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
Operator
section

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.



Operator
section

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.
Operator
section

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-
Operator
section

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.


Operator
section

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.
Operator
section
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
Page 9
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.
Operator
section
Operator
section

KT series chillers –Installation and Operation manual
Issue 11.3
Page 10
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.

KT series chillers –Installation and Operation manual
Issue 11.3
Page 11
Fluid flow and pressure
KT chillers fitted with a 2 or 3 litre per minute pump are capable of producing up to 150
psi, because of the high pressure volumetric pump. These units are normally supplied fac-
tory set to run at an operating pressure of 35 psi, which is suitable for most applications.
The pressure setting is controlled by an internal bypass valve, which will open above the
preset level to protect your application from higher pressures.
It is possible for customers to change the operating pressure of all K series chillers, except
KT chillers fitted with a 6 litre/minute pump1. For details of this procedure, refer to the
technician section.
4.0 Maintenance requirements, Operator
Caution: Failure to carry out service at the specified intervals may permanently damage
your equipment. For maintenance and service requirements for technicians, and for trou-
bleshooting, refer to the technician section.
Exterior cleaning: Wipe up any spillages using a damp cloth only. Do not use detergents.
Interval
Actions
Weekly
Check fluid level
Check external connections for leaks
Annually
Change the fluid
1The 6 litre/minute pump is specially designed for low pressure applications, and the flow rate and pressure
settings cannot be changed on these units.

Operator
section

KT series chillers –Installation and Operation manual
Issue 11.3
Page 12
5.0 Technician section
Warning: Opening the refrigeration system may expose the operative to toxic and corro-
sive compounds (HF). Take protective measures including suitable eye protection.
Warning: Gases may exceed 300 psi (20 bar) during operation.
Warning: All refrigerants do not support combustion and are asphyxiating gases.
Warning: After switching off, the condenser cooling fan blades continue to rotate. Do not
attempt servicing whilst the blades are rotating.
Warning: All chillers contain water and electricity in close proximity. Always ensure the
unit is isolated before service. All K series chillers are protected from over current by the
master circuit breaker. Never bypass this component.
5.1 Fluid flow and pressure adjustment
It is possible to change the operating pressure of all K series chillers, except KT chillers
fitted with a 6 litre/minute pump2, as follows:
1. Remove the cover from the chiller, giving access to the top compartment.
2. With the chiller running, release the locking nut on the pressure relief valve.
3. Turn the valve knob anticlockwise to reduce the flow/pressure, clockwise to in-
crease the flow/pressure.
2The 6 litre/minute pump is specially designed for low pressure applications, and the flow rate and pressure
settings cannot be changed on these units.
Technician
section

Technician
section

KT series chillers –Installation and Operation manual
Issue 11.3
Page 13
Caution:
Changing the flow/pressure with the pressure relief valve will also change the preset pres-
sure safety setpoint. This will move to a lower pressure than the factory setting when de-
creasing the flow/pressure, and to a higher pressure when increasing the flow/pressure.
Caution:
When the flow/pressure is manually increased by the pressure relief valve, the safety pro-
vided by the valve will be effected at higher pressures than standard. For this reason,
please ensure that it is safe for your application to operate at pressures in excess of 35 psi.
A blockage in your application could result in the pressure exceeding the raised safety
pressure.
We recommend that pressures exceeding 60psi must never be used.
5.2 Maintenance and service requirements
Caution: Failure to carry out service at the specified intervals may permanently damage
your equipment.
Interval
Actions
Weekly
Check fluid level (unless checked by Operator)
Check external connections for leaks (unless checked by Operator)
Monthly
Check the condenser (air intake) is free from obstructions or accumulations of debris.
Cleaning may be achieved with a domestic vacuum cleaner with brush attachment.*
Annually
Change the fluid (unless changed by Operator)
Check for fluid leaks throughout the whole system.
Check the condenser for fouling.
*Caution: Never blow the condenser out with compressed air.




KT series chillers –Installation and Operation manual
Issue 11.3
Page 14
5.3 Troubleshooting
Symptom
Causes
Compressor not running,
but fan running
Is the controller displaying an alarm?
If there is no obvious cause, check…
The condenser is clean
Ambient temperature not above 30C
The likely cause is the compressor’s internal protection has been activated and
should restart in five minutes.
Noisy operation /
High fluid pressure
And/or low flow
Check:
No restrictions in the pipe work
Pressure set too low (factory set pressure altered?)
Clean system with weak detergent solution, rinse thoroughly to remove all de-
tergent. Use Hexid fluid as coolant.
Fluid lines becoming fo-
uled brown or green
Algae contamination.
Clean system with weak detergent solution, rinse thoroughly to remove all de-
tergent. Replace fluid lines with black lines, if not already fitted, to inhibit al-
gae growth. Use Hexid fluid as coolant.
Fluid seen leaking from
system
Under high humidity conditions, fluid may appear to be leaking from the sys-
tem. This is usually just condensation, but do check for fluid leaks.
Poor cooling
Continued failure to cool may indicate high ambient temperature or excessive
load applied to the unit. Check these first
Otherwise, may be caused by blocked condenser.
Clean with soft brush or vacuum cleaner with brush attachment
Technician
section

KT series chillers –Installation and Operation manual
Issue 11.3
Page 15
6.0 Warranty terms and conditions
i. ATC provides a comprehensive return to base 2 year parts, 1 year labour warranty
from delivery as standard on all new K series chillers, provided that they have been in-
stalled and operated in accordance with this manual.
ii. At the discretion of ATC, goods may be serviced on site or a service loan unit may be
supplied. Warranty cover excludes the cost of travel by engineers and loan unit rental
charges.
iii. During the first year of the warranty period, freight costs to and from ATC are for
ATC’s account.
iv. During the second year of the warranty, freight costs to and from ATC are for the cus-
tomer’s account.
v. A purchase order is required on the Returned Material Declaration Form, which will
only be charged to if there is any non-warranty work involved, or if the original packa-
ging is not available and either an empty crate is required and/or new packaging for the
repaired unit is required.
Registration
The warranty registration card must be completed and returned to ATC.
This does not affect your statutory rights.

KT series chillers –Installation and Operation manual
Issue 11.3
Page 16
6.1 Return of goods procedure
If the unit is damaged during transit, or subsequently develops a fault requiring its return to
ATC, the following procedure must be followed.
1. Call the ATC service point
You will be issued with a Return Materials Authorisation number (‘Q number’) and a Return Ma-
chine Declaration (RMD) form by fax. A copy of the RMD form is on the last page of this manual.
2. Return the completed RMD form to ATC by fax, together with your purchase order
number, prior to shipment of the chiller.
3. Pack the returning item securely, enclosing a copy of the completed RMD form, and
ensure that the packaging is clearly labelled with the Q number. Neither ATC nor your
shipper will be liable for any damage incurred in transit.
4. Upon receipt of the completed RMD form, an engineer will be allocated or a service
loan unit* will be despatched if available.
* Please note that ATC will raise an invoice as part of the service loan procedure, and you
will receive a credit against this upon the safe return of the loan unit.
Address for return units:
Applied Thermal Control Ltd.
Goods Inward
Garden Court
Gee Road
Whitwick, Leicestershire,
LE67 4NB
UK
Tel: [phone]
Fax: [phone]
6.2 Specifications

KT series chillers –Installation and Operation manual
Issue 11.3
Page 17
Environmental
For indoor use only
Altitude: up to 2000 metres
Ambient temperature range: 4C - 40C
Maximum relative humidity: 80% for ambient temperatures up to 31C, decreasing
linearly to 50% relative humidity at 40C ambient temperature.
Mains supply voltage not to exceed 10% of the nominal voltage.
Installation Category II
Pollution Degree 2
KTR
Cooling capacity: 480 Watts at 22C
Dimensions, height x width x depth: 515 x 315 x 315mm (20 x 12.4 x 12.4 inches)
Weight: 30kg (66lbs)
Cooling temperature range: 4C - 30C
Pumps available
High pressure volumetric type: 2litre/minute or 3litre/minute
Low pressure centrifugal type: 6 litre/minute
Fluid connections: ¼”BSP x 10mm (3/8”) Nickel plated brass hose tail adaptors.
Custom connections available.
Temperature stability: 0.2C, with stable load, dependent on stable ambient tem-
perature
Power requirements: 3 Amps 230V 50/60Hz, 7 Amps 115V 60Hz
Warranty: 2 years parts, 1 year labour.
KTC
Cooling capacity: 480 Watts at 22C
Dimensions, height x width x depth: 515 x 315 x 315mm (20 x 12.4 x 12.4 inches)
Weight: 30kg (66lbs)
Cooling temperature range: 4C - 30C
Pumps available
High pressure volumetric type: 2litre/minute or 3litre/minute
Low pressure centrifugal type: 6 litre/minute
LED temperature display resolution: 1C standard, 0.1C option
Fluid connections: ¼”BSP x 10mm (3/8”) Nickel plated brass hose tail adaptors.
Custom connections available.
Temperature stability: 0.2C with stable load, dependent on stable ambient tem-
perature
Power requirements: 3 Amps 230V 50/60Hz, 7 Amps 115V 60Hz
Warranty: 2 years parts, 1 year labour.

KT series chillers –Installation and Operation manual
Issue 11.3
Page 18
KTD
Cooling capacity: 480 Watts at 22C
Dimensions, height x width x depth: 515 x 315 x 315mm (20 x 12.4 x 12.4 inches)
Weight: 30kg (66lbs)
Cooling temperature range: 4C - 30C
Pumps available
High pressure volumetric type: 2litre/minute or 3litre/minute
Low pressure centrifugal type: 6 litre/minute
LED temperature display resolution: 1C standard, 0.1C option
Fluid connections: ¼”BSP x 10mm (3/8”) Nickel plated brass hose tail adaptors.
Custom connections available.
Temperature stability: 0.1C
Power requirements: 3 Amps 230V 50/60Hz, 7 Amps 115V 60Hz
Warranty: 2 years parts, 1 year labour.

KT series chillers –Installation and Operation manual
Issue 11.3
Page 19
EC Declaration of Conformity
Applied Thermal Control Ltd.
Garden Court
Gee Road
Whitwick
Leicestershire
LE67 4NB
K series chiller range (all standard configurations)
Serial Number: …………………
The equipment meets the requirements of the Machinery Directive
2006/42/EC and the Low Voltage Directive 2006/95/EC
Meets the directive on Electromagnetic compatibility
89-336-EEC Specifications EN50081-1 (1992) (Emissions)
and EN50082-1 (1992) Immunity
Signed
Glenn Stevens Robert Poniatowski
Production Manager Managing Director

KT series chillers –Installation and Operation manual
Issue 11.3
Page 20
In case of repair requirement, please complete both parts of the form, and fax to ATC
PART 1: RETURNED MATERIAL DECLARATION FORM
Returns Number: Q0_ - ___
Your Name and Address:
…………………………………………………
…………………………………………………
…………………………………………………
…………………………………………………
Your purchase order number:
…………………………………………………
Machine part number:
Machine serial number:
…………………………………………………
…………………………………………………
Collection for return to ATC –please tick one:
ATC to arrange shipment
Customer to arrange shipment
Reason for return:
…………………….………………………………………………………………………….
If faulty, list symptoms:
…………………….………………………………………………………………………….
Address for delivery of machine
(if different from 1, above):
…………………………………………………
…………………………………………………
…………………………………………………
…………………………………………………
Please note that a minimum non-refundable inspection fee of £60 will be charged on all equipment returned for repair with the exception of equipment still under warranty.
PART 2: HEALTH & SAFETY DECLARATION
Machine part number:
…………………………………………………
Machine serial number:
…………………………………………………
I, ……………………., of ……………………………………., confirm that the above unit
is free from chemical, biological or nuclear hazard and that the unit presents no physical
hazard, including electrical.
Signed and dated:
…………………………………………………











