ATC G04 Series Manual

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
Table of Contents
1.0 INTRODUCTION........................................................................................................3
1.1 SAFETY NOTICES......................................................................................................................4
1.2 UNPACKING UNITS WEIGHING OVER 60kg(133lbs) ON CASTORS..........................................5
1.3 SITE REQUIREMENTS...............................................................................................................5
1.4 WARRANTY REGISTRATION....................................................................................................7
2.0 PRODUCT SPECIFICATION .....................................................................................8
3.0 QUICK START GUIDE...............................................................................................9
4.0 INSTALLATION........................................................................................................10
4.1 HOSE RECOMMENDATIONS..................................................................................................10
4.2 CONNECTING ADAPTERS TO PRODUCT BULKHEAD FITTINGS..............................................10
4.3 BACKFILLING..........................................................................................................................11
4.4 VOLTAGE SELECTION.............................................................................................................11
4.4 FILLING PROCEDURES ...........................................................................................................11
4.5 DRAINING A SYSTEM.............................................................................................................12
5.0 OPERATION............................................................................................................13
5.1 CHANGING SET POINT...........................................................................................................14
5.2 REGULATING PRESSURE/FLOW.............................................................................................14
6.0 BASIC TROUBLESHOOTING.......................................................................................16
7.0 END USER MAINTANANCE.........................................................................................17
8.0 DECLARATIONS AND APPROVAL..............................................................................18

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
1.0 INTRODUCTION
By selecting a K04/G04 series chiller you have invested in many years of experience in the design and
manufacture of precision temperature control instrumentation.
ATC has built your 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.
39 Hayhill Industrial Estate, Barrow Upon Soar
Leicestershire,
LE12 8LD
United Kingdom
Tel: [phone]
E-mail: [e-mail]

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
1.1 SAFETY NOTICES
GENERAL SAFETY INFORMATION
For your safety, we draw your attention to the following warning and caution marks
throughout the manual. Warning symbols can be found on the unit. Ensure you have read
through all warnings before starting the unit.
The safe operation of ATC products always remains the responsibility of the operator. This
equipment is intended to be used as a liquid temperature conditioning device –it requires no
external pump, nor any further manipulation of temperature. If the equipment is used in a
manner not specified by the manufacturer, the protection provided by the equipment may be
impaired. 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.
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.
Caution: Filling/topping up of the tank should only be undertaken with the unit
switched off, to prevent back-filling of the fluid.
Caution: This product contains no user-serviceable parts. Repair and service requires
specialized knowledge and tools to be provided by ATC or its local agent. Any
unauthorized tampering with the heat exchanger system automatically invalidates
warranty.
Warning: Hot and cold surfaces are present during operation. Take caution and care
when touching pump during operation.
Warning: Water pressures of up to 10 bar during operation.
Warning; Water and electricity near one another. Always ensure the unit is isolated
before service. The product is protected from overcurrent by fuses. Never bypass this
component.
During fault diagnostics and maintenance, it may be necessary to remove panels,
which expose the operator to the dangers of pressurized systems, hot or cold pipes
and electrical circuits. Only qualified personnel who are aware and equipped to deal
with these systems should only carry out such work.
Any temporary electrical supply to the chiller should be correctly earthed and
connected through an earth leakage trip.
In case of unexpected coolant leakage, safety glasses should always be worn when
the chiller is operated with the covers removed.
Under no circumstances leave the cooler unattended with the side panels removed.
Never alter settings of pressure switches, overloads, circuit breakers or any safety
device without first consulting Applied Thermal Control.

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
1.2 UNPACKING UNITS WEIGHING OVER 60kg(133lbs) ON CASTORS
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. 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.
As the unit weighs >60kg, ATC recommends it should be lifted with slings through the underside,
using a forklift or overhead crane. ATC highly recommends that it is not manually lifted, and that
safe slinging and lifting practices are adhered to.
Remove the unit from its original packaging and ensure that there is no packaging left around the
cooling ducts. There is no internal product packaging that requires the chiller to be opened.
Please retain all packaging in the unlikely event that the chiller needs to be returned to our local
representatives.
1.3 SITE REQUIREMENTS
1
Storage temperature range. Without process fluids, -20°C to +70°C.
2
Storage humidity range. Non-condensing, relative humidity 5% to 95%. Before starting
product, allow product to acclimate for 24h in location of use when storing outside operating
humidity range.
3
Operating temperature range. With appropriate process fluids, +4°C to +65°C.
4
Operating humidity range. 80% for ambient temperatures up to +31°C (+88°F), decreasing
linearly to 50% relative humidity at +40°C (+104°F) ambient temperature.
5
Hard, level surface. A level surface is important for ensuring proper filling and allowing air to
escape.
6
Electrical supply 230V ±10% (50Hz) single phase1. The Internal circuit breaker is rated at 15
Amps, normal operating current is 9 Amps. For the K04 the Internal circuit breaker is also
rated at 15 Amps with normal operating current at 11 Amps.
7
Clearance. Clearance is required to:
a) Provide unobstructed access to the electrical box door to use overload handle in
case of emergency.
b) Fit hoses and electrical supply to the side of the unit allowing recommended bending
radii.
c) Allow maintenance access points on side panels to be removed.
d) Allow process to take place –all models require the coolest, cleanest air that can be
provided to achieve the best performance. This model draws air in from the left-
hand side (when viewing from the front of the unit) and reject heated air from the
right-hand side.
e) 0.5m clearance is recommended on air-on and air-off sides.
8
Plumbing. Tubing, piping or hose must be clean and compatible with the fluid to be used.
The product is compatible with deionized water, tap water and water-glycol mixtures such as
Hexid A4 and A6. Ensure the connected pipework is suitable for handling the nominal
flowrate at system pressure ≥6bar.

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
9
Indoor use only. Altitude up to 2000m above sea level. Ensure the unit has adequate
ventilation.
Caution: Always use ATC recommended fluids in our products –many sealing
compounds and materials are present and unapproved fluids have the potential to
corrode your application and damage seals.
Caution: Do not use inadequately rated wiring. Consult an electrician if you are unsure.
Caution: The safety of any system incorporating the equipment is the responsibility of
the assembler of the system.
Caution; Do not replace detachable mains cords with inadequately rated cords. Contact
ATC for appropriately rated products.

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
1.4 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.

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
2.0 PRODUCT SPECIFICATION
Model
G04/K04
Weight
90kg
198lbs
Form factor
Floorstanding
Dimensions
L600 x W513 x H888mm
L23.6 x W20.2 x H35”
Noise level
53dB(A)@1m
Toolless access
No
Technology
Vapor Compression
Cooling capacity
(Ambient temperature at +30°C with setpoint of +20°C)
3.5kW
11,942BTU/h
0.995TR
Refrigerant
G04: R290 (Propane)
K04: R407C
Temperature range
+4°C to +35°C (standard)
-20°C to +65°C (extended)
Control method
PID via Hot Gas Bypass
Stability
±0.1°C
Resolution
0.1°C
Sensor type
PT100
System volume
3L
PD pump options
P5, P10, P17
Pressure relief
Internal, PRV, 20-150psi
Process fittings
1/2" BSPPF
Supply (-0spec)
230Vac 50Hz 1~ 9A
Supply (-2spec)
220Vac 60Hz 1~/2~ 9A
1st party approvals
CE, UKCA
Empty fluid tank alarm
Visual, lamp
Low fluid flow alarm
Visual, lamp
Temp range alarm
Visual, lamp
Fridge HP switch
Standard
Motor thermal cutout
Standard
Overcurrent protection
Standard, via MCB
Overcurrent restart
Manual
Emergency off
Not present
Warranty options
2-year parts, 1-year labor
Enhanced on request
Rated duty cycle
S1 Continuous

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
3.0 QUICK START GUIDE
QUICK START GUIDE
1
Remove all the packaging (Section 1.2)
2
Connect chiller’s outlet and inlet process to your application
3
Fill up the chiller with appropriate coolant
4
Use the name plate on the back of the chiller to verify the appropriate
voltage and supply the power using provided cables.
5
Turn the power switch ON
6
Slowly add more coolant as process lines fill and the coolant is
circulated around the process system.
7
Using the controller, set the desired temperature.

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
4.0 INSTALLATION
4.1 HOSE RECOMMENDATIONS
Having ensured that your installation meets all site requirements, it is best practice that the fluid
lines between your application and the chiller have the following characteristics.
1
Short in length –this reduces friction-based pressure drop and addition ambient heat load.
2
Large diameter bore –at least 12mm (1/2”).
3
Free from 90° bends –to limit the effects of water hammer. If this cannot be avoided, sharp
changes of direction should be minimized so far as possible. Doing this correctly can yield higher
pump performance and extend time between maintenance intervals. It will also reduce electrical
energy consumption.
4
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.
Failing this, it is recommended to use a domestic bleach in solution with tap water, diluted to
the point where the bleach can longer be smelled by human nose.
5
Opaque, ideally black –to inhibit light passing through the tube and algae building up.
Alternatively, solid ABS or copper pipe can be used where application chemistry allows.
6
Insulation, where low temperature process is planned –the process line from chiller to
application contains the feed of low temperature fluid. Insulation prevents heat from entering
this line and can promote better stability. Uninsulated return lines are helpful where free cooling
can be obtained by allowing heat to transfer to air –likewise, insulating the return line is helpful
if the fluid temperature is below ambient.
Caution; Never use transparent tubing. UV light will pass through, prompting growth of
organic contamination.
4.2 CONNECTING ADAPTERS TO PRODUCT BULKHEAD FITTINGS
1
Standard units are supplied with 1/2” British Standard Pipe Parallel Female (BSPPF) threads (also
known as G threads (ISO228)) by default. These fittings are not valved and will ‘drop’ the volume
of the system if left open to atmosphere.
2
Ensure the appropriate thread sealants are used in the fitting of adapters to hose. For metallic
mating parts, we recommend Loctite 577. For plastic adaptors such as those supplied with the
product, we recommend using ~8-12mm wide PTFE tape, wrapped around the male thread
before tightening.
3
Ensure that the system is correctly connected. The ‘donut’ labels around the ports are clearly
marked with inlet and outlet symbols and function in both English and French language. Ports
marked as outlet means fluid leaves the product and must be connected to the process inlet.
4
Check all joints are tight and leak free.
5
Where this product is incorporated into other equipment, it is the responsibility of the
assembler to ensure safety

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
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Installation, Operation & Service Manual
G04/K04
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4.3 BACKFILLING
1
In situations where the chiller is situated physically lower than the application being cooled,
fluid will apply pressure to the water circuit of the product.
2
The weakest seal is normally the tank lid, and this is typically where fluid will escape the unit.
3
Ideally, the product will be located higher or level with the product waterline. If this is not
possible, a non-return solenoid valve kit can be installed as an optional standard assembly.
4
Please raise any questions with the sales team on [e-mail].
4.4 VOLTAGE SELECTION
Different chillers will have different requirement for electrical supply. The specification and
requirement can be found on the back plate of the chiller. Please ensure that the voltage
supply and number of phases are correct on the site and your power supply can handle the
stated current draw.
4.4 FILLING PROCEDURES
a) Check all application valves are open, including solenoid valves and variable position valves.
i) The product will require an open water circuit to pump into.
ii) Any obstructions can increase the time, or entirely prevent the bleeding of air from the
system.
b) Remove the cap from the tank lid on the top of the product.
i) Fill the tank to just underneath the bottom of the filling port.
c) Switch the unit on
i) Immediately after toggling this switch (assuming the power cord is connected and
switched on), the pump will start running.
ii) Keep the unit running until the water level in the tank drops and cuts out on the level
switch interlock.
iii) Turn the unit off at the main switch.
iv) Fill the tank again to lift the level switch.
v) Start the product
Caution: Do not run the pump dry. Do not deadhead the pump.
d) Repeat step c) until the chiller does not cut out on the level switch.
e) Now with the unit running:
i) Leave the cap off the tank for >30mins to allow air to escape, or very loosely screwed on
to prevent water splashing out of the tank if the unit has a ‘flow through’ design.
f) Check the application and tubing for signs of leaks whilst the chiller is running.
i) Replace the tank lid fully when satisfied the system is full and bled of air and no
abnormal sound can be heard from the pump


Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
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4.5 DRAINING A SYSTEM
a) Isolate the unit. Have a suitable bucket or drain on-hand.
i) Remove the tank lid to allow air into the system.
ii) Disconnect hoses individually. Be aware hoses as well as the unit are filled with fluid.
iii) Use tank drain tap (If fitted)
iv) Consider using the red transport plugs to block product ports to give yourself time to
empty hoses before continuing to empty the product.
b) Local rules affect where fluid can be disposed of.
Ensure hazardous products do not enter the water course and are reclaimed from the unit for
professional disposal.

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
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5.0 OPERATION
K04/G04 series chillers are fitted with a high performance KR1 PID controller, which can control
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.
DISPLAY CONTENTS DURING NORMAL OPERATION
1
Physical navigation buttons, up, down, return and enter.
2
8888.8 is the actual read value on input sensor.
3
888.8 is the setpoint value.
4
Rectangles bottom left 1-4 display when output is active.
5
MAN LED shows in manual mode (fixed output value).
6
°C or °F shows units as settable in the ‘inP’ group.
7
AL LED appears when output is beyond a set alarm point.
ACCESS TO SETTINGS
8
Push the return button for more than 5 seconds. The upper display will show PASS while the
lower display will show 0.
9
Using up and down buttons set the programmed password –full access is granted by entering
‘40’. ATC are not responsible for damage either to the chiller or the connected equipment as a
result of changing parameters without ATC’s oversight.
10
During parameter modification the instrument continues to perform process control. In certain
conditions, when a configuration change can produce a significant change to the process, it is
advisable to temporarily stop the controller from controlling during the programming procedure
(control outputs will be OFF).
A password equal to 2000 + the programmed value (i.e. 2000 + 40 = 2040). The control will
restart automatically when the configuration procedure will be manually closed.
11
Push the return button. If the password is correct the display will show the acronym of the first
parameter group ‘inP’. Push button for more than 5 seconds, the instrument will come back to
the “standard display”.
12
The configuration parameters are collected in various groups. Every group defines all parameters
related with a specific function (control, alarms, output functions).
13
Push return button for more than 5 seconds, the instrument will come back to the “standard
display”. For specific settings and guidance, review the controller datasheets provided by ATC. If
you are not in receipt of these, please contact ATC using the information in the header of this
document.
GENERAL NAVIGATION
14
Return button; A short press allows to exit from the current parameter group and select a new
parameter group. A long press allows you to close the configuration parameter procedure (the
instrument will come back to the “standard display”).
15
Enter button; When the upper display is showing a group and the lower display is blank, this key
allows to enter in the selected group. When the upper display is showing a parameter and the
lower display is showing its value, this key allows to store the selected value for the current
parameter and access the next parameter within the same group.
16
Up button; Allows to increase the value of the selected parameter.
17
Down button; Allows to decrease the value of the selected parameter.
18
Pushing both Return and Enter buttons moves back to the previous group. Press return first to
start. The selection of the group is cyclic (on a carousel), so it is possible to move back around to
the group you require.

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
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5.1 CHANGING SET POINT
ACHIEVING DESIRED SET POINT
1
Push and hold the enter button until it shows “SP 1”
2
Use the up and down arrows to set the temperature
3
Press enter button again to set the temperature
4
The set value now will be activated, and the chiller will start
5.2 REGULATING PRESSURE/FLOW
POSITIVE DISPLACEMENT PUMPS & DISCRETE PRESSURE RELIEF VALVE
This arrangement comprises a positive displacement pump (most commonly a rotary vane type)
with a spring-loaded pressure relief valve to provide better overpressure setting control with
minimal flow losses compared to fixed orifice bypasses/reliefs. This annex describes ATC’s default
settings and how to adjust the system.
It is important to understand the basic principle that all else being equal, higher flow results in a
higher demand for pressure. The motor generates the power required to turn the pump head and
create that pressure. The more restrictive a water circuit is, the higher the pressure required to
maintain flowrate. Positive displacement pumps are designed to generate high pressure and are
mechanically tight - their RPM dictates flowrate. See image above.
1
Pump discharge –fluid leaves the pump head and enters the gauge-tee assembly. It passes
the temperature sensor at the tee, and when the pressure relief is inactive, fluid heads
towards no. 2.
2
Outlet to process –fluid heads out of the product to the application. Whatever restrictions
lie downstream, fluid leaving this point has not passed through the pressure relief valve.
3
Pressure gauge connection –connection to a pressure gauge on the front panel of the
product. This displays the pressure in the water circuit, at the pump outlet, not the
application which will be lower.
4
Pressure Relief Valve (PRV) –spring tension in the body of the PRV determines whether fluid
travels through point 2 or passes through to point 7.

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
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Installation, Operation & Service Manual
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5
PRV adjustment knob –rotate clockwise to increase maximum delivery pressure. Rotate
anti-clockwise to limit maximum delivery pressure.
6
PRV adjustment locknut –release this locknut to adjust no.5. Ensure it is tightened once
adjustments are made. If it is not, vibration may cause the adjustment knob to move on
itself.
7
Bypass flow outlet –where the pressure requirement to overcome restrictions downstream
of no.2 rises to be higher than the setting at no.5, the spring inside no.4 will compress and
allow liquid to start bleeding through to no.7. It is important to understand that the nature of
the spring means there can be no black and white point for pressure relief setting –the
spring will slowly compress and bleed flow until all flow passes through no.7. When fully
bypassing, all flow stays inside the chiller to protect the application.
SETTING PRESSURE RELIEF VALVE(BYPASS)
Unless otherwise agreed at point of sale, the default setting for this type of pump and PRV
arrangement is 3.33bar (50psi). If the relief valve has been interfered with and you would like to
bring the chiller back to its default pressure setting. Follow the instruction below:
1
Isolate the chiller
2
Disconnect from the application if connected- Review draining process from Section 4.5
3
Connect the chiller’s process inlet to process outlet –a short run hose around 1-2m (3-6ft) will
be adequate.
4
Start the chiller and follow the fill procedure from Section 4.4 - fluid will now be running
through a short loop with very low pressure required to overcome the restriction.
5
With the chiller running, very slowly kink the short run of hose fitted above –this simulates a
blocked application –this is known as ‘deadheading’ the pump. Without PRV, the pump motor
would stall or hoses might blow off. Watch the pressure gauge climb as you apply the kink.
6
The pressure gauge will eventually stop climbing with the hose fully kinked –note the value;
this is the setting of the PRV where all flow is bypassed.
7
Contact ATC if you’re unsure over whether your desired setting is reasonable for the product
you have.

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
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6.0 BASIC TROUBLESHOOTING
AIRCOOLED CHILLER TROUBLESHOOTING
#
SYMPTOM
CAUSES
1
Compressor or
pump motor not
running.
Large condenser
fan is running,
and control
illuminated.
Level switch may have been tripped –Fill the tank up again to resolve the
issue
High pressure switch may have been tripped:
a) Check fan spins freely and that condenser is clear of debris.
b) Assess whether the ambient temperature is too high.
c) Assess whether ventilation/air circulation is poor.
d) Assess whether surrounding equipment is generating hot air and
feeding it into the chiller air intakes.
If fitted, a low-pressure switch may have been tripped –this indicates
refrigerant loss. A multimeter is required to test this.
If running at a high setpoint, or if operating conditions have changed and
raised the fluid temperature, it is possible the compressor has turned itself on
high temperature internal protection.
2
Noisy Operation
Pump motor or fan motor bearings may have failed.
Pump head vane or seal may have failed.
In a 3-phase system, phase rotation may be incorrect.
3
High fluid
pressure/low
flow rate
Fluid lines may have become fouled through solid debris or biological growth.
Ensure biocides or pre-mixed biocidal process fluids are being used.
Ensure hoses are not transparent or translucent –UV light entering prompts
growth.
General fluid leak can lead to flow rate failure.
Excess fittings, too many sharp direction changes, too small a diameter hose
for flowrate or hoses too long at the wrong diameter.
4
Fluid collecting or
leaking
Leaks are impossible to diagnose remotely, but usually you will see a pool of
fluid on a lower surface. Do not confuse this with condensation from cold
parts of the fridge.
Review the chemical compatibility of your fluid with the chiller. Contact ATC if
you are unsure.
5
Poor Cooling
Performance
Check if the fans are running.
Clean the condenser coil.
Excess thermal load applied.
Assess whether the ambient temperature is too high.
Assess whether ventilation/air circulation is poor.
Assess whether surrounding equipment is generating hot air and feeding it
into the chiller air intakes.
Please contact ATC if you could not find the information you were looking for or still have an issue
with the unit

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
7.0 END USER MAINTANANCE
Caution: Failure to carry out service at the specified intervals may permanently
damage your equipment.
Print this sheet out and display close to the chiller to maximize the visibility of
maintenance requirements.
Weekly
Week 1
Week 2
Week 3
Week 4
Check Fluid Level –Top up as
required
Monthly
J
F
M
A
M
J
J
A
S
O
N
D
Check the
condenser is free
from dust or
accumulation of
debris
Annually
Y1
Y2
Y3
Y4
Y5
Y6
Drain process fluid and
replace with fresh fluid
Check for fluid leaks
throughout chiller and
application
Clear any debris from inside
the chiller
A vacuum cleaner is recommended for cleaning out the condenser, while soft cloths and IPA
are recommended for cleaning metallic surfaces. If any spillages have occurred, best practice
is to allow the water to evaporate off and wipe up remaining glycol residue with a cloth. Always
clean with power supply isolated.
Caution: Never blow out the condenser with compressed air
Caution: If the main lead is lost or damaged, contact ATC who will be able to supply
correct specification replacement.

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Installation, Operation & Service Manual
G04/K04
Rev 1 –05/04/23
8.0 DECLARATION AND APPROVALS