Applied Thermal Control | KTD | Instruction manual | Applied Thermal Control KTD 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: +44 (0) 1530 839998
Fax: +44 (0) 1530 813786
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K4, K6, K9 series chillers – Installation and Operation manual
Contents
1.0 INTRODUCTION ................................................................................................................................. 3
Safety ..................................................................................................................................................... 4
1.1 WARRANTY REGISTRATION ......................................................................................................................... 5
1.2 UNPACKING............................................................................................................................................. 5
1.3 SITE REQUIREMENTS.................................................................................................................................. 6
2.0 INSTALLATION ................................................................................................................................... 7
3.0 OPERATION ..................................................................................................................................... 12
3.1 – CHANGING THE SET POINT ...................................................................................................................... 12
4.0 MAINTENANCE AND SERVICE REQUIREMENTS ................................................................................ 13
4.1 – TROUBLESHOOTING ............................................................................................................................... 14
Symptom: Chiller too warm ................................................................................................................. 14
Symptom: Chiller too warm ................................................................................................................. 15
Symptom: Chiller too warm ................................................................................................................. 15
Symptom: Unit cycles rapidly or shuts down after short period of operation...................................... 16
5.0 WARRANTY TERMS AND CONDITIONS ............................................................................................ 17
5.1 RETURN OF GOODS PROCEDURE ................................................................................................................ 18
6.0 DIMENSIONS AND PERFORMANCE, K SERIES ................................................................................... 19
6.1 DIMENSIONS AND PERFORMANCE, K4 ........................................................................................................ 19
6.2 DIMENSIONS AND PERFORMANCE, K6 ........................................................................................................ 20
6.3 DIMENSIONS AND PERFORMANCE, K9 ........................................................................................................ 21
EC DECLARATION OF CONFORMITY......................................................................................................... 22
PART 1: RETURNED MATERIAL DECLARATION FORM .............................................................................. 23
APPENDIX 1: WATER COOLED CONDENSER OPTION ............................................................................... 24
APPENDIX 2: INTEGRAL DEIONISING CARTRIDGE OPTION ....................................................................... 25
INDEX ...................................................................................................................................................... 27
Issue 10.33
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K4, K6, K9 series chillers – Installation and Operation manual
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K4, K6, K9 series chillers – Installation 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:
Fax:
e-mail:
+44 (0) 1530 839998
+44 (0) 1530 813786
sales@app-therm.com
For your information, all chillers comprise four functional elements:
1
Refrigeration
2
Fluid handling
3
Electrical
4
Control
Issue 10.33
Provides cooling and heating to the fluid, also known as the
secondary refrigerant.
Repairs require specialist skills and tools.
Includes the pump, but excludes the pump motor.
Repairs require basic skills and a limited number of commonly
available specialised parts
Covers all electrical components, including pump motor,
compressor and alarms or interlocks. Sound electromechanical
skills are required.
Comprises controller, sensor and actuator. Sound
electromechanical skills are required.
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K4, K6, K9 series chillers – Installation and Operation manual
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 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 ‘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
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 chillers – Installation 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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K4, K6, K9 series chillers – Installation and Operation manual
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 +4C to +40C, ideally indoors. Cooling
capacity is lost above 30C.

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 15C. 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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K4, K6, K9 series chillers – Installation and Operation manual

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 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 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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K4, K6, K9 series chillers – Installation and Operation manual
on the right side of the chiller cover, when viewed from the front. Access is via the four
securing screws on the cover plate.
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 outer cover from the chiller, then remove cover from the tank
3. Fill with Hexid to 30mm 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 of 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.
There are two on-board circuit breakers protecting the chiller. The main three phase MCB
is located on the front panel. This also acts as the emergency off (EMO) and requires
continuity via the terminal strip located at the rear of the unit. Should a remote EMO be
required, a separate EMO may be fitted in series. The other MCB, protecting the single
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K4, K6, K9 series chillers – Installation and Operation manual
phase components (fans, controller and solenoid), is located to the rear of the electrical
box inside the unit. See Figure 1, page 11.
Setting the maximum permissible fluid pressure
If your chiller is fitted with a rotary vane pump, it will be fitted with a pressure control
valve as standard. This type of pump is ideal for small capacity chillers as it is very
efficient and capable of very high pressures with little or no loss of fluid flow at higher
pressures. ATC fit a pressure control valve as standard, to protect your application from
damaging over pressure. Pump types affected by the pressure control system are P5,
P8, P10 and P17. The valve simultaneously limits the maximum permissible system
pressure and the operation flow and pressure characteristics. It is important to understand
that the pressure displayed during normal operation is lower than the peak pressure in a
deadhead situation. In the event of blockage of a return line from the application, the
pressure may exceed 10 bar (150 psi). The pressure control valve is factory set to 50 psi
(1.5 bar). If your application is incapable of sustaining this pressure, the following
adjustment must be made:
1. Connect a short length of flexible hose between the inlet and outlet of the chiller.
2. Following the ‘filling procedure’ (see earlier this section) carefully fill the tank with
fluid and switch on.
3. With the chiller running, fold the flexible tubing back on itself, and secure with a
cable tie to block the fluid outlet.
4. Read the pressure displayed on the front panel.
5. Adjust the pressure using the pressure control valve (‘A’ in Figure 2, page 11) until
your known maximum system pressure shows on the front panel. NOTE - in optional
low temperature chillers, this is metallic and covered in insulating material
The maximum system pressure attainable has now been adjusted. Please be aware that the
actual running pressure will be lower than this value. If the maximum system pressure is
close to the actual pressure achieved during normal operation, only a proportion of the
pump’s output will be supplied to your application.
Issue 10.33
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K4, K6, K9 series chillers – Installation and Operation manual
Adjusting fluid flow and pressure
It is possible to change the operating pressure of the chiller, also using the pressure
control valve, as follows:
1. With the chiller running, release the locking nut on the pressure control valve.
2. Turn the valve knob (‘A’ in Figure 2, page 11) anticlockwise to reduce the
flow/pressure, clockwise to increase the flow/pressure. NOTE - in optional low
temperature chillers this is metallic and covered in insulating material
3. The pressure can be observed on the gauge on the front panel.

Caution:
Changing the flow/pressure with the pressure control valve will also change the preset
pressure safety setpoint. 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 control 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
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.
Issue 10.33
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K4, K6, K9 series chillers – Installation and Operation manual
Figure 1: MCB locations, looking from rear of chiller
3 phase circuit breaker
Single phase circuit breaker
Figure 2: Pressure control valve location - viewed from above
Rear panel
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K4, K6, K9 series chillers – Installation and Operation manual
3.0 Operation
K4, K6 and K9 chillers have been configured to provide temperature stability to 0.1C.
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 temperature warning via the LED on the display 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, 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 Push the ‘P’ button, 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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K4, K6, K9 series chillers – Installation and Operation manual
K39 Controller error messages
If the set point is moved more than 10C the alarm may be triggered. The alarm will
silence as soon as the set and measured temperatures are within 10°C. It is only possible
to set the temperature outside the preset values of -4C and +35C for chillers with
optional high and low temperature range extensions.
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.
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K4, K6, K9 series chillers – Installation and Operation manual
4.1 – Troubleshooting
This section outlines common refrigeration system faults. In most cases a refrigeration
service technician will have to carry out the necessary repairs as these involve specialist
skills and tools. It is very important that the prime cause of the problem is identified and
rectified.
Whenever service or repair work is carried out on the refrigeration system, the refrigerant
should be pumped into a recovery vessel if it cannot be held in the system receiver. If the
refrigerant is uncontaminated, it can be re-used. Otherwise, it should be returned to the
refrigerant manufacturer for recycling. Legally, companies other than refrigerant
manufacturers may recycle refrigerant, but checks should be made to ensure the quality of
the recycled product is acceptable. Refrigerants should not be vented to the atmosphere
because of their unacceptably high ozone depletion potentials and greenhouse strengths.
The tables below address each of the symptoms listed. The left hand column gives the
possible causes, the next column identifies checks that should be carried out and the right
hand column identifies actions, which should be taken. The shaded checks and actions are
those, which should only be carried out by a refrigeration service technician, and give an
indication to the end user of the type of rectification necessary. Unshaded checks and
actions are those, which the end user can undertake. The list is not exhaustive, but covers
the most common problems encountered in commercial refrigeration.
Symptom: Chiller too warm
Cause…
Check…
Action…
Compressor not running
Power on?
Switch on
Compressor failed?
Compare
measured
winding
resistances
manufacturer’s values
Compressor start/run relay or
capacitor failed?
Find reason and rectify fault
Compressor tripped on controls
or pressure switches?
Check high/low pressure trips and
fluid level before repairing wiring
motor
against
continued…
Issue 10.33
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K4, K6, K9 series chillers – Installation and Operation manual
Symptom: Chiller too warm
Cause…
Check…
Action…
Compressor not running
Loose wiring?
Locate and correct cause of fault.
Fuses and/or earth leakage trip
OK?
Check crimped terminals
Phase failure of 3 phase supplies
Check orientation of phases by
looking at fluid flow direction.
Check…
Action…
Refrigerant volume OK?
Find leaks, repair, add refrigerant
Evaporator fouled?
Clean evaporator
Evaporator iced?
Adjust defrost settings or repair
defrost system
Refrigerant volume OK?
Reduce refrigerant charge
Condenser fouled?
Clean condenser
Fan motor/blade OK?
Repair/replace
Incorrect superheat
TEV setting correct?
Adjust TEV
Evaporator or condenser fans
working incorrectly
Direction of rotation OK?
Reverse rotation
Fan motor/blade OK?
Repair/replace
Condenser fouled?
Clear fouling from air-side face of
condenser
Fin block fouled?
Blow through fin block with
compressed air, or with specialist
fin block cleaner
Evaporator fin block frozen?
Adjust defrost settings or repair
defrost system
Refrigerant volume OK?
Find leaks, repair, add refrigerant
Pressure drop through filters?
Clean filters
Condenser blockage?
Clean condenser
Symptom: Chiller too warm
Cause…
Compressor is running, but
under the following conditions:
Low evaporating pressure
High condensing pressure
Evaporator or condenser air flow
restricted
Prolonged bubbles in liquid line
sight glass
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K4, K6, K9 series chillers – Installation and Operation manual
Symptom: Chiller too cold
Cause…
Check…
Action…
Thermostat
Temperature and differential OK?
Adjust setting to maximum level
for product quality
Thermostat / bulb damaged?
Repair/replace
Control circuit OK?
Correct faulty wiring/control
Equipment runs continuously
Symptom: Unit cycles rapidly or shuts down after short period of operation
Cause…
Check…
Action…
Thermostat
Temperature and differential OK?
Adjust setting to maximum level
for product quality
LP switch
Refrigerant volume OK?
Find leaks, repair, add refrigerant
Evaporator fouled/iced?
Clean evaporator,
defrost system
Water-cooled condenser control
valve failed open?
Check for running water when
chiller is shut down
Condenser fouled?
Clean condenser
Fan assembly damaged?
Repair/replace
Poor water supply to watercooled condenser? Failed valve?
Check
cooling
water
supply/temperature/pressure.
Check water flow out of chiller
when running
Ambient too high / inadequate air
flow?
Reduce ambient / increase cool air
supply to condenser
As for HP switch, above
As for HP switch, above
Cause…
Check…
Action…
Compressor noisy
3 phase direction OK?
Correct orientation
Compressor mounting vibration?
Improve vibration isolation
Compressor oil level OK?
Repair leaks, add oil
Drive and alignment of open
compressors OK?
Repair drive and/or realign motor
and compressor
Electrical supply unbalanced?
Correct supply
Condensing unit pipe work OK?
Improve isolation and fixing
HP switch
Discharge temperature protection
repair/adjust
Symptom: Other malfunction
Condensing unit noisy
continued…
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K4, K6, K9 series chillers – Installation and Operation manual
Symptom: Other malfunction
Cause…
Condenser
noisy
or
evaporator
fan
Check…
Action…
Fixing of fan to motor shaft OK?
Tighten
Motor bearings OK?
Lubricate or replace motor
Fan blade OK?
Repair/replace
Motor mounting bolts OK?
Tighten
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
installed 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
customer’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
packaging 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
cover.
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K4, K6, K9 series chillers – Installation and Operation manual
5.1 Return of goods procedure
If the unit is damaged during transit, or subsequently develops 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 on page 23 of this manual.
2. Return the completed RMD form to ATC by fax, together with your purchase order
number.
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: +44 (0) 1530 839998
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K4, K6, K9 series chillers – Installation and Operation manual
6.0 Dimensions and performance, K series
6.1 Dimensions and performance, K4
APPLIED THERMAL CONTROL K4
High precision recirculating chiller
Feature
Dimensions L x W x H
Cooling capacity (fluid @ 17°C)
Microprocessor-based temperature controller
Temperature adjustable
Temperature stability
Temperature range
Extended temperature range - Optional
Digital temperature display
Temperature alarm - Standard off-set +/- 10°C
Low fluid level alarm Option
Low flow alarm option
Auto diagnostic functions
System volume
Pressure control system
Compatible fluids
Fluid connections
Pump P5
Pump P10
Pump P17
Weight
Wheels for mobility
Power requirements
Warranty
Computer interface optional
Water cooled condenser
Issue 10.33
K4
775 x 510 x 853 mm
4500 watts
3 term P.I.D digital
1°C increments
+/- 0.1 C
+4 to +35C
-30 to +90C
Standard
Adjustable High / Low
Visual
Visual
Controller and sensor
7 litres
Standard fitment internal - user adjustable
Hexid fluids / water / propylene glycol
12mm i.d. hose tails & 3/4” BSP male
5 Litres per minute up to max. pressure of
150 psi (10 bar)
10 Litres per minute, up to 150 psi (10 bar)
17 Litres per minute, up to 150 psi (10 bar)
125kg
Standard (2 locking)
13 Amps 210-230VAC 1ph 50 Hz
2 years parts one year labour.
RS 485 serial to modbus standard
Optional
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K4, K6, K9 series chillers – Installation and Operation manual
6.2 Dimensions and performance, K6
APPLIED THERMAL CONTROL K6
High precision recirculating chiller
Feature
Dimensions L x W x H
Cooling capacity (fluid @ 17°C)
Microprocessor-based temperature controller
Temperature adjustable
Temperature stability
Temperature range
Extended temperature range - Optional
Digital temperature display
Temperature alarm - Standard off-set +/- 10°C
Low fluid level alarm
Auto diagnostic functions
System volume
Pressure control system
Compatible fluids
Fluid connections
Pump P5
Pump P10
Pump P17
Compressor over - load protection
Emergency Off (EMO)
Tool-less access
Weight
Wheels for mobility
Power requirements
Warranty
Computer interface optional
Water cooled condenser
Issue 10.33
K6
775 x 510 x 853 mm
6000 watts
3 term P.I.D digital
1°C increments
+/- 0.1 C
+4 to +35C
-30 to +90C
Standard
Adjustable High / Low
Standard Visual with pump interlock
Controller and sensor
7 litres
Standard fitment internal - user adjustable
Hexid fluids / water / propylene glycol
12mm i.d. hose tails & 3/4” BSP male
5 Litres per minute up to max. pressure of
150 psi (10 bar)
10 Litres per minute, up to 150 psi (10 bar)
17 Litres per minute, up to 150 psi (10 bar)
Standard
Via main circuit breaker (MCB)
No
125kg
Standard (2 locking)
10 Amps 208-230VAC 1ph 50 Hz or
5 Amps 380-415VAC 3ph 50/60Hz
2 years parts one year labour.
RS 485 serial to modbus standard
Optional
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K4, K6, K9 series chillers – Installation and Operation manual
6.3 Dimensions and performance, K9
Applied Thermal Control K910003
High Precision Recirculating Chiller
Feature
Dimensions L x W x H
Cooling capacity (water @ 20 oC)
Temperature controller
Temperature adjustable
Temperature stability
Temperature range
Digital temperature display
Temperature alarm - Standard offset  10
o
C
Auto diagnostic functions
Low Water Level Alarm
System volume
Pressure control system
Compatible fluids
Fluid connections
Pump P10
Compressor over - load protection
Emergency Off (EMO)
Tool-less access
Weight
Wheels for mobility
Power requirements
Condenser
Issue 10.33
K910003
775 x 510 x 853 mm
8.5 kW (Max ambient 24C)
3 term P.I.D digital
1 oC increments
+/- 0.1 oC
+4 to +35 oC
Standard
Adjustable, High / Low
Controller and sensor
Optional
10 litres
Standard - user adjustable
Hexid fluids / water / propylene glycol
6.5, 9 & 12mm id hose tails & 3/4” BSP
male
10 litres per minute up to 150 psi (10 bar)
Standard
Via main circuit breaker (MCB)
Yes
125kg
Standard (2 locking)
10 amps 208 VAC, 3ph, 50/60Hz
16 amps 208VAC, 3ph, 60Hz
Air Cooled
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K4, K6, K9 series chillers – Installation and Operation manual
EC Declaration of Conformity
Applied Thermal Control Ltd.
Garden Court
Gee Road
Whitwick
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
Robert Poniatowski
Managing Director
Issue 10.33
Glenn Stevens
Production Manager
Page 22
K4, K6, K9 series chillers – Installation and Operation manual
In case of repair requirement, please complete both parts of the form, and fax to ATC
Part 1: Returned Material Declaration Form

Returns Number: Q1_ - ___

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:

Issue 10.33
…………………………………………………
Page 23
K4, K6, K9 series chillers – Installation and Operation manual
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 front grille 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
Outlet
Right
Left
with respect to the chiller unit.
All other operation features are the same as those described in the main body of this
manual.
Issue 10.33
Page 24
K4, K6, K9 series chillers – Installation and Operation manual
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.
Issue 10.33
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K4, K6, K9 series chillers – Installation and Operation manual
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Issue 10.33
Page 26
K4, K6, K9 series chillers – Installation and Operation manual
Index
RMD form ............................................... 18, 23
C
controller, PID .................................................... 12
error messages .............................................. 13
S
set point .................................... See PID controller
E
T
electrical supply ................................................... 6
temperature
stability ......................................................... 12
Troubleshooting diagnosis
symptom - other ..................................... 16, 17
symptom - shuts down after short operation
................................................................. 16
symptom - too cold ....................................... 16
symptom - too warm .............................. 14, 15
symptom - unit cycles rapidly ....................... 16
F
filling procedure ................................................... 8
fluid lines
installation requirements ................................ 7
type ................................................................. 7
P
packaging materials, retention of ........................ 6
PID controller
programming set point ................................. 12
pressure
adjusting operating ....................................... 10
maximum recommended .............................. 10
safety setpoint .............................................. 10
setting maximum permissible ......................... 9
V
voltage selection, if fitted .................................... 7
W
warranty
registration ............................................... 5, 17
terms and conditions ................................ 5, 17
R
Return of goods procedure ................................ 18
Issue 10.33
Page 27
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