Applied Thermal Control KTR User manual

KT series chillers –Installation and Operation manual
Issue 11.3
Page 1
K SERIES CHILLERS
KTR, KTC, KTD
STANDARD MODELS
INSTRUCTION MANUAL
Issue 11.3
Applied Thermal Control Ltd.
Garden Court, Gee Road
Whitwick, Leicestershire
LE67 4NB
Tel: [phone]
Fax: [phone]
3046567

KT series chillers –Installation and Operation manual
Issue 11.3
Page 2
1.0 INTRODUCTION 3
Safety 4
1.1 Warranty registration 5
1.2 Unpacking 5
1.3 Site requirements 6
2.0 INSTALLATION 6
Fluid line requirements 6
Voltage selection option 7
Chiller filling procedure 8
3.0 OPERATION 9
KTR models only 9
KTC models only 9
KTD models only 10
Adjusting the set point (KTD only) 10
4.0 MAINTENANCE REQUIREMENTS, OPERATOR 11
5.0 TECHNICIAN SECTION 12
5.1 Fluid flow and pressure adjustment 12
5.2 Maintenance and service requirements 13
5.3 Troubleshooting 14
6.0 WARRANTY TERMS AND CONDITIONS 15
Registration 15
6.1 Return of goods procedure 16
6.2 Specifications 16
Environmental 17
KTR 17
KTC 17
KTD 18
EC DECLARATION OF CONFORMITY 19
Appendix 1 –Water cooled condenser option 21
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KT series chillers –Installation and Operation manual
Issue 11.3
Page 3
1.0 Introduction
By selecting a K series chiller you have invested in many years experience in the design
and manufacture of precision temperature control instrumentation.
ATC has built your K series chiller without compromise to meet the objectives of perfor-
mance and reliability.
Please read this manual carefully to ensure you understand the operation of the machine
and how to use the unit safely and efficiently.
If you have any questions regarding installation or repair of this unit please contact ATC
at:
Applied Thermal Control Ltd.
Garden Court
Gee Road
Whitwick, Leicestershire,
LE67 4NB
U.K.
Tel: [phone]
Fax: [phone]
e-mail: [email protected]
Or contact an approved ATC distributor.

KT series chillers –Installation and Operation manual
Issue 11.3
Page 4
Safety
For your safety we draw your attention to the following Warning and Caution statements
throughout this manual, identified by the symbols…
and 
respectively. The safe operation of a KT series chiller remains the responsibility of the op-
erator at all times.
Attention: Failure to comply with a Caution will invalidate product warranty and absolve
ATC from any liability, howsoever caused, and could result in permanent damage to equip-
ment.
Caution: Failure to comply with a ‘Warning’may result in personal injury or death. ATC
does not accept any liability for injury caused through use of this equipment.
_________________
Warning: If the equipment is used in a manner not specified by the manufacturer, the pro-
tection provided by the equipment may be impaired.
Warning: There are no user serviceable parts in this equipment.
Caution: The high integrity refrigeration system contains no user-serviceable parts. Repair
and service requires specialised knowledge and tools. Any unauthorised tampering with
the refrigeration system automatically invalidates warranty.



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KT series chillers –Installation and Operation manual
Issue 11.3
Page 5
1.1 Warranty registration
The warranty registration card must be completed and returned to ATC.
This does not affect your statutory rights.
1.2 Unpacking
Please check that both the packaging and the unit are undamaged. If there is any doubt, it
is vital that you inform both ATC and the carrier before making a claim on the carrier.
There are no hidden shipping bolts or other fixings. You should inspect the packaging for
signs of transit damage before signing for the unit, and if possible unpack the unit before
signing. Once you have signed for the goods, ATC cannot be held responsible for any tran-
sit damage subsequently found.
Warning: 30kg (66lb) –Two person lift required.
Remove the unit from its original packaging and ensure that there is no packaging left
around the cooling ducts.
Please retain all packaging in the unlikely event that the chiller needs to be returned to
our local representatives.
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KT series chillers –Installation and Operation manual
Issue 11.3
Page 6
1.3 Site requirements
Hard, level surface.
Clean, dust free environment. Air-cooled chillers move large volumes of air, and
large amounts of air-borne contamination will result in fouling of the condenser.
This will reduce the capacity of the unit and in extreme cases cause a system shut-
down.
Non-condensing ambient, from +4C to +40C. Maximum cooling capacity is
achieved at 22C, and will de-rate by 2% per C until capacity is lost at 30C.
Electrical supply. Two standard versions are available, 230V 50Hz 3A or 115V
60Hz, 6A. Other options are available on request.
Clearance front and rear of the unit at least 250mm (10 inches).
Plumbing to be clean and compatible with the fluid to be used. It is advisable that
the minimum of right angle bends and compression fittings are used to reduce pres-
sure losses in the pipework. See also section 2.0
2.0 Installation
Having ensured that your installation meets all of the site requirements identified in section
1.3, it is best practice that the fluid lines between your application and the chiller have the
following characteristics.
Fluid line requirements
As short as possible. Ideally between 1 and 2 metres (between 3 and 6 feet).
Large diameter. Ideally at least 12mm (½ inch) internal diameter
Black tubing, to inhibit growth of algae. Alternatively, use solid copper or welded
ABS.
Free from right angle bends
Clean. If your installation is to existing pipe work, the system should be flushed
clean prior to filling. Hexid fluids are the recommended coolant choice as they pro-
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KT series chillers –Installation and Operation manual
Issue 11.3
Page 7
vide excellent corrosion protection, freeze protection, algae inhibition and good
heat transfer properties.
Caution: Always use ATC recommended fluids in your K series chiller. Never use other
anti-freeze mixtures, as they may corrode your application and will damage the K series
pump seals.
All connections should be made using the fittings and clips provided. Where threaded or
compression type fluid joints are to be made, always use a suitable jointing compound such
as PTFE tape.
Voltage selection option
Caution: If your KT chiller is rated for multi-tap and dual frequency operation, it is essen-
tial that the voltage selector switch on the KT chiller is set to match the voltage and fre-
quency available at your site. The voltage selector switch cover plate can be found on the
right side of the chiller cover, when viewed from the front. Access is via the four securing
screws on the cover plate.
Having ensured that the system is correctly connected, with the inlets and outlets having
the correct orientation relative to your application, all joints tight and leak free, and with
the unit isolated from the electrical supply, prepare to fill the unit with Hexid fluid.


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KT series chillers –Installation and Operation manual
Issue 11.3
Page 8
Chiller filling procedure
1. Check valves in your application are open
2. Remove lid from the coolant reservoir
3. Fill with Hexid to within 40mm (1½ inches) of the tank rim.
4. Switch the unit on.
5. Wait while the fluid level drops in the tank.
6. Switch the unit off.
7. Repeat steps 3 to 5 until all of the air has been purged from the system.
8. Top up to a level 40mm (1½ inches) below the tank rim.
9. Check the inlet and outlet connections, and the inside of your application carefully for
leaks. If no leaks are found, the system is ready to be run.
Warning: Always isolate the chiller from the electrical supply when filling the tank.
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Component identification photograph, KT series
(model shown is KTR)
Mains inlet
Coolant reservoir lid
Neon
On / Off switch
Lifting handle (front)
Coolant inlet connection
Coolant outlet connection

KT series chillers –Installation and Operation manual
Issue 11.3
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3.0 Operation
KTR models only
Connect the mains cable and switch the unit on. The neon will illuminate, and the chiller
runs automatically. KTR chillers have been configured to provide temperature stability to
0.2C, and the actual temperature achieved will be in the range 12C-20C, depending on
the load and ambient temperature. This model is designed to provide a reliable and inex-
pensive alternative to tap water.
The pump in the standard version KTR6*** may require priming, simply achieved by
switching the unit on and off repeatedly until no bubbles are seen in the tank.
KTC models only
Connect the mains cable and switch the unit on, and the temperature display will illumi-
nate. KTC chillers have been configured to provide temperature stability to 0.2C, and
the actual temperature achieved will be in the range 12C-20C, depending on the load and
ambient temperature. This model is designed to provide a reliable and inexpensive alterna-
tive to tap water.
The KTC includes digital coolant temperature display and high/low temperature and low
fluid level alarms. The single neon and icon provide visual alert to the
alarm conditions:
High temperature alarm: Preset at 25C–neon, buzzer* and HI warning display
Low temperature alarm: Preset at 7C–neon, buzzer* and LO warning display
Low fluid alarm: Neon and buzzer* and AL warning display
* The buzzer can be muted by pressing the “U”button on the controller.
No adjustments can be made to the factory-set cooling parameters.
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KT series chillers –Installation and Operation manual
Issue 11.3
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KTD models only
Connect the mains cable and switch the unit on, and after a short self-test, the temperature
controller will show coolant temperature. The KTD chiller is fitted with a high perfor-
mance 3 term PID controller, which is capable of controlling temperature to within 0.1C
of set point. The single neon, alert icon and buzzer provide visual and
audible alarm to both high and low temperature (triggered if the temperature deviates more
than 10C either side of the set point), and to low fluid level.
Setting a new set point.(KTD Only)
Push the ’P’button, then release it. The display will flash ‘SP 1’.
To modify the set point, press the ‘UP’button to increase it or the ’DOWN’button to de-
crease it.
Once the new set temperature is displayed the value is stored automatically after approxi-
mately 10 seconds, ‘SP 1’will continue to flash during this time.
K 39 Controller error messages
If the set point is moved more than 10  C the alarm may be triggered. The alarm resets
when coolant temperature cones within 10°C of the set point. It is not possible to set the
temperature outside the preset values of -4  C and +35  C.