ATC K-Series User manual

Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 1
K SERIES CHILLERS
Kt1
STANDARD MODELS
INSTRUCTION MANUAL
Issue 3.1
Applied Thermal Control Ltd.
Garden Court, Gee Road
Whitwick, Leicestershire
LE67 4NB
Email [email protected]
Tel: [phone]
Fax: [phone]

Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 2
Contents
1.0
Introduction
3
Safety notices
4
1.1
Warranty registration
5
1.2
Unpacking
5
1.3
Site requirements
6
2.0
Installation
Voltage selection
Coolant filling
6
7
7
3.0
Operation
9
4.0
Maintenance and service requirements
11
4.1
Troubleshooting
12
5.0
Warranty terms and conditions
13
5.1
Return of goods procedure
14
6.0
Dimensions and performance
15
7.0
EC Declaration of Conformity
16
8.0
Returned Material documentation
17

Kt1 series chillers –Installation and Operation manual
Issue 3.1
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 oper-
ation 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 Ltd.
Garden Court
Gee Road
Whitwick,
LE67 4NB
Tel: [phone]
Fax: [phone]
e-mail: [email protected]

Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 4
Safety
For your safety we draw your attention to the following Warning and Caution statements
throughout the manual, identified by the symbols…
and 
respectively. The safe operation of a KT series chiller remains the responsibility of the
operator at all times.
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: Use of this equipment in any manner not specified by the manufacturer may re-
sult in the protection provided by the equipment being impaired.
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, in excess of 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 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 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. The Kt1 has an on-off switch and four protective fuses.
Never bypass these components.



Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 5
Caution: Filling/topping up of the tank should only be undertaken with the unit switched
off, to prevent backflooding 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.
1.1 Warranty registration
Caution: The warranty registration card must be completed and returned in order to acti-
vate cover. Failure to do so will limit warranty to three months from date of despatch from
ATC.
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 transit dam-
age 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.



Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 6
1.3 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,
reducing 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
35 C.
Electrical supply single phase 208VAC 5% (60Hz) 7A, 230VAC 5% (50Hz)
7A, 220VAC 5% (60Hz) 7A.
Electrical terminations.
Live: Brown
Neutral: Blue
Earth: Green/yellow
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 sec-
tion 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:
Short
Large diameter (ideally at least 12mm internal diameter)
Free from right angle bends, to suppress water hammer and reduce pressure losses

Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 7
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
system 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 trac-
es 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
jointing compound such as PTFE tape.
Voltage selection
Caution: If your Kt1 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.
The voltage selector switch can be found on the front of the chiller. Access is gained by
removing the two knobs on the front ventilation panel to expose the selector switch. Con-
firm the required voltage setting, then always replace the cover for normal operation.



Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 8
Coolant Filling
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 protec-
tion, freeze protection, algae inhibition, pump protection 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 screw cap from the tank
3. Fill with Hexid to 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 of the air has been purged from the system.
8. Top up to 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 sys-
tem is now ready to be run.
Warning: Always isolate the chiller from the electrical supply when filling the tank.


Kt1 series chillers –Installation and Operation manual
Issue 3.1
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3.0 Operation
Kt1 chiller has been configured to provide temperature stability to 0.1 C.
The chiller includes a dual digital display, high/low temperature and low fluid level alarms.
High temperature alarm: 10 C above set point
Low temperature alarm: 10 C below set point
Low fluid alarm / No flow alarm: Neon indication (off)
K series chillers are fitted with a high performance 3 term PID controller, which is capable
of controlling the set temperature to within 0.1 C of 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, 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
decrease 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.

Kt1 series chillers –Installation and Operation manual
Issue 3.1
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K 39 Controller error messages
Fluid flow and pressure
Kt1 series chillers contain a high pressure volumetric pump capable of 150 psi. All units
are normally supplied with a pre-set maximum of 50 psi unless a different pressure is re-
quired.. Pressures above this will cause the internal safety bypass valve to open, protecting
your application from potentially dangerous pressures.
It is possible for users to change the operating pressure of the chiller, as follows:
1. Switch off the chiller.
2. Remove the cover from the chiller by removing the 4 screws on each side. Release
the earth connection tab mounted on the underside of the cover, left hand side as
viewed from the front.
3. Switch on the chiller and while running, release the locking nut on the pressure re-
lief valve; a grey valve mounted on the pump head and located at the right side of
the chiller, as viewed from the front.
4. Turn the valve knob anticlockwise to reduce the flow/pressure, clockwise to in-
crease the flow/pressure. Secure the locking nut once you have achieved your de-
sired pressure.
5. The pressure can be observed on the gauge on the front panel.
6. Switch off the chiller, replace cover , securing the earth tab and secure with the
screws provided.