ATC K, KT1, K1, K3 Instruction 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

KT1

STANDARD MODELS

INSTRUCTION MANUAL

Issue 3.2

KT1 series chillers – Installation and Operation manual

Issue 3.2 1

Contents

1.0

Introduction

2

Safety

3

1.1

Unpacking

4

1.2

1.3

Site requirements
Warranty registration

5
6

2.0

Installation
Voltage selection
Coolant filling

7
7
8

3.0

Operation

9

4.0

Maintenance and service requirements

11

4.1

Troubleshooting

12

5.0

Return of goods procedure

13

6.0

Dimensions and performance

14

7.0

EC Declaration of Conformity

15

KT1 series chillers – Installation and Operation manual

Issue 3.2 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: [e-mail]

KT1 series chillers – Installation and Operation manual

Issue 3.2 3

Safety

For your safety we draw your attention to the following Warning and Caution statements
throughout the manual.
The safe operation of a KT 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 dam-

age to equipment.

Warning: Use of this equipment in any manner not specified by the manufacturer may

result 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 cor-

rosive 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. The KT1 has an on-off switch and four protec-

tive fuses. Never bypass these components.

Caution: Filling/topping up of the tank should only be undertaken with the unit

switched off, to prevent back-flooding of the fluid.

KT1 series chillers – Installation and Operation manual

Issue 3.2 4

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 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.

KT1 series chillers – Installation and Operation manual

Issue 3.2 5

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,
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
section 2.0

KT1 series chillers – Installation and Operation manual

Issue 3.2 6

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.

KT1 series chillers – Installation and Operation manual

Issue 3.2 7

2.0 Installation

Having ensured that your installation meets all the site requirements identified in section

1.2, 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

• 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
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
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.
Confirm the required voltage setting, then always replace the cover for normal operation.

KT1 series chillers – Installation and Operation manual

Issue 3.2 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
protection, 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 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 3.2 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 approx­imately 10 seconds, ‘SP 1’ will continue to flash during this time.

K 39 Controller error messages

KT1 series chillers – Installation and Operation manual

Issue 3.2 10

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
required. 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

relief 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

increase the flow/pressure. Secure the locking nut once you have achieved your
desired 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 3.2 11

Caution:
Changing the flow/pressure with the pressure relief valve will also change the pre-set
pressure safety set-point. This will move to a lower pressure than the factory setting
when decreasing 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 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 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 accumula­tions 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 3.2 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
system. 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 3.2 13

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 [e-mail].

• 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

KT1 series chillers – Installation and Operation manual

Issue 3.2 14

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

4°C - 35°C

Pumps available

P5, P10, P17

LED temperature display

0.1°C resolution standard.

Temperature control

Microprocessor 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 3.2 15

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;

o BS EN 61000-6-3:2007+A1:2011 (Emissions).
o BS EN 61000-6-1:2007 (Immunity).

• Low Voltage Directive 2014/35/EU.

• RoHS Directive 2011/65/EU;

o The 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