KTR Series Chillers User Manual
Contents
1. try to repeat the auto tuning Check the functioning of within 12 hours probe and actuator and try to repeat the auto tuning Loop control interrupted Check the working of probe Loop break alarm and actuator and swap the instrument to rEG control Possible anomaly of the Push key FP EEPROM memor If the set point is moved more than 10 C the alarm may be triggered The alarm resets when coolant temperature cones within 10 C of the set point It is not possible to set the temperature outside the preset values of 4 C and 35 C Issue 11 3 Page 10 KT series chillers Installation and Operation manual Fluid flow and pressure KT chillers fitted with a 2 or 3 litre per minute pump are capable of producing up to 150 il a a aD oF psi because of the high pressure volumetric pump These units are normally supplied fac tory set to run at an operating pressure of 35 psi which is suitable for most applications The pressure setting is controlled by an internal bypass valve which will open above the preset level to protect your application from higher pressures It is possible for customers to change the operating pressure of all K series chillers except KT chillers fitted with a 6 litre minute pump For details of this procedure refer to the technician section 4 0 Maintenance requirements Operator Caution Failure to carry out service at the specified intervals may pe2. EEC Specifications EN50081 1 1992 Emissions and EN50082 1 1992 Immunity Signed Glenn Stevens Robert Poniatowski Production Manager Managing Director Issue 11 3 Page 19 KT series chillers Installation and Operation manual INKO In case of repair requirement please complete both parts of the form and fax to ATC PART 1 RETURNED MATERIAL DECLARATION FORM Returns Number QO a 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 I 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 amp SAFETY DECLARATION Machine part number Machine serial number Ieee te nee eee OU ee eae eens eet A N confirm that the above unit L is free from chemical biological or nuclear hazard and that the unit presents no physical hazard including electrical Signed and dated Issue 11 3 Page 20 KT series chillers Installation and Operation manual Appendix 1 Water cooled condenser option The water cooled condenser option 1s available as an alternative to the air cooled standard vers
3. Operation manual 1 3 Site requirements Hard level surface 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 This will reduce the capacity of the unit and in extreme cases cause a system shut down Non condensing ambient from 4 C to 40 C Maximum cooling capacity is achieved at 22 C and will de rate by 2 per C until capacity is lost at 30 C Electrical supply Two standard versions are available 230V 50Hz 3A or 115V 60Hz 6A Other options are available on request Clearance front and rear of the unit at least 250mm 10 inches 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 to reduce pres sure losses in the pipework 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 Fluid line requirements As short as possible Ideally between 1 and 2 metres between 3 and 6 feet Large diameter Ideally at least 12mm L inch internal diameter Black tubing to inhibit growth of algae Alternatively use solid copper or welded ABS Free from right angle bends Clean If your installation is to
4. the equipment may be impaired Warning There are no user serviceable parts in this equipment 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 Issue 11 3 Page 4 KT series chillers Installation and Operation manual al a a e aD Ou 1 1 Warranty registration The warranty registration card must be completed and returned to ATC This does not affect your statutory rights 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 tran sit damage subsequently found AN Warning 30kg 66lb Two person lift required 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 Issue 11 3 Page 5 KT series chillers Installation and
5. KT series chillers Installation and Operation manual K SERIES CHILLERS KTR KTC KTD STANDARD MODELS INSTRUCTION MANUAL Issue 11 3 TERT W CE ST 3046567 Applied Thermal Control Ltd Garden Court Gee Road Whitwick Leicestershire LE67 4NB Tel 44 0 1530 839998 Fax 44 0 1530 813786 Issue 11 3 Page KT series chillers Installation and Operation manual 1 0 INTRODUCTION Safety 1 1 Warranty registration 1 2 Unpacking 1 3 Site requirements 2 0 INSTALLATION Fluid line requirements Voltage selection option Chiller filling procedure 3 0 OPERATION KTR models only KTC models only KTD models only Adjusting the set point KTD only 4 0 MAINTENANCE REQUIREMENTS OPERATOR 5 0 TECHNICIAN SECTION 5 1 Fluid flow and pressure adjustment 5 2 Maintenance and service requirements 5 3 Troubleshooting 6 0 WARRANTY TERMS AND CONDITIONS Registration 6 1 Return of goods procedure 6 2 Specifications Environmental KTR KTC KTD EC DECLARATION OF CONFORMITY Appendix 1 Water cooled condenser option Issue 11 3 K OC N ona Oo et O cDo o v vo O 11 12 12 13 14 15 15 21 Sa a a e aD Ou Page 2 KT 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 instrumentatio
6. ated from the electrical supply prepare to fill the unit with Hexid fluid Issue 11 3 Page 7 KT series chillers Installation and Operation manual Chiller filling procedure a S aD Ou Check valves in your application are open Remove lid from the coolant reservoir Fill with Hexid to within 40mm 1 inches of the tank rim Switch the unit on Wait while the fluid level drops in the tank Switch the unit off Repeat steps 3 to 5 until all of the air has been purged from the system Top up to a level 40mm 1 inches below the tank rim a ee a a Check the inlet and outlet connections and the inside of your application carefully for leaks If no leaks are found the system is ready to be run Warning Always isolate the chiller from the electrical supply when filling the tank Component identification photograph KT series model shown is KTR Coolant reservoir lid On Off switch Lifting handle front Neon 14 4 Mains inlet Coolant outlet connection Coolant inlet connection Issue 11 3 Page 8 KT series chillers Installation and Operation manual 3 0 Operation Operator section KTR models only Connect the mains cable and switch the unit on The neon will illuminate and the chiller runs automatically KTR chillers have been configured to provide temperature stability to 0 2 C and the actual temperatur
7. cified intervals may permanently damage your equipment Actions Check fluid level unless checked by Operator Check external connections for leaks unless checked by Operator 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 unless changed by Operator Check for fluid leaks throughout the whole system Check the condenser for fouling Caution Never blow the condenser out with compressed air Issue 11 3 Page 13 KT series chillers Installation and Operation manual INKO 5 3 Troubleshooting Symptom Compressor not running but fan running Noisy operation High fluid pressure And or low flow Fluid lines becoming fo uled brown or green Poor cooling Issue 11 3 Technician Is the controller displaying an alarm If there is no obvious cause check e The condenser is clean e Ambient temperature not above 30 C The likely cause is the compressor s internal protection has been activated and should restart in five minutes Check e No restrictions in the pipe work e Pressure set too low factory set pressure altered Clean system with weak detergent solution rinse thoroughly to remove all de tergent Use Hexid fluid as coolant Algae contamination Clean system with weak detergent solution rinse thoroughly to remove all de t
8. e achieved will be in the range 12 C 20 C depending on the load and ambient temperature This model is designed to provide a reliable and inex pensive alternative to tap water The pump in the standard version KTR6 may require priming simply achieved by switching the unit on and off repeatedly until no bubbles are seen in the tank KTC models only Connect the mains cable and switch the unit on and the temperature display will illumi nate KTC chillers have been configured to provide temperature stability to 0 2 C and the actual temperature achieved will be in the range 12 C 20 C depending on the load and ambient temperature This model is designed to provide a reliable and inexpensive alterna tive to tap water The KTC includes digital coolant temperature display and high low temperature and low fluid level alarms The single neon and icon provide visual alert to the alarm conditions High temperature alarm Preset at 25 C neon buzzer and HI warning display Low temperature alarm Preset at 7 C neon buzzer and LO warning display Low fluid alarm Neon and buzzer and AL warning display The buzzer can be muted by pressing the U button on the controller No adjustments can be made to the factory set cooling parameters Issue 11 3 Page 9 a a aD oF o KT series chillers Installation and Operation manual INKO KTD models only Connect the mains cable and swi
9. ed and returned to ATC This does not affect your statutory rights Issue 11 3 Page 15 KT series chillers Installation and Operation manual INKO 6 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 e You will be issued with a Return Materials Authorisation number Q number and a Return Ma chine Declaration RMD form by fax A copy of the RMD form is on the last page of this manual 2 Return the completed RMD form to ATC by fax together with your purchase order number prior to shipment of the chiller 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 Leicestershire LE67 4NB UK Tel 44 0 1530 839998 Fax 44 0 1530 813786 6 2 Specifications Issue 11 3 Page 16 KT series c
10. ergent Replace fluid lines with black lines if not already fitted to inhibit al gae growth Use Hexid fluid as coolant Continued failure to cool may indicate high ambient temperature or excessive load applied to the unit Check these first Otherwise may be caused by blocked condenser Clean with soft brush or vacuum cleaner with brush attachment Page 14 KT series chillers Installation and Operation manual INKO 6 0 Warranty terms and conditions ii iii iV 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 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 During the first year of the warranty period freight costs to and from ATC are for ATC s account During the second year of the warranty freight costs to and from ATC are for the cus tomer s account 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 packa ging is not available and either an empty crate is required and or new packaging for the repaired unit is required Registration The warranty registration card must be complet
11. existing pipe work the system should be flushed clean prior to filling Hexid fluids are the recommended coolant choice as they pro Issue 11 3 Page 6 ial a a a aD Ou o m gt aD D KT series chillers Installation and Operation manual INKO vide excellent corrosion protection freeze protection algae inhibition and good heat transfer properties a o aD Ou 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 All connections should be made using the fittings and clips provided Where threaded or compression type fluid joints are to be made always use a suitable jointing compound such as PTFE tape Voltage selection option Caution If your KT chiller is rated for multi tap and dual frequency operation it is essen tial that the voltage selector switch on the KT chiller is set to match the voltage and fre quency available at your site The voltage selector switch cover plate can be found 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 isol
12. hillers Installation and Operation manual Environmental KTR KTC For indoor use only Altitude up to 2000 metres Ambient temperature range 4 C 40 C Maximum relative humidity 80 for ambient temperatures up to 31 C decreasing linearly to 50 relative humidity at 40 C ambient temperature Mains supply voltage not to exceed 10 of the nominal voltage Installation Category II Pollution Degree 2 Cooling capacity 480 Watts at 22 C Dimensions height x width x depth 515 x 315 x 315mm 20 x 12 4 x 12 4 inches Weight 30kg 66lbs Cooling temperature range 4 C 30 C Pumps available High pressure volumetric type 2litre minute or 3litre minute Low pressure centrifugal type 6 litre minute Fluid connections O BSP x 10mm 3 8 Nickel plated brass hose tail adaptors Custom connections available Temperature stability 0 2 C with stable load dependent on stable ambient tem perature Power requirements 3 Amps 230V 50 60Hz 7 Amps 115V 60Hz Warranty 2 years parts 1 year labour Cooling capacity 480 Watts at 22 C Dimensions height x width x depth 515 x 315 x 315mm 20 x 12 4 x 12 4 inches Weight 30kg 66lbs Cooling temperature range 4 C 30 C Pumps available High pressure volumetric type 2litre minute or 3litre minute Low pressure centrifugal type 6 litre minute LED temperature display resolution 1 C standard 0 1 C option Fluid connections O BSP x 10mm 3 8 N
13. ickel plated brass hose tail adaptors Custom connections available Temperature stability 0 2 C with stable load dependent on stable ambient tem perature Power requirements 3 Amps 230V 50 60Hz 7 Amps 115V 60Hz Warranty 2 years parts 1 year labour Issue 11 3 Page 17 KT series chillers Installation and Operation manual INKO KTD Cooling capacity 480 Watts at 22 C Dimensions height x width x depth 515 x 315 x 315mm 20 x 12 4 x 12 4 inches Weight 30kg 66lbs Cooling temperature range 4 C 30 C Pumps available High pressure volumetric type 2litre minute or 3litre minute Low pressure centrifugal type 6 litre minute LED temperature display resolution 1 C standard 0 1 C option Fluid connections O BSP x 10mm 3 8 Nickel plated brass hose tail adaptors Custom connections available Temperature stability 0 1 C Power requirements 3 Amps 230V 50 60Hz 7 Amps 115V 60Hz Warranty 2 years parts 1 year labour Issue 11 3 Page 18 KT series chillers Installation and Operation manual EC Declaration of Conformity Applied Thermal Control Ltd Garden Court Gee Road Whitwick Leicestershire LE67 4NB K series chiller range all standard configurations Serial Number 06 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
14. ion Chillers with a water cooled condenser require an in house cooling water supply which meets the following recommended specifications e 5 litres minute e 1 bar minimum differential pressure across chiller e 25 C maximum temperature but lower is better Coolant and house water connections There are two pairs of water connections on the rear of water cooled chillers The lower pair are the recirculating coolant connections these are the connections for the coolant sup ply to your application The higher pair are the connections for the house water supply Standard configuration for both coolant and house water is Inlet Left Outlet Right with respect to the chiller unit All other operation features are the same as those described in the main body of this man ual Issue 11 3 Page 21
15. llers except KT chillers fitted with a 6 litre minute pump as follows 1 Remove the cover from the chiller giving access to the top compartment 2 With the chiller running release the locking nut on the pressure relief valve 3 Turn the valve knob anticlockwise to reduce the flow pressure clockwise to in crease the flow pressure The 6 litre minute pump is specially designed for low pressure applications and the flow rate and pressure settings cannot be changed on these units R o m Ss o m S D Issue 11 3 Page 12 KT series chillers Installation and Operation manual INKO 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 by the pressure relief valve the safety pro vided 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 35 psi A blockage in your application could result in the pressure exceeding the raised safety pressure We recommend that pressures exceeding 60psi must never be used 5 2 Maintenance and service requirements Caution Failure to carry out service at the spe
16. n 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 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 at Applied Thermal Control Ltd Garden Court Gee Road Whitwick Leicestershire LE67 4NB U K Tel 44 0 1530 839998 Fax 44 0 1530 813786 e mail sales app therm com Or contact an approved ATC distributor Issue 11 3 Page 3 KT series chillers Installation and Operation manual a a n aD Ou Safety For your safety we draw your attention to the following Warning and Caution statements throughout this manual identified by the symbols A ma O respectively The safe operation of a KT series chiller remains the responsibility of the op erator at all times Attention 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 equip ment Caution 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 If the equipment is used in a manner not specified by the manufacturer the pro tection provided by
17. rmanently damage your equipment For maintenance and service requirements for technicians and for trou bleshooting refer to the technician section Exterior cleaning Wipe up any spillages using a damp cloth only Do not use detergents Weekly Check fluid level Check external connections for leaks Annually Change the fluid The 6 litre minute pump is specially designed for low pressure applications and the flow rate and pressure settings cannot be changed on these units Issue 11 3 Page 11 KT series chillers Installation and Operation manual INKO 5 0 Technician section AN Warning Opening the refrigeration system may expose the operative to toxic and corro Ss om z o m 3 D an sive compounds HF Take protective measures including suitable eye protection AN Warning Gases may exceed 300 psi 20 bar during operation AN Warning All refrigerants do not support combustion and are asphyxiating gases AN Warning After switching off the condenser cooling fan blades continue to rotate Do not attempt servicing whilst the blades are rotating AN Warning All chillers contain water and electricity in close proximity Always ensure the unit 1s isolated before service All K series chillers are protected from over current by the master circuit breaker Never bypass this component 5 1 Fluid flow and pressure adjustment It is possible to change the operating pressure of all K series chi
18. tch the unit on and after a short self test the temperature controller will show coolant temperature The KTD chiller is fitted with a high perfor mance 3 term PID controller which is capable of controlling temperature to within 0 1 C of set point The single neon alert icon e kk dnd buzzer provide visual and audible alarm to both high and low temperature triggered if the temperature deviates more than 10 C either side of the set point and to low fluid level Setting a new set point KTD Only 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 de crease 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 K 39 Controller error messages 5z Probe interrupted Verify the comreci The measured variable connection between probe is under the probe s and instrument and then limits under range verify the comeci The measured variable functioning of the probe is over the probe s limits J Auto tuning not Swap the instrument to possible because the OFF control OFF and process value is higher then to automatic control with Func HEAt rE S in order to make the than SP SP 2 or error message disappear lower with Func Once the error has been than SP found
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