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
Page 9
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
Page 10
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.

Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 11
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 with the pressure relief valve, the safety
provided 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 50 psi,
even if the pressure setting on the chiller reads lower than this. A blockage in your applica-
tion could result in the pressure exceeding the raised safety pressure, and while the Kt1
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.
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.





Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 12
4.1 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 not too high
No temporary power failure
The likely cause is the compressor’s internal protection has been activated
(normally caused by high ambient temperature) and should restart in five
minutes.
Noisy operation /
High fluid pressure
And/or low flow
Check:
Pump 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
correct 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
system
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
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
Fan Failure

Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 13
5.0 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 pack-
aging is not available and either an empty crate is required and/or new packaging for
the repaired unit is required.
Registration
Please complete the warranty registration and return to ATC for initiation of warranty cov-
er.

Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 14
5.1 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
You will be issued with a Return Materials Authorisation number (‘Q number’) and a
Return Machine Declaration (RMD) form by fax. A copy of the RMD form is in sec-
tion 8.0 of this manual.
2. Return the completed RMD form to ATC by fax, together with your purchase order
number. You must complete the RMD as no repair can be considered until the com-
plete form is received.
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
LE67 4NB
Tel: [phone]

Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 15
6.0 Dimensions and performance
Kt1
Cooling Capacity
At 20 C set point and 20 C ambient
1000 Watts 50Hz
1200 Watts 60Hz
Dimensions H x W x D
490 x 370 x 560 mm
Weight
60 Kg
Temperature range
4C - 35 C
Pumps available
P5, P10
LED temperature display
1 C resolution standard.
0.1 C option.
Temperature control
Autotune P.I.D.
Pressure gauge
Standard
Fluid connections
3/8” and ½” barb supplied
Custom connections available
Temperature stability, under stable
conditions
0.1 C
Power requirements
7 Amps, 230V 50Hz
7 Amps, 208V 60Hz
7 Amps, 220V 60Hz
Warranty
2 years parts, 1 year labour

Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 16
EC Declaration of Conformity
Applied Thermal Control Ltd.
Garden Court
Gee Road
Whitwick
Leicestershire, LE67 4NB
UK
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
Robert Poniatowski Glenn Stevens
Managing Director Production Manager

Kt1 series chillers –Installation and Operation manual
Issue 3.1
Page 17
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:
…………………………………………………











