 Display
3 Liquid level display of cooling
medium
4 Tank filling nozzle for
cooling medium
5 Rating plate
(two-part)
cooling medium
8 Cable entry
11 Bleeding nozzle
Device description

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SK 3360.100-250-470
Legend
2 Display
3 Liquid level display of
cooling medium
4 Tank filling nozzle for
cooling medium
5 Rating plate
cooling medium
8 Cable entry
11 Bleeding nozzle
(only SK3360.47x)
1
6
11SK 3360.10x
1
6
1
6
SK 3360.20x SK 3360.47x
Device description

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General functional description
Legend
1 Condenser, air-cooled
2 Condenser fan
3 Filter dryer
4 Expansion valve
5 Water level switch (optional)
6 Temperature probe
7 Fill nozzle
8 Tank drain
9 Cooling medium pump
10 Cooling medium tank
11 Flow switch
12 Evaporator (plate heat exchanger)
13 Compressor
14 Pressure switch
Device description

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Dimensions: 3320.6xx and 3334.6xx
Dimensions: 3318.6xx and 3319.6xx
Assembly and connection

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Dimensions: 3360.47x
300
300
AIR
OUT
AIR IN
Assembly and connection

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Input
External
Fault indication External detector
exhaustercompressor pump
High
pressure
switch
Flow switch
Detector medium
Detector antifreez protection
Detector air entry
Detector air exit
Electrical circuit diagram 1

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Input Fault indication External detectorApproval
entry
compressor exhauster pump High
pressure
switch
Flow switch
switch
Detector medium
Detector antifreez protection
Detector air entry
Detector air exit

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Standard for all mini-chillers
Benefits:
 Protection against dirt, dust and oil
 Less maintenance required
 Energy-efficient
Without nano-coating With nano-coating
Nano-coating

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Overview:
Chiller Leistung MCB Modell Typ
SK3318.600 960W PB2010 230V/1/50-60 Hz
SK3318.610 960W PB2010 230V/1/50-60 Hz
SK3319.600 1490 W PB2010 230V/1/50-60 Hz
SK3319.610 1490 W PB2010 230V/1/50-60 Hz
SK3318.609 960W PB2010 115V/1/60 Hz
SK3318.619 960W PB2010 115V/1/60 Hz
SK3319.609 1490 W PB2010 115V/1/60 Hz
SK3319.619 1490 W PB2010 115V/1/60 Hz
SK3320.600 3000 W PB2010 400V/3/50-60 Hz
SK3334.600 4500 W PB2010 400V/3/50-60 Hz
SK3334.660 6000 W PB2010 400V/3/50-60 Hz
SK3360.100 1000 W PB2010 400V/3/50-60 Hz
SK3360.250 2000 W PB2010 400V/3/50-60 Hz
SK3360.470 4000 W PB2010 400V/3/50-60 Hz
SK3360.475 4000 W PB2010 400V/3/50-60 Hz
MCB 230V
MCB 115V
MCB 400 / 460V
Micro-controller box (MCB)

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Ordering replacement parts:
Model No. Short text
3396.638 SK MICROCONTR. F. MINI CHILLER 115 V
3396.637 SK MICROCONTR. F. MINI CHILLER 230 V
3396.627 SK MICROCONTR. F. MINI CHILLER 400-460 V
3396.639 SK DISPLAY F. MINI CHILLER
3396.640 SK CONNECTION CABLE DISPLAY CONTR.
3396.628
Conversion kit: 400-460 V
Consisting of power box, display, display cable
Micro-controller box (MCB) PB2010

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Terminal Description
J1 Serial interface (service tool / PLC)
X10 Alarm relays 1 & 2 / ext. release
M1 Compressor
M2 Fan
M3 Pump
F50 High pressure switch
F60 Flow sensor
J2 Display
B1 Sensor: cooling medium temperature
B2 Sensor: icing of evaporator
B3 Sensor: condenser, external
B4 Sensor: condenser, internal
B5 Sensor: room temperature (optional)
Front
Rear
X 10 X 1 0
Serialconnection
L 1 N
2 3 0 V a c
P E
J 1
B4
B3
B2
M2 M1
M3 F50
F60
B1
J2
Connections: MCB 230V

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Terminal Description
J1 Serial interface (service tool / PLC)
X10 Alarm relays 1 & 2 / ext. release
M1 Compressor
M2 Fan
M3 Pump
M4 Solid state relay (optional HGBP valve)
F50 High pressure switch
F60 Flow sensor
F70 Level switch (optional)
J2 Display
B1 Sensor: cooling medium temperature
B2 Sensor: icing of evaporator
B3 Sensor: condenser, external
B4 Sensor: condenser, internal
B5 Sensor: room temperature (optional)
Front
Rear
Connections: MCB 400 / 460V

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Display layout
Conversion kit 230 V / 400-460 V
consisting of power box, display, display cable
Display
attachment
Open
display
cover here
Connections: MCB 230V and 400 / 460V

PLC outputs
The settings for the PLC outputs have the following meanings:
0  No PLC output switched on
0  No output connected
1 - 8  You can find the respective circuit of the PLC output under error code.
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Interface / PLC outputs

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1. 7-segment display
2. LED temperature display
3. Control key
Mini-chillers have a 3-digit 7-segment display to indicate operating states and control keys to set
operating parameters.
After the power supply is switched on, the display “E0” appears initially for approx. 20 seconds to
indicate that the unit is operational (boot phase controller). After the boot phase, the chiller will start
to work. During operation, the inlet temperature (to the equipment) of the cooling medium circuit is
displayed via the indicators, alternating with any error messages that are present in form of error
codes. Two LEDs °C and °F are used as indicators for the temperature unit: °C (Celsius) or
°F (Fahrenheit).
You can perform the following activities via indicators and control keys:
• Reading temperature values
• Reading out the error memory
• Acknowledging error messages
• Resetting the pump
• Reading out and setting parameters for the control
Display and assignment of keys

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Key functions during operation:
- Key:
- Press and hold down for display of the software version.
- With activated error memory: press 10 sec. to delete the error memory.
- Key:
Display of temperature values: sensors 1 – 5 in succession
Sensor 1: medium temperature (is constantly displayed, or after 30 sec. menu time-out)
Sensor 2: icing
Sensor 3: condenser, external (filter mat)
Sensor 4: condenser, internal (filter mat)
Sensor 5: room temperature (if combined control is active)
+ - Hold down keys for approx. 5 sec.  jump to parameterisation level
- Key:
- Manual alarm reset
- Parameterisation is interrupted if no key is pressed for approx. 30 seconds (10 seconds if an
alarm is expected). If this happens, the value is not stored. The display indicates the preset
values again.

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Key functions during operation:
- Key:
- In selection mode: incrementing the parameter numbers from P01 to P30
- In editing mode: increasing the parameter value
- Key :
- In selection mode: decrementing the parameter numbers from P01 to P30
- In editing mode: reducing the parameter value
- Key :
- In parameter selection  switch to editing mode
- In editing mode  accept parameter and increment to the next parameter
- After the last parameter (“End” display)  exit parameter adjustment

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TopTherm chillers allow both fixed value control as well as combined room-
temperature-based control. The units are set to“Fixed value control” in the factory. If
you have connected an external room temperature sensor that is available as an
optional accessory, you can activate the “Combined control” mode via parameter 13
on the control. With combined control, other control parameters have to be set or
taken into account. See example: combined control.
Combined control Fixed value control
Regulation with positive hysterese
on
off
Cooling on
Cooling off
Cooling on
Cooling off
room
room
room
Difference
Hysteresis
Parameter example
Difference to the room temperature
Switching hysteresis combined regulation
Room temperature
Switching hysteresis
Room temperature
Differenz value
Most given value
Minimum given value
20
Tw / °C
t/min
Cooling ON
Cooling OFF
Setpoint Tw: 20°C
Switching hysteresis: 2 K
Control types

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Combined control
Medium setpoint temperature can dynamically follow the room temperature with a
difference of +/- 10 K.
The difference value is programmable.
 Medium temp. > room temperature
Difference value NEGATIVE
 Medium temp. < room temperature
Difference value POSITIVE
Legend
1. 7-segment display
2. LEDs temperature unit
3. Operation button
Control types

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Combined control
Difference value POSITIVE
Medium temp. < room temperature
 Value range: 1 K – 10 K
Difference value 0
 The control follows the room temperature.
Difference value NEGATIVE
Medium temp. > room temperature
 Value range: - 10 K – - 1 K
+
TRaum
TMedium
-
TMedium
TRaum
Control types

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Combined control (example):
Negative hysteresis
Difference value: +5 K (parameter 3)
Hysteresis: 2 K (parameter 6)
temperature
time
Regulation with negative hysteresis
Room temperature
Cooling off
Cooling on
Control types

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Only MCB 400V (3 ~)
No.
Parameter
Min.
value
Max.
value
Factory
setting
Setting Explanation
Fixed value control
1
Setpoint temperature with
fixed value control
10.0°C 30.0°C 20.0°C
If fixed value control is set for
parameter 13, the setpoint
temperature can be selected here.
2
Switching hysteresis,
fixed value control
2 K 5 K 2 K
If fixed value control is set for
parameter 13, the switching hysteresis
can be determined here.
Combined control
3
Difference from room
temperature
-10.0°C 10.0°C 5.0 °C
If combined control is set for
parameter 13, the setpoint
temperature can be set with this
parameter as the difference compared
to room temperature. Negative values
result in a setpoint above the ambient
temperature.
Meaning of the control parameters

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No.
Parameter
Min.
value
Max.
value
Factory
setting
Setting Explanation
4 Minimum setpoint 7.0°C P5 10.0°C
If combined control is set for parameter
13, the lower setpoint can be limited
with this value.
5 Maximum setpoint P4 35.0°C 28.0°C
13, the upper setpoint can be limited
with this value.
6
Switching hysteresis,
combined control
2 K 5 K 2 K
13, the switching hysteresis can be
determined here.
7
Tolerance for error message
“F.01”
3.0°C 15.0°C 5.0°C
If the cooling medium temperature
exceeds the activation temperature of
the compressor by the value set here,
error message F.01 and an alarm are
generated.
8
Heater control: medium
(only MCB 400 V)
1.0°C
5.0°C
(+ OFF)
OFF
Option: if tank heater is installed.
The heater will cut in if the tank
temperature drops below the value set
here.
If OFF is set, the heater will never cut
in.

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No.
Parameter
Min.
value
Max.
value
Factory
setting
Setting Explanation
9 Integrated real-time clock
The hour (0 - 24), minute (0 - 59) ,
year (00 - 99), month (1 - 12), day (1 -
31), summertime (OFF, EU; USA, S1 -
S12, E1 - E12) are displayed in
succession.
10
Switching times
Compressor
OFF ON OFF
Selection: day of the week
(1Mon - 7Sun, ESC),
start time (hh, mm),
end time (hh, mm)
11
Switching times
Heater (only MCB 400 V)
OFF ON OFF
Only if P8 is not OFF.
Selection: day of the week
(1Mon - 7Sun, ESC),
start time (hh, mm),
end time (hh, mm)

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No.
Parameter
Min.
value
Max.
value
Factory
setting
Setting Explanation
12
Code number 1
(password protection)
1 999 123
To call up the parameters P13 - P19, the code number 123 has to
be set.
13 Control mode Ct Ft Ft
Ct: combined control
Ft: fixed value control
14
Heater function:
antifreeze (option)
(only MCB 400 V)
OFF ON OFF
Optional if a heater is installed.
ON : +2°C OFF : +5°C
15
Hot gas bypass (option)
(only MCB 400 V)
OFF ON OFF
OFF: bypass control unused
ON: bypass control activated
If P15 is activated, the switching hysteresis (P2 and P6). is
deactivated. The PID controller will automatically aim for optimum
switching hysteresis. The latter is dependent on the PID setting.
Then P, I and D values, cycle time and switching hysteresis of the
controller are each set in turn.
Parameters (PID controller)
[range] (factory setting):
Proportional band P [0.1 - 99.9] K (1.0)
Integral time I [0 - 999] sec, 0 = inactivate (300)
Derivative time D [0 - 999] sec, 0 = inactivate (50)
Cycle time C [4 - 100] sec (10)
Note
Analyse the controlled system for optimization and contact
customer service.

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No.
Parameter
Min.
Value
Max.
Value
Factory
setting
Setting Explanation
16
Setpoint for filter mat
monitoring
4.0 K
70.0 K
(+ OFF)
OFF
Do the setting as follows (setting range: 4.0 – 70.0 K,
switching difference 2.0 K, fixed setting): activate the
recooling unit with a clean filter mat inserted.
Set the value approx. 10.0 Kelvin above the difference
between the temperature sensors B3 and B4 with the buttons
&
.
17 Changeover:°C/°F °C °F °C
°C: display temperatures in Celsius
°F: display temperatures in Fahrenheit
18
Evaluation of external
release signal
1
5
(+ OFF)
OFF
OFF: normal mode
1: Stand-by with signal missing
2: Cooling off with signal missing (pump active)
3: Control via external controller
4: If signal to ext. input is pending, the clock function is
deactivated.
5: Stand-by with signal missing. If the system is on Stb. 
the alarm relay 1 (contact 4-5) opens.
19
Acknowledgement of
error messages
OFF ON OFF
If this function is activated (ON), the error messages are also
displayed with auto-reset on the display until an
acknowledgement takes place via the Enter key.
20 Factory setting 1 999 555 555: do factory setting (default values)

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No.
Parameter
Min.
value
Max.
value
Factory
setting
Setting Explanation
Service level
(is not documented vis-à-vis the customer)
20 Code numbers 2 1 999
234
876
This level is reached if at the end after
level 19 is pressed for approx.10
secs.
Various service functions can be
selected via these code numbers:
234: access to parameters 21 - 29
876: call up hardware test routine
21
Minimum pause time of the
compressor
60 s 360 s 180 s
The minimum pause time of the
compressor is determined via this
parameter, i.e., starting at the time the
compressor was switched off; this
applies to the shut-off in control mode
as well as in case of error.
22 Device address 1 99 1
For software download and
PC diagnostic program
23 Delay of ext. signal 0.5 s 5.0 s 1.0 s
How long an external signal is
recognised as valid can be set via this
parameter.

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No.
Parameter
Min.
value
Max.
value
Factory
setting
Setting Explanation
24
Level switch present
(only MCB 400 V)
1
2
(+ OFF)
OFF
OFF: no level switch installed
1: level switch with NC contact (opener)
2: level switch with NO contact (closer)
25
Delay time: level switch
(only MCB 400 V) 0.5 s 30.0 s 1.0 s
How long a signal of the level switch (on
or off) is recognised as valid can be set
via this parameter.
26 Waiting time: pump 0 s 300 s 20 s
Waiting time for switching the pump on
after network-on
27
Delay: evaluation of cooling
output
60 s 900 s 180 s
The compressor has to run for the time
set here until an evaluation of cooling
output takes place.
28 Call-up of alarm relay settings See meanings of error codes
29 Call-up of PLC status settings See meanings of error codes
30 Flow sensor NC
NO
(OFF)
NO
OFF: no flow sensor installed
1: flow sensor with NC contact (opener)
2: flow sensor with NO contact (closer)

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Alarm Description Alarm relay
Min. / default / max.
PLC setting Compressor Fan Pump Reset
F.01 Cooling medium
temperature exceeded
0 / 1 / 3 1 ON ON ON Auto
F.02 Winding protection:
compressor
4 / 8 / 8 2 OFF OFF ON Man
F.03 Icing 4 / 4 / 8 3 OFF OFF ON Auto
F.04 High pressure switch 4 / 5 / 8 4 OFF ON 1 OFF Auto + man
> 3
F.05 Winding protection: fan 4 / 8 / 8 5 OFF OFF ON Auto
F.06 Winding protection: pump 4 / 5 / 8 6 OFF OFF OFF Auto + man
>3
F.07 Filter mat contaminated 0 / 2 / 8 7 ON ON ON Reset:
0-3 = auto
4-7 = man
F.08 Low medium temperature
if a tank heater is installed
(optional)
0 / 5 / 8 8 OFF OFF OFF Man
F.09 Incorrect rotary field /
phase missing
5 / 5 / 5 8 OFF OFF OFF Auto
Only MCB 400V (3 ~)
Meaning of the error codes

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Alarm Description Alarm relay
Min. / default /
max.
PLC Compressor Fan Pump
Reset
F.10 No cooling output 4 / 8 / 8 1 OFF OFF ON Auto
F.11 No flow (pump) 4 / 5 / 8 8 OFF OFF OFF Auto
F.81 Sensor break / short circuit:
sensor B1
sensor B2
sensor B3
sensor B4
sensor B5
F.13 Mains voltage too low 5 / 5 / 5 7 OFF OFF OFF Auto
F.14 Mains voltage too high 5 / 5 / 5 7 OFF OFF OFF Auto
F.15 Level switch 5 / 5 / 5 2 OFF OFF OFF Man
F.16 Condenser sensor
interchanged
4 / 5 / 8 8 OFF OFF OFF
Man
CN Lack of communication
between the controller and the
display
- - - - -
Man
Only 400 V MCB (3 ~)

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The contacts of the connection terminals for the alarm relays are assigned as follows:
Legend
Cooling
off
Compressor & fan OFF
Pump ON
System
off
Pump, compressor, fan OFF
Setting:
alarm relay
Meaning
0 Both alarm relays remain closed when a malfunction
occurs.
1 Alarm relay 1 drops out when a malfunction occurs.
2 Alarm relay 2 drops out when a malfunction occurs.
3 Both alarm relays drop out when a malfunction occurs.
4 Cooling off; both alarm relays remain closed when a
malfunction occurs.
5 System off; alarm relay 1 drops out when a
malfunction occurs.
6 Cooling off; alarm relay 2 drops out when a
malfunction occurs.
7 Cooling off; both alarm relays drop out when a
malfunction occurs.
8 Cooling off; alarm relay 1 drops out when a
malfunction occurs.

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 Recording of switching cycles (compressor, fan, pump)
 Operating hours of all switching components
 Phasing, voltage curve, error evaluation, software update.
 Storage of parameters set, remote maintenance, parameterisation
overview
Temperatures
Freezing
Room
Liquefier, air enterance
Liquefier, air outlet
Rittal service tool

Cable
Clip with box
Lenght:
Connecter
IS-S/16.07.2014 45
If a data cable is available (old: Stephan Elektronik), it can
continue to be used.
MCB Product
230 V SK3318.6XX / SK3319.6XX
400 V / 460 V SK 3320.6XX / SK3334.6XX / SK3334.66X /
SK 3360.1XX / SK3360.25X / SK3360.4XX
Model No. Description
SK 3159000
Interface cable: TopTherm chiller 1-6 kW (Rittal
service tool)
Pin assignment
Data cable for the service tool

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• If the equipment is set up higher than the chiller -> non-return valve in the outlet and magnetic
valve in the return line of the water circuit to prevent overflow.
• Danger of damage to the pump due to dry run. If the equipment circuit can be switched off, a
bypass valve has to be installed between the intake and return line so as to protect the pump.
Application: technology and components

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Link Service-Checkliste
Datum / date Ersteller /author Aktualisierunge n / update
14.06.2013 Rev.1.06 Andreas Karl Maske, Auswahlfeld, Inbetr. Checklisten
Rev. 1.06 Ersteller: Andreas Karl Datum: 14.06.2013
Letzte Aktualisierungen / last update
Bitte auswählen / please to choose
Internationale Checklisten / International Service Checklist Update Checklist
Artikelnummer / Articlenumber
Hier bitte Hauptdaten eintragen / please fill in maindates
Meldungsnummer /Notification
Service Reports
What do I have to pay attention to?

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Required information which should be provided in the service report
•Degree of contamination
•Can the customer installations cause vibration at the unit? If yes, please
explain.
•Mounting of the unit
•Ambient conditions (furnace, galvanising plant, wood processing, chemical
plant, etc.)
•Ambient temperatures
•Air humidity
•Is a SNMP card installed and in use?
•Free cooling available
•Is a SNMP card installed and in use?
•Has the customer tampered with the unit in any way?
Service Reports

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Required information which should be provided in the service report
•Which controller is installed, and with which software version?
•Inlet temperature
•Is the inlet water filtered?
•Is a bypass present?
•How are the TaccoSetters set?
•How is the piping designed? (Was black iron piping used?)
•Do the parameters of the unit match those given in the documentation? If not,
please explain.
Service Reports

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All relevant information relating to parts and components which are judged to
be defective and thus need to be replaced within the framework of service
assignments (returns of defective components) can be found by way of the
following link:
http://riwiki.de.flg.int/Rittal/QM/VA-KP-QM-002-016
Service Reports
Component returns in connection with service assignments

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Do you have any questions?

Service training top therm chiller 1 6 k w-eng_01.10.2014

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