ATC K-Series User manual

Applied Thermal Control Limited
Unit 1 Garden Court, Gee Road, Whitwick Business Park, Coalville, Leicestershire, LE67 4NB.
United Kingdom
T:[phone] –[e-mail] –www.app-therm.com
K SERIES CHILLERS
K1, K3
STANDARD MODELS
INSTRUCTION MANUAL
Issue v 10.24

K1, K3 series chillers –Installation and Operation manual
Issue 10.24
Page 1
Contents Page
1.0
Introduction
2
Safety
3
1.1
Unpacking
4
1.2
Site requirements
5
1.3
Warranty registration
6
2.0
Installation
7
3.0
Operation
9
3.1
Changing the Set Point
9
3.2
Changing the Flow and Pressure
10
4.0
Maintenance and service requirements
12
4.1
Status lights and troubleshooting
12
Figure 1: K1, K3 internal features
13
5.0
Return of goods procedure
15
6.0
Dimensions and performance
16
7.0
EC Declaration of Conformity
17
Appendix 1: Water cooled condenser option
18
Appendix 2: Integral deionising cartridge system
18

K1, K3 series chillers –Installation and Operation manual
Issue 10.24
Page 2
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
performance 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
direct.
Applied Thermal Control Limited
Unit 1 Garden Court
Gee Road
Whitwick Business Park
Coalville
Leicestershire
LE67 4NB
United Kingdom
Tel: [phone]
e-mail: [email protected]

K1, K3 series chillers –Installation and Operation manual
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Page 3
Safety
For your safety we draw your attention to the following Warning and Caution statements
throughout the manual.
The safe operation of a K series chiller always remains the responsibility of the operator.
Caution: 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 equipment.
Warning: 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: No user serviceable parts.
Warning: Very hot surfaces, more than 100°C
Warning: Very cold surfaces and gases, lower than -40°C. Severe frostbite hazard.
Warning: Opening the refrigeration system may expose the operative to toxic and
corrosive compounds (HFC’s). 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 fan blades continue to rotate. Do not attempt service
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.
Caution: Filling/topping up of the tank should only be undertaken with the unit switched
off, to prevent back-flooding of the fluid.
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.

K1, K3 series chillers –Installation and Operation manual
Issue 10.24
Page 4
1.1 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 transit damage
subsequently found.
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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1.2 Site requirements
•Hard, level surface. Ideally smooth to allow freewheeling of castors, which are
designed for indoor use.
•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, re-
ducing the capacity of the unit and in extreme cases causing a system
shut-down.
•Non-condensing ambient, from +4°C to +40°C. Cooling capacity is lost above 30°C.
•Electrical supply 230V +10% (50Hz) single phase
1
. For the K3 the Internal circuit
breaker is rated at 15 Amps, normal operating current is 13Amps. For the K1 the In-
ternal circuit breaker is rated at 10 Amps, normal operating current is 6Amps.
•Clearance front and rear of the unit at least 250mm.
•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. See also
section 2.0
1
Switch selectable options for operation at 208VAC 60Hz, 230VAC 50Hz and 220VAC 60Hz are available on
request.

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1.3 Warranty registration
Please visit the website warranty registration page to ensure ATC can offer you the best
possible support;
https://www.app-therm.com/warranty-registration/
a) For how long is my ATC product under warranty?
ATC provides a comprehensive return to base 2-year parts, 1-year labour warranty from delivery as
standard on all new equipment, provided it has been installed and operated in accordance with the
manual.
b) Where will ATC fulfill the product warranty?
ATC’s standard warranty terms are Return to Base (RTB) –issues with chillers are often easily
solvable over the phone or email, or by reviewing ATC’s technical guidance on the web and in the
product manual. On occasion, at the discretion of ATC, goods may be serviced on site FOC or a
service loan unit may be supplied. Warranty cover excludes the cost of travel by engineers and
loan unit rental charges. Obtaining onsite service for a product, even in full warranty, is a
chargeable service.
c) Who is liable for shipping charges in the event of warranty failure?
During the first year of the warranty period, freight costs to and from ATC are covered by ATC.
During the second year of the warranty, freight costs to and from ATC are payable by the customer.
d) I’m experiencing problems with my chiller. It’s within warranty – what do I do next?
Contact ATC to discuss the issue you are having on [phone] or
[e-mail]. Be sure to have your model number and serial number on-hand to aid
those attempting to solve remotely.
e) Telephone support couldn’t fix my chiller – what do I do next?
An RMA form must be completed. This allows both the end-user and ATC to clarify your details, to
set the party responsible for shipping costs, and to set a different return address if desired.
Shipping advice is provided, and the end-user must sign a declaration that states the unit is safe to
handle. Return the form by email for fastest response.
f) What happens if my chiller failed outside warranty or requires non-warranty repair work?
A purchase order will be requested to cover an initial inspection –this will only be invoiced if the
inspection shows there is no fault. If packaging is required, i.e. a crate, a separate charge will be
levied. If the end user prefers ATC to arrange a collection, a shipping charge may be levied.
g) Our process must continue running –can we have a loan unit whilst our chiller is in repair?
ATC hold several standard air-cooled chillers at the factory for the sole purpose of offering for loan.
These are available on a first-come, first-serve basis. Models up-to 3kW capacity are available.

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2.0 Installation
Having ensured that your installation meets all 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:
•Short
•Large diameter (ideally at least 12mm internal diameter)
•Free from right angle bends, to suppress water hammer
•Opaque, ideally black, to inhibit growth of algae. Alternatively, use solid copper or
welded ABS. Caution: Never use transparent tubing.
•Clean. If your installation is to existing pipe work, it is good practice to flush the sys-
tem with either a commercially available central heating cleaner or 5% acetic acid
solution. The system should be flushed clean with tap water to remove all traces of
cleaner prior to filling the system.
All connections should be made using either the ATC ‘easy clamp’ or a jubilee type clip.
Where threaded or compression type fluid joints are to be made, always use a suitable joint-
ing compound such as PTFE tape.
Voltage selection
Caution: If your K1 or K3 series chiller is rated for multi voltage and dual frequency
operation, it is essential that the voltage selector switch on the chiller is set to match the
voltage and frequency available at your site.
On the K1 Chiller the voltage selector switch can be found on the left side of the chiller when
viewed from the front, mounted on the vertical support located behind the
removable side cover. Access is gained by removing the side cover completely to expose the
selector switch. Always replace the cover for normal operation.

K1, K3 series chillers –Installation and Operation manual
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On the K3 Chiller the voltage selector switch can be found under the access port in the top
of the chiller, mounted on the rear of the electrical box. Access is gained by removing the
assess port to expose the selector switch. Always replace the port for normal
operation.
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.
Hexid fluids are the preferred coolant choice as they provide 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.
Filling procedure
1. Check all valves are open, including solenoid valves located in your application.
2. Remove the filler access door in the top cover, then remove cover from the tank
3. Fill with Hexid to just below the rim of the tank neck.
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 the air has been purged from the system.
8. Top up to 30mm below the rim of the tank neck to ensure the level switch is made.
9. Check the system carefully for leaks, including the inside of your application. The
system is now ready to be run.
Warning: Always isolate the chiller from the electrical supply when filling the tank.

K1, K3 series chillers –Installation and Operation manual
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3.0 Operation
K series chillers are fitted with a high performance 3 term PID controller, which is capable of
controlling temperature to within 0.1°C of set point. In addition, there is a high and low tem-
perature warning via the LED on the display (5) of the controller, which is
triggered if the temperature deviates more than 10°C from the set point.
3.1 –Changing the Set Point
This procedure permits rapid programming of the active Set Point and possibly the alarm
thresholds.
Push the ’P’ button (1), then release it. The display will flash ‘SP 1’.
To modify the set point, press the ‘UP’ button (3) to increase it or the ’DOWN’ button (2) to
decrease it.
Once the new set temperature is displayed Push the ’P’ button (1), then release it.
The value is stored automatically after approximately 10 seconds, ‘SP 1’ will continue to
flash during this time.

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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 tempera-
ture outside the pre-set values of +4°C and +35°C.
3.2 –Changing the Flow and Pressure
K series chillers contain a high pressure volumetric pump capable of 150 psi. All units are
supplied with a pre-set maximum of 50 psi. Pressures above this will cause the internal safety
bypass valve to open, protecting your application from potentially dangerous
pressures.
It is possible for customers to change the operating pressure of the chiller, as follows:
•Remove the top panel (K1) or left side panel {viewed from the front} (K3) from the
chiller by removing 2 screws at the rear of the panel.
•With the chiller running, release the locking nut on the pressure relief valve; a grey
valve located at the right side of the chiller, as viewed from the front.
•Turn the valve knob anticlockwise to reduce the flow/pressure, clockwise to
increase the flow/pressure. Re-tighten the lock-nut.
•The pressure can be observed on the gauge on the front panel.

K1, K3 series chillers –Installation and Operation manual
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Caution:
Changing the flow/pressure with the pressure relief valve will also change the pre-set 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 with the pressure relief valve, the safety pro-
vided by the valve will be affected at higher pressures than standard. For this reason, please
ensure that it is safe for your application to operate at pressures in excess of 50 psi, even if
the pressure setting on the chiller reads lower than this. A blockage in your application could
result in the pressure exceeding the raised safety pressure, and while the K series chiller is
tested to 120 psi, your application may not be safe at this pressure.
We recommend that pressures exceeding 100psi must never be used.

K1, K3 series chillers –Installation and Operation manual
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4.0 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
Monthly
Check the condenser (air intake) is free from obstructions or accumula-
tions of debris. Cleaning may be achieved with a domestic vacuum
cleaner with brush attachment.*
Annually
Change the fluid.
Check for fluid leaks throughout the whole system.
Check the condenser for fouling.
* Caution: Never blow the condenser out with compressed air.
4.1 Status lights and troubleshooting
The status panel on the front of your K series chiller is fitted with three amber lights, config-
ured such that ‘three ambers are good’; i.e. when they are lit, the parameter is operating
within design limits.
If an indicator light is not lit, this indicates an alert situation with the corresponding param-
eter, as follows:
TEMPERATURE
COOLANT LEVEL
COOLANT FLOW

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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 not too high
•No temporary power failure
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:
•Filter, if fitted
•No restrictions in the pipe work
•Operating coolant pressure set too low
Clean fluid path with weak detergent solution, flush and replace fluid with cor-
rect Hexid fluid.
Fluid lines becoming
fouled brown or green
Algae contamination.
Clean system with weak detergent solution, replace fluid lines with opaque
(ideally black) lines to inhibit algae growth. Use Hexid fluid.
Fluid seen leaking from sys-
tem
Under high humidity conditions, fluid may appear to be leaking from the sys-
tem. This is usually just condensation, but it is always prudent to check for
fluid leaks.
Poor fluid flow
Flush with clean water, replace fluid with Hexid.
Poor cooling
Check fan is rotating continuously
Almost always caused by blocked condenser.
Clean with soft brush or vacuum cleaner with brush attachment
Continued failure may indicate high ambient or excessive load applied to the
unit. Check these first

K1, K3 series chillers –Installation and Operation manual
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K1, K3 series chillers –Installation and Operation manual
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5.0 Return of goods procedure
If the unit is damaged during transit, or subsequently develop a fault requiring its return to
ATC, the following procedure must be followed.
1. Call the ATC service point on [phone] or email [email protected].
•You will be issued with a Return Materials Authorisation number (‘Q number’).
2. Return the completed RMA form to ATC, together with your purchase order number.
3. Pack the returning item securely, enclosing a copy of the completed RMA 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 RMA 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 Limited
Goods Inward
Unit 1 Garden Court
Gee Road
Whitwick Business Park
Coalville
Leicestershire
LE67 4NB
United Kingdom

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6.0 Dimensions and performance
K1
K3
Cooling Capacity
1750 Watts
3200 Watts
Dimensions H x W x D
575 x 420 x 545 mm
720 x 550 x 560 mm
Weight
66 Kg
82 Kg
Temperature range
4°C - 35°C
4°C - 35°C
Pumps available
P5, P10, P17
P5, P10, P17
LED temperature display
0.1°C resolution standard.
0.1°C resolution standard.
Temperature control
Microprocessor P.I.D.
Microprocessor P.I.D.
Pressure gauge
Standard
Standard
Fluid connections
3/8” and ½” barb supplied
Custom connections availa-
ble
3/8” and ½” barb supplied
Custom connections available
Temperature stability
0.1°C
0.1°C
Power requirements
6 Amps, 230V 50Hz
13 Amps, 230V 50Hz
Warranty
2 years parts, 1 year labour
2 years parts, 1 year labour

K1, K3 series chillers –Installation and Operation manual
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Applied Thermal Control Ltd
Garden Court, Gee Road
Whitwick, LE67 4NB, United Kingdom
Tel: [phone]
Email: [e-mail]
EC Declaration of Conformity (DoC)
K-Series
DOCUMENT DETAILS
Date
22/JUN/2018
Compiled by
MJH
Revision
11.0
Document layout;
Governed by Machinery Directive 2006/42/EC, Annex II.
REGISTERED BUSINESS ADDRESS
Applied Thermal Control Ltd, Garden Court, Gee Road, Whitwick, LE67 4NB, UK
AUTHORISATION TO COMPILE THE TECHNICAL FILE
Mitchell Howard, Applied Thermal Control Ltd, Garden Court, Gee Road, Whitwick, LE67 4NB, UK
DESCRIPTION & IDENTIFICATION OF MACHINERY
Generic denomination;
K-Series.
Function;
Recirculating chiller
Model;
All with ‘K’ prefix.
Type;
Air-cooled or water-cooled vapour compression-based.
Serial number;
Commercial name;
As above.
NOTIFIED BODY
Not applicable.
QUALITY ASSURANCE SYSTEM
QMS International Ltd, Muspole Court, Muspole Street, Norwich, NR3 1DJ, United Kingdom.
ASCB Registered; 201409-2
DECLARATION
The manufacturer declares that the machinery described above fulfils all the relevant provisions of the;
•Machinery Directive 2006/42/EC.
•EMC Directive 2014/30/EU, via harmonised standards;
oBS EN 61000-6-3:2007+A1:2011 (Emissions).
oBS EN 61000-6-1:2007 (Immunity).
•Low Voltage Directive 2014/35/EU.
•RoHS Directive 2011/65/EU;
oThe machinery above contains no Lead (Pb), Mercury (Hg), Cadmium (Cd), Hexavalent
Chromium (Cr6+), Polybrominated Biphenyls (PBB) or Polybrominated Diphenyl Ether (PBDE).
PERSON EMPOWERED TO DRAW UP DECLARATION
Robert Poniatowski, CEO
Signed in Coalville, UK, date 22/JUN/2018

K1, K3 series chillers –Installation and Operation manual
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Appendix 1: Water cooled condenser option
The water-cooled condenser option is available as an alternative to the air-cooled standard
version.
Chillers with a water-cooled condenser require an in-house cooling water supply, which
meets the following recommended specifications:
•10 litres/minute
•1 bar minimum differential pressure across chiller
•25°C maximum temperature, but lower is better
The modulation valve, which can be found behind the left-hand grille towards the rear of
the chiller, does not require adjustment. It is factory set to control the refrigeration system
at an optimum pressure and temperature.
Coolant and house water connections
There are two pairs of water connections on the rear of water-cooled chillers. The left-hand
pair are the recirculating coolant connections; these are the connections for the coolant
supply to your application. The right-hand pair are the connections for the house water
supply.
Standard configuration for both coolant and house water is
Inlet Right
Outlet Left
with respect to the chiller unit.
All other operation features are the same as those described in the main body of this man-
ual.
Appendix 2: Integral deionising cartridge option
If your K series chiller is supplied with the integral deionising cartridge, it is very important
that this cartridge is replaced every three months, or when the cartridge media in the
appropriate window turns from blue to brown, whichever is the sooner.
The only approved replacement cartridge is order code WA012, available from ATC or from
our authorised distributors.