ATC W 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
W-Series
DOCUMENT DETAILS
Date
14/JUN/2022
Author(s)
MJH
Page
1 / 5
Revision
1
Opening section W-Series 1

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
W-Series
DOCUMENT DETAILS
Date
14/JUN/2022
Author(s)
MJH
Page
2 / 5
Revision
1
CHANGE LOG
Date
Revision
Page ref
Change
14/JUN/2022
1
ALL
First release
Opening section W-Series 2

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
W-Series
DOCUMENT DETAILS
Date
14/JUN/2022
Author(s)
MJH
Page
3 / 5
Revision
1
PRODUCT SPECIFICATIONS
W08
W16
W24
W32
W40
Enclosure no.
MA323
MA420
MA378
MA407
MA407
Width
W980mm
W985mm
W1180mm
W1180mm
W1180mm
Depth
D680mm
D895mm
D1000mm
D1000mm
D1000mm
Height
H1480mm
H1580mm
H1733mm
H1733mm
H1733mm
Dry weight
199kg
254kg
325kg
385kg
420kg
Wet weight
269kg
344kg
505kg
585kg
620kg
Noise level
74dBA@1m
74dBA@1m
70dBA@1m
67dBA@1m
67dBA@1m
Acceptable environment
Indoor/Outdoor
Indoor/Outdoor
Indoor/Outdoor
Indoor/Outdoor
Indoor/Outdoor
Components IP rating
IP54 (or better)
IP54 (or better)
IP54 (or better)
IP54 (or better)
IP54 (or better)
Toolless access
No
No
No
No
No
Cooling technology
Vapour compression
Vapour compression
Vapour compression
Vapour compression
Vapour compression
Evaporator technology
Brazed Plate HE
Brazed Plate HE
Brazed Plate HE
Brazed Plate HE
Brazed Plate HE
Cooling capacity at +30°C ambient
8kW
16kW
24kW
32kW
40kW
Refrigerant
R407C
R407C
R407C
R407C
R407C
Setpoint standard range
+5 to +25°C
+5 to +25°C
+5 to +25°C
+5 to +25°C
+5 to +25°C
Control method
Compressor on/off
Compressor on/off
Compressor on/off
Compressor on/off
Compressor on/off
Temperature stability
±1°C
±1°C
±1°C
±1°C
±1°C
Setpoint resolution
0.1°C
0.1°C
0.1°C
0.1°C
0.1°C
Total Heat Rejection (THR)
13.5kW
22kW
31kW
41kW
52kW
Ambient temperature range
+10 to +40°C
+10 to +40°C
+10 to +40°C
+10 to +40°C
+10 to +40°C
Cold start support
N/A
N/A
Crankcase heater
Crankcase heater
Crankcase heater
Fluid tank volume
70L
90L
180L
200L
200L
Sight tube level gauge
Yes
Yes
Yes
Yes
Yes
Tank drain facility
Yes
Yes
Yes
Yes
Yes
Fluid connections
1” BSPPF
1” BSPPF
1” BSPPF
1.5” BSPPF
1.5” BSPPF
Pump options (*nominal)
P10, P17, P25*
P17, P25, P40*
P25, P40*
P40, P80*
P80*, P120
Chemical compatibility
Water / Water-glycol
Water / Water-glycol
Water / Water-glycol
Water / Water-glycol
Water / Water-glycol
Temperature out of range DRO
Standard
Standard
Standard
Standard
Standard
Compressor HP switch
Standard
Standard
Standard
Standard
Standard
Hydraulic magnetic overloads
Standard
Standard
Standard
Standard
Standard
Supply on indicator lamp
Standard
Standard
Standard
Standard
Standard
System running indicator lamp
Standard
Standard
Standard
Standard
Standard
Water low indicator lamp
Standard
Standard
Standard
Standard
Standard
Pump fault indicator lamp
Standard
Standard
Standard
Standard
Standard
Refrigeration fault indicator lamp
Standard
Standard
Standard
Standard
Standard
Over/under pressure cut-outs.
Standard
Standard
Standard
Standard
Standard
Coolant under temperature switch
Standard
Standard
Standard
Standard
Standard
Low Pump flow switch
Standard
Standard
Standard
Standard
Standard
Low coolant level switch
Standard
Standard
Standard
Standard
Standard
1st party approvals
UKCA, CE
UKCA, CE
UKCA, CE
UKCA, CE
UKCA, CE
3rd party approvals
None
None
None
None
None
Opening section W-Series 3

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
W-Series
DOCUMENT DETAILS
Date
14/JUN/2022
Author(s)
MJH
Page
4 / 5
Revision
1
SAFETY NOTICES
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 6 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 mains fusing. Never bypass this component.
Warning; 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.
Warning; Any temporaryelectrical supply to the chiller should be correctly earthed and connected through
an earth leakage trip.
Warning: In case of unexpected coolant leakage, safety glasses should always be worn when the chiller
is operated with the covers removed.
Warning; Under no circumstances leave the cooler unattended with the side panels removed.
Warning; Never alter settings of pressure switches, overloads, circuit breakers or any safety device
without first consulting Applied Thermal Control.
Opening section W-Series 4

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
W-Series
DOCUMENT DETAILS
Date
14/JUN/2022
Author(s)
MJH
Page
5 / 5
Revision
1
INCLUDED ANNEXES
Specific technical product information is provided in the following series of annexes.
Annex A-3 201105 Shipping & Unpacking - Crane or forklift required
Annex B-15 220614 Site & Environmental Requirements for W-Series
Annex C-5 220309 Installation - Generic air-cooled with 1.5inch fittings
Annex C-6 220309 Installation - Generic air-cooled with 0.5inch fittings
Annex C-8 220309 Installation - Generic air-cooled with 1.0inch fittings
Annex D-7 211129 Fluid Handling & Startup Procedures - W-Series
Annex E-15 210301 KR1 - how to use
Annex E-15G 220328 KR1 Program W-Series
Annex F-6 220311 Centrif or turbine pump using throttling valve
Annex G-15 220614 Troubleshooting - Initial help for air-cooled W-Series
Annex H-1 191121 End-user maintenance - air-cooled units with water as fluid
Annex I-1 210830 Maintenance for technicians - Generic refrigerated units
Annex J-5 200706 EU Compliance Statement Conflict Minerals
Annex J-7 200715 EU Compliance Statement REACH
Annex J-8 200827 EU Compliance Statement POPs
Annex J-9 220406 EU DoC W-Series
Annex J-10 201111 EU Compliance Statement RoHS
Annex J-14 211124 UKCA DoC W-Series
Annex K-1 200623 Standard warranty terms of ATC
Annex L-12 220610 Volt Free Contacts
Annex L-23 220614 On-off fan control
Annex L-51 220614 Remote Stop-Start
Annex M-10 220614 Recommended spares, W-Series
Annex R-2 120701 SDS Refrigerant HFC-R407C
Annex R-3 200203 SDS Hexid A4 v6.4
Opening section W-Series 5

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Shipping & Unpacking
Annex A-3
DOCUMENT DETAILS
Date
03/FEB/2021
Author(s)
MJH / LW / AMI
Page
1 / 1
Revision
2
SHIPPING & UNPACKING –CRANE OR FORKLIFT REQUIRED
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. If possible, unpack the unit before signing. Once you have signed for the goods, ATC
cannot be held responsible for any transit damage subsequently found.
Remove the unit from its original packaging and ensure that there is no packaging left around the cooling ducts.
There is no internal product packaging that requires the product to be opened.
When moving the unit, ensure pallet truck or forklift are rated appropriately for weight. Moving the unit off the
pallet should be done with either a forklift (using forklift guide channels if present on your product) or slings and a
crane (unless lifting eyebolts (craning points) are present on your product). Positioning the unit on the shopfloor
can be achieved by moving on castors (if present) or using a pallet truck –if your unit has rigid feet, once
positioned, screw down the four adjustable floor pads until the weight is taken off the castors. Tighten the locking
nuts when adjusted.
Please retain all packaging in the unlikely event that the chiller needs to be returned to our local
representatives.
Annex A-3 201105 Shipping & Unpacking - Crane or forklift required 6

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Site & Environmental Requirements
Annex B-15
DOCUMENT DETAILS
Date
14/JUN/2022
Author(s)
MJH
Page
1 / 2
Revision
1
SITE & ENVIRONMENTAL REQUIREMENTS FOR W-SERIES
This guide may apply to your product if it is a standard model from the W-Series. It describes the requirements for
all services and conditions necessary for years of trouble-free running. If you require more detail, please contact
ATC for support using the details in the header of this document.
GUIDANCE
1
Storage temperature range. Without process fluids, -20°C to +50°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, -20°C to +40°C.
4
Operating humidity range. 80%RH for ambient temperatures up to +31°C (+88°F), decreasing linearly to
50%RH 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. All standard W-Series units are three phase chillers.
Mains supply via an earth leakage detecting residual current device (RCD) is recommended.
Current consumption quoted is based on nominal pump sizes described in product specification table.
ATC cannot make recommendations for power supply wire gauge nor supply capacity. Follow local
regulations and consult trained electricians. The product rating label contains the necessary information.
Model
W08
W16
W24
W32
W40
Supply suffix
-3
-3
-3
-3
-3
Nominal voltage
400Vac
400Vac
400Vac
400Vac
400Vac
Voltage tolerance
±5%
±5%
±5%
±5%
±5%
Frequency
50Hz
50Hz
50Hz
50Hz
50Hz
Supply mode
3P+N+E
3P+N+E
3P+N+E
3P+N+E
3P+N+E
Current (L-L)
15A
22A
28A
TBC
TBC
Current (L-N)
8.5A
12.5A
16A
TBC
TBC
Fan overload
Fuse, T4A
Fuse, T4A
TBC
TBC
TBC
Compressor overload
GV2, 6-10A
GV2, 6-10A
TBC
TBC
TBC
Pump overload
GV2, 4-6.3A
GV2, 4-6.3A
TBC
TBC
TBC
PSU overload
Fuse, T0.5A
Fuse, T0.5A
Fuse, T0.5A
Fuse, T0.5A
Fuse, T0.5A
7
Cooling airflow supply. Standard W-series chillers are engineered for nominal duty in ambient
temperature of +30°C. The chiller will run up to ambient temperatures of +40°C without modification.
Depending on heatload and ambient temperatures, the built-in cooling fan runs in an on-off control strategy.
8
Clearance. Clearance is required to achieve the following;
a)
Ensure the electrical door can be opened fully and a human can always access the E-Stop button.
b)
Fitting of hoses to the water-connections panel with appropriate hose/pipe bend radius.
c)
Fitting of electrical supply cable gland with appropriate cable bend radius.
d)
Access to maintenance side panels when they need to be removed.
e)
Air-on and air-off faces require at least 0.5m, preferably 1m. Any ducting or blocked vent faces will
lead to reduced performance and possibly shortened product life. The exact amount of clearance can
be determined by the OEM or end user.
9
Plumbing. Tubing, piping or hose must be clean and compatible with the fluid to be used. The product is
compatible with tap water and water-glycol mixtures such as Hexid A4 and A6. Ensure connected pipework
does not apply undue load on the chiller’s pump. Where tap water is used, ensure the chiller is specified
with frost protection option if ambient temperatures is expected to be lower than +8°C.
10
Outdoor & Indoor use OK.Altitude up to 2000m above sea level. Ensure the unit has adequate ventilation.
Where possible, it is still recommended to shelter the chiller from the sun.
Annex B-15 220614 Site & Environmental Requirements for W-Series 7

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Site & Environmental Requirements
Annex B-15
DOCUMENT DETAILS
Date
14/JUN/2022
Author(s)
MJH
Page
2 / 2
Revision
1
11
Installation category. Transient overvoltage category II; Pollution degree 2. Temporary overvoltages
occurring on mains supply are acceptable within limits defined in the aforementioned categories.
Caution: Always use ATC recommended fluids in your chiller –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.
Annex B-15 220614 Site & Environmental Requirements for W-Series 8

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Installation
Annex C-5
DOCUMENT DETAILS
Date
9/MAR/2022
Author(s)
MJH
Page
1 / 2
Revision
2
INSTALLATION FOR AIR-COOLED UNITS WITH 1-1/2" BSPPF FITTINGS
This guide applies to the following product groups;
-K-, G-, W-Series refrigerated units, where heatload is rejected to air.
-A-Series airblast units, where heatload is rejected to air.
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 minimizes exposure to ambient heat load.
2
Large diameter bore –we recommend hose internal diameter (ID) on 1-1/2” BSPPF fittings is no smaller
than 1-1/4” (32mm), and preferably larger than 1-1/2” (38mm).
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. ATC can offer commercial-grade cleaning solutions –contact us for information.
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.
CONNECTING ADPATERS TO PRODUCT BULKHEAD FITTINGS
1
This document described the use of 1-1/2” 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 standard products, 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 outlets mean
fluid leaves the product and must be connected to the process inlet or house water return line.
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.
Annex C-5 220309 Installation - Generic air-cooled with 1.5inch fittings 9

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Installation
Annex C-5
DOCUMENT DETAILS
Date
9/MAR/2022
Author(s)
MJH
Page
2 / 2
Revision
2
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 water-line. 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 [email protected]m.
Annex C-5 220309 Installation - Generic air-cooled with 1.5inch fittings 10

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Installation
Annex C-6
DOCUMENT DETAILS
Date
9/MAR/2022
Author(s)
MJH
Page
1 / 2
Revision
2
INSTALLATION FOR AIR-COOLED UNITS WITH 1/2" BSPPF FITTINGS
This guide applies to the following product groups;
-K-Series, R-Series and G-Series refrigerated units, where heatload is rejected to air.
-A-Series airblast units, where heatload is rejected to air.
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.
CONNECTING ADPATERS 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.
Annex C-6 220309 Installation - Generic air-cooled with 0.5inch fittings 11

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Installation
Annex C-6
DOCUMENT DETAILS
Date
9/MAR/2022
Author(s)
MJH
Page
2 / 2
Revision
2
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 water-line. 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 [email protected]m.
Annex C-6 220309 Installation - Generic air-cooled with 0.5inch fittings 12

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Installation
Annex C-8
DOCUMENT DETAILS
Date
9/MAR/2022
Author(s)
MJH
Page
1 / 2
Revision
2
INSTALLATION FOR AIR-COOLED UNITS WITH 1" BSPPF FITTINGS
This guide applies to the following product groups;
-K-, G-, W-Series refrigerated units, where heatload is rejected to air.
-A-Series airblast units, where heatload is rejected to air.
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 minimizes exposure to ambient heat load.
2
Large diameter bore –we recommend hose internal diameter (ID) on 1” BSPPF fittings is no smaller than
3/4” (19mm), and preferably larger than 1” (25.4mm).
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. ATC can offer commercial-grade cleaning solutions –contact us for information.
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.
CONNECTING ADPATERS TO PRODUCT BULKHEAD FITTINGS
1
This document described the use of 1” 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 standard products, 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 outlets mean
fluid leaves the product and must be connected to the process inlet or house water return line.
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.
Annex C-8 220309 Installation - Generic air-cooled with 1.0inch fittings 13

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Installation
Annex C-8
DOCUMENT DETAILS
Date
9/MAR/2022
Author(s)
MJH
Page
2 / 2
Revision
2
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 water-line. 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 [email protected]m.
Annex C-8 220309 Installation - Generic air-cooled with 1.0inch fittings 14

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Fluid Handling & Startup Procedures
Annex D-7
DOCUMENT DETAILS
Date
29/NOV/2021
Author(s)
MJH
Page
1 / 1
Revision
1
FILLING, STARTING & DRAINING OF W-SERIES UNITS
This guide describes the filling, starting and draining processes common to all W-Series products, standard or
non-standard. It assumes the unit is connected to mains and is live. Start with the e-stop and process start-stop
switch in the off position. Read this guide in its entirety before starting the process.
FILLING & STARTING
1
Check all application valves are open, including solenoid valves and variable position valves –the
chiller will require an open water circuit to pump into - any obstructions can increase the time, or entirely
prevent the bleeding of air from the system.
2
Remove the cap from the tank filler port - this can be found on the water-bulkhead fitting panel on the
side of the chiller –fill the tank to the maximum level as indicated by the sight tube. Filling past this point will
cause the tank liquid to overflow via the marked overflow pipe, also on the same face of the chiller.
3
Open the red-handled valve mounted on the outlet fitting, fully anti-clockwise –this valve is used to
either throttle the pump down in models where there is no other form of control (i.e. external bypass,
inverters, etc) and most importantly for a centrifugal pump’s health, to set a minimum head.
4
Turn your attention to the electrical box door –the process stop-start switch and e-stop button should
both still be in the off position. The supply-OK lamp should be on, signifying the alarm circuit has 24Vdc
available and that 3-phase power is available at the contactors. Ensure the filler port cap is still off –air will
need to escape.
5
Turn the stop/start switch –the ‘level OK’lamp should illuminate and pump should start. As the pump
starts and flow increases, the ‘pump OK’lamp should illuminate as the flow switch becomes satisfied. If the
fridge system high- and low-pressure switches are satisfied, we should also see the ‘refrigeration OK’lamp
come on, but only if the preceding three lamps are on. Any unexpected noises should prompt you to turn
the unit off at this point. The pump should now be running, and the pump pressure display should show the
operating pressure in bar.
6
As the chiller runs, observe the sight gauge on the front of the unit –watch the water level drop as the
air in the system is displaced. Allow the level to drop to the fill level marked on the gauge –turn the unit off
on the stop/start switch. Fill through the filler port until the level is at full again.
7
Repeat this process until the sigh gauge no longer drops from full –take care not to refill past the
maximum mark. Allow the unit to run for at least 60mins to ensure air has left the system.
8
Whilst the chiller runs, review internal and external hoses for signs of leaks –when satisfied the unit
is fully bled of air, review the fill level once more and replace the fill port lid.
Caution; Do not run the pump dry. Do not deadhead the pump.
DRAINING
1
The drain is connected to one half of a tee fitted to the tank –the other half leads to the sight tube.A
1/2" ID hose is used to connect to that tee. The drain hose is left vented and retained high to prevent
accidental draining.
4
Once the unit is drained, return the drain tube to the high position –any fluid remaining in the tank will
need to be siphoned manually –it is not possible to fully empty the tank.
5
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.
Annex D-7 211129 Fluid Handling & Startup Procedures - W-Series 15

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Controller Operation
Annex E-15
DOCUMENT DETAILS
Date
1/MAR/2021
Author(s)
MJH
Page
1 / 1
Revision
1
BASIC PROGRAMMING GUIDE KR1 (ALL MODELS)
This guide may apply to your product if you require general navigation advice and help accessing settings. If you
are planning to change the settings in any way, you may need a copy of the existing settings which are model
dependent, signified by a letter on the end of Annex E-15, i.e. Annex E-15A.
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.
Annex E-15 210301 KR1 - how to use 16

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Controller Operation
Annex E-15G
DOCUMENT DETAILS
Date
6/APR/2022
Author(s)
MJH
Page
1 / 2
Revision
2
W-SERIES PROGRAM PURPOSE
Internal part number
EA902 (24V) & EA894 (100-240Vac)
Manufacturer part number
Ascon Tecnologic KR1
Program purpose
1) Set safe working limits
2) Set on-off control strategy, asymmetric (cont=On.FA), i.e. fridge pulls down
to +20’C setpoint and switches off. Temperature rises to +22’C (HSEt=2),
fridge turns on again and pulls down.
PROGRAM
Group inP
Group ‘out’
Group ‘AL1’
Group ‘AL2’
Setting
Value
Setting
Value
Setting
Value
Setting
Value
SEnS
Pt1
o1.F
nonE
AL1t
nonE
AL2t
nonE
dP
1
o1.AL
n/a
Ab1
n/a
Ab2
n/a
SSc
n/a
o1.Ac
n/a
AL1L
n/a
AL2L
n/a
FSc
n/a
o2F
c.rEG
AL1H
n/a
AL2H
n/a
Unit
°c
o2.AL
n/a
AL1
n/a
AL2
n/a
FiL
10
o2Ac
dir
HAL1
n/a
HAL2
n/a
inE
our
o4F
nonE
AL1d
n/a
AL2d
n/a
oPE
100
o4.AL
n/a
AL1o
n/a
AL2o
n/a
io4.F
out4
o4Ac
n/a
diF1
oFF
diF2
n/a
di.A
0
Group ‘AL3’
Group ‘LbA’
Group ‘rEG’
Group ‘SP’
Setting
Value
Setting
Value
Setting
Value
Setting
Value
AL3t
nonE
LbAt
oFF
cont
On.FA
nSP
1
Ab3
n/a
LbSt
n/a
Auto
n/a
SPLL
10.0
AL3L
n/a
LbAS
n/a
tunE
n/a
SPHL
35.0
AL3H
n/a
LbcA
n/a
Aut.r
n/a
SP
20.0
AL3
n/a
SELF
n/a
SP2
n/a
HAL3
n/a
HSEt
2
SP3
n/a
AL3d
n/a
cPdt
n/a
SP4
n/a
AL3o
n/a
Pb
n/a
A.SP
SP1
ti
n/a
SP.rt
trin
td
n/a
SPLr
Loc
Fuoc
n/a
SP.u
inF
tcH
n/a
SP.d
inF
rcG
n/a
tcc
n/a
rS
n/a
Str.t
n/a
db.S
n/a
od
n/a
St.P
0
SSt
oFF
SS.tH
999.9
Annex E-15G 220328 KR1 Program W-Series 17

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Controller Operation
Annex E-15G
DOCUMENT DETAILS
Date
6/APR/2022
Author(s)
MJH
Page
2 / 2
Revision
2
Group ‘tin’
Group ‘PrG’
Group ‘PAn’
Group ‘Ser’
Setting
Value
Setting
Value
Setting
Value
Setting
Value
tr.F
nonE
Pr.F
nonE
PAS2
20
Add
1
tr.u
n/a
Pr.u
n/a
PAS3
40
bAud
9600
tr.t1
n/a
Pr.E
n/a
PAS4
300
trSP
nonE
tr.t2
n/a
Pr.Et
n/a
uSrb
tunE
tr.St
n/a
Pr.S1
n/a
diSP
SPF
Pr.G1
n/a
di.CL
0
Pr.t1
n/a
AdE
5
Pr.b1
n/a
diS.t
oFF
Pr.E1
n/a
FiLd
0.5
Pr.S2
n/a
dSPu
AS.Pr
Pr.G2
n/a
oPr.E
ALL
Pr.t2
n/a
oPEr
Auto
Pr.b2
n/a
Pr.E2
n/a
Pr.S3
n/a
Pr.G3
n/a
Pr.t3
n/a
Pr.b3
n/a
Pr.E3
n/a
Pr.S4
n/a
Pr.G4
n/a
Pr.t4
n/a
Pr.b4
n/a
Pr.E4
n/a
Pr.St
n/a
Group ‘COn’
Group ‘CAL’
Setting
Value
Setting
Value
Co.tY
oFF
AL.P
0
UoLt
n/a
AL.o
!TESTRIG!
cur
n/a
AH.P
999.9
h.Job
n/a
AH.o
!TESTRIG!
t.Job
n/a
Annex E-15G 220328 KR1 Program W-Series 18

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Pressure & Flow Adjustment
Annex F-6
DOCUMENT DETAILS
Date
11/MAR/2022
Author(s)
MJH
Page
1 / 2
Revision
2
CENTRIFUGAL OR TURBINE PUMP USING THROTTLING VALVE
This arrangement comprises a centrifugal or turbine type pump with typically a gate, needle or ball valve
downstream of the pump discharge to throttle the pump flowrate. Without any relief, it is critical to ensure the pump
is not deadheaded (no flow, and no relief). From many years of experience, ATC have found this method of
maintaining a high head pressure on the pump to extend the service life and all but eliminate pump leaks. The valve
is closed slowly until the desired flowrate or maximum pressure is met for the application, read from the panel-
mounted pressure gauge. This annex describes ATC’s default settings and how to adjust the system.
REPRESENTATIVE COMPONENT LAYOUT & FUNCTIONS
A
It is important to understand the basic principle that all
else being equal, higher flow results in a higher
demand for pressure to overcome forces of friction
and viscosity. The pump motor generates the motive
force required to turn the pump head and create that
pressure.
B
The more restrictive a water circuit is, the higher the
pressure required to maintain flowrate. Centrifugal
and turbine-type pumps are designed to generate
lower pressure and higher flowrates. They are
mechanically loose which usually leads to a longer
lifetime in service.
1
Pump suction –centrifugal and turbine pumps are
not self-priming. The suction port/inlet must be
flooded by a source of liquid. This is usually the tank
with water line higher than pump suction.
2
Pump discharge –connection to the application –
more restrictions downstream reduce flowrate.
3
Service pressure gauge –this displays the
pressure between pump discharge and throttling
valve. This is normally higher than the process
pressure gauge. It should never be lower than 2bar.
4
Temperature sensor –on systems where
temperature control hardware is fitted, the sensor is
typically in the discharge line.
5
Fixed orifice throttling valve –if fully closed (fully
CW) the pump is ‘deadheaded’ and will lead to
damage in the short-term. If fully open (fully CCW),
the pump is not restricted in any way –dependent on
process pressure and flow requirements, the valve
can be closed slowly until the desired conditions are
reached.
6
Process pressure gauge –reads the pressure in
the line that is created when the customer’s
application is connected.
7
Discharge to process –cooled/chilled water
connection to the application.
8
Return from process –typically sent to either tank,
airblast radiator or refrigeration heat exchanger.
Annex F-6 220311 Centrif or turbine pump using throttling valve 19

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
Operating Manual; Pressure & Flow Adjustment
Annex F-6
DOCUMENT DETAILS
Date
11/MAR/2022
Author(s)
MJH
Page
2 / 2
Revision
2
ADJUSTING THE THROTTLING VALVE
1
Units with this type of pressure and flow control are typically shipped fully open to prevent deadheading.
When the end user or commissioning engineer first runs the unit, the full force of the pump will be available
without relief –if this is likely to cause damage, the valve can be closed partially, and the service pressure
gauge monitored.
2
Set the chiller/cooler running whilst connected to the application –bleed air from the system as per
instruction in Annex D.
3
Using the service mounted process gauge, use pressure to determine flowrate –centrifugal and
turbine pump flowrates can be determined by reading the pump curve.
4
Where pressure or flow is too high, the throttling valve can be closed down –where pressure or flow
is too low, it can be opened. Typically ATC size pumps to provide some excess pressure availability.
5
Ensure the service pressure gauge is always at a minimum of 2bar.
Annex F-6 220311 Centrif or turbine pump using throttling valve 20