ATC K4, K6, K9 Instruction Manual

K SERIES CHILLERS

K4, K6, K9

STANDARD MODELS

INSTRUCTION MANUAL

Issue 10.33

Applied Thermal Control Ltd.

Garden Court, Gee Road

Whitwick, Leicestershire

LE67 4NB

Tel: [phone]

Fax: [phone]

(Left intentionally blank)

K4, K6, K9 series chillersInstallation and Operation manual

Contents

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K4, K6, K9 series chillersInstallation and Operation manual

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K4, K6, K9 series chillersInstallation and Operation manual

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 Ltd.

Garden Court

Gee Road

Whitwick

LE67 4NB

Tel:	[phone]
Fax:	[phone]
e-mail:	[e-mail]

For your information, all chillers comprise four functional elements:

1	Refrigeration	Provides cooling and heating to the fluid, also known as the
		secondary refrigerant.
		Repairs require specialist skills and tools.
2	Fluid handling	Includes the pump, but excludes the pump motor.
		Repairs require basic skills and a limited number of commonly
		available specialised parts
3	Electrical	Covers all electrical components, including pump motor,
		compressor and alarms or interlocks. Sound electromechanical
		skills are required.
4	Control	Comprises controller, sensor and actuator. Sound
		electromechanical skills are required.

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K4, K6, K9 series chillersInstallation and Operation manual

Safety

For your safety we draw your attention to the following Warning and Caution

and

respectively. The safe operation of a K 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: Failure to comply with a 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 100C

Warning: Very cold surfaces and gases, lower than -40C. Severe frostbite hazard.

Warning: Opening the refrigeration system may expose the operative to toxic and corrosive 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: Always ensure the unit is isolated before service. Three phase represents increased danger from electric shock.

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.

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K4, K6, K9 series chillersInstallation and Operation manual

Caution: Your K series chiller is fitted with a high pressure volumetric pump, capable of supplying fluids at 150psi. Ensure that your plumbing is compatible.

Caution: Filling/topping up of the tank should only be undertaken with the unit switched off, to prevent backflooding of the fluid.

Caution: All connections must be made with those supplied.

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.

Caution: THREE PHASE UNITS ARE NOT PHASE LOCKED, and whilst running the pump backwards will not damage the unit, the pump and compressor will not operate correctly if this is done.

1.1 Warranty registration

Caution: The warranty registration card must be completed and returned in order to activate 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 damage subsequently found.

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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.

1.3 Site requirements

Hard, level surface. Ideally smooth, to allow freewheeling of the castors, which are designed for indoor use.

Non-condensing ambient, from +4C to +40C, ideally indoors. Cooling capacity is lost above 30C.

Clean, dust free environment. Air-cooled chillers move very large volumes of air. Large amounts of air-borne contamination will result in fouling of the condenser, reducing the capacity of the unit, and extreme cases may cause a system shut down.

Water supply (applies only to water cooled chillers). Water cooled K series chillers up to and including the K6 all require clean process water at a flow rate of at least 10 litres per minute at a pressure of not less than 1 bar (15psi). The systems are designed for water to the chiller at 15C. If the water available does not meet these requirements, please consult ATC for specific advice regarding your installation. Please have the following information available: (i) cooling water flow, (ii) cooling water pressure, (iii) cooling water temperature and (iv) chiller serial number.

Suitable power. The supply requirements can be determined from the details printed on the rating plate. All ATC units are designed for a 15% to +10% fluctuation in supply voltage. Ensure that the house supply circuit breaker is suitably rated and is of the slow-blow type, since the chiller is capable of momentarily drawing ten times the current shown on the rating plate at startup.

Clearance front and rear of the unit at least 500mm.

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Outside installation. The unit is compatible with outdoor installation, provided that shelter from direct rainfall and sunlight is provided. It is strongly recommended that Hexid A4 is used to provide baseline frost protection.

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

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

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 with Hexid.

All connections should 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 K series chiller is rated for multi-tap and dual frequency operation, it is essential that the voltage selector switch on the K series chiller is set to match the voltage and frequency available at your site. The voltage selector switch cover plate can be found

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