ATC XF050 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
XF050 / XF085 / XF120
DOCUMENT DETAILS
Date
9/JUN/2022
Author(s)
MJH
Page
1 / 5
Revision
1
Opening section XF050, 085, 120 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
XF050 / XF085 / XF120
DOCUMENT DETAILS
Date
9/JUN/2022
Author(s)
MJH
Page
2 / 5
Revision
1
CHANGE LOG
Date
Revision
Page ref
Change
10/JUN/2022
1
ALL
First release
Opening section XF050, 085, 120 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
XF050 / XF085 / XF120
DOCUMENT DETAILS
Date
9/JUN/2022
Author(s)
MJH
Page
3 / 5
Revision
1
PRODUCT SPECIFICATIONS –OVERVIEW
ADMINISTRATIVE DATA
CAD assembly dwg no.
MA503
MA503
MA503
Standard model numbers
XF050
XF085
XF120
PHYSICAL ATTRIBUTES
Physical dimensions
W750 x D1100 x H1060mm
W750 x D1100 x H1060mm
W750 x D1100 x H1060mm
Construction
Sheet steel gauge 1.5mm
Epoxy polyester powder coat
Sheet steel gauge 1.5mm
Epoxy polyester powder coat
Sheet steel gauge 1.5mm
Epoxy polyester powder coat
Mounting type
Skids, transverse mounting
Skids, transverse mounting
Skids, transverse mounting
Acceptable environment
Indoors or outdoors sheltered
Indoors or outdoors sheltered
Indoors or outdoors sheltered
Dry weight
TBC
TBC
TBC
Wet weight
TBC + 45kg
TBC + 80kg
TBC + 80kg
Noise level
≤50dB(A)@1m
≤50dB(A)@1m
≤50dB(A)@1m
Toolless access
No
No
No
TEMPERATURE CONTROL ATTRIBUTES
Technology
Water-to-water heat exchanger
Water-to-water heat exchanger
Water-to-water heat exchanger
Control method
Modulating valve
Modulating valve
Modulating valve
Temperature stability
±0.5°C
±0.5°C
±0.5°C
Cooling capacity condition 1
25kW (5°K rise over supply)
42kW (5°K rise over supply)
60kW (5°K rise over supply)
Cooling capacity condition 2
50kW (10°K rise over supply)
85kW (10°K rise over supply)
120kW (10°K rise over supply)
Cooling capacity condition 3
100kW (20°K rise over supply)
170kW (20°K rise over supply)
240kW (20°K rise over supply)
Maximum ambient
+40°C
+40°C
+40°C
Design flowrate
80L/min
120L/min
150L/min
Temperature range (standard)
+4°C to 50°C
+4°C to 50°C
+4°C to 50°C
Temperature resolution
0.1°C
0.1°C
0.1°C
Maximum Total Heat Rejection
Applied load, plus power in
Applied load, plus power in
Applied load, plus power in
WATER CIRCUIT ATTRIBUTES
System volume
60L
110L
110L
Pump options
P40, P80, P120
P80, P120, P150
P120, P150
Pressure relief control
Optional gate valve
Optional gate valve
Optional gate valve
Standard fittings
1-1/2" BSPPF (ISO G)
1-1/2" BSPPF (ISO G)
1-1/2" BSPPF (ISO G)
Standard chemical compatibility
Hexid, Water, Glycol mix
Hexid, Water, Glycol mix
Hexid, Water, Glycol mix
ELECTRICAL ATTRIBUTES
Standard power supply
400Vac 3~ 50Hz
400Vac 3~ 50Hz
400Vac 3~ 50Hz
Current at 400V 3~
7A (4A/phase)
8A (4.6A/phase)
8A (4.6A/phase)
Standard supply configuration
L1 / L2 / L3 / N / E
L1 / L2 / L3 / N / E
L1 / L2 / L3 / N / E
Standard overcurrent restart mode
Manual
Manual
Manual
SAFETY INTERLOCKS, STANDARDS & INDICATORS
1st party approvals
CE, UKCA
CE, UKCA
CE, UKCA
3rd party approvals
UL/CSA-ready
UL/CSA-ready
UL/CSA-ready
Empty fluid reservoir alarm
Process stop interlock
Process stop interlock
Process stop interlock
Low fluid flow alarm
Available option
Available option
Available option
House water pressure alarm
Available option
Available option
Available option
Process water pressure alarm
Available option
Available option
Available option
Temperature out of range alarm
Standard
Standard
Standard
DC power supply lamp
Standard
Standard
Standard
Fluid tank level alarm
Standard
Standard
Standard
Emergency off
Via overload handle
Via overload handle
Via overload handle
Interlock restored restart mode
Manual (automatic option)
Manual (automatic option)
Manual (automatic option)
Opening section XF050, 085, 120 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
XF050 / XF085 / XF120
DOCUMENT DETAILS
Date
9/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 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 MCB (miniature circuit breaker). 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.
Opening section XF050, 085, 120 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
XF050 / XF085 / XF120
DOCUMENT DETAILS
Date
9/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-2 220609 Shipping & Unpacking - Crane or forklift with caveat
Annex B-14 220609 Site & Environmental Requirements for XF050 XF085 XF120
Annex C-9 220609 Installation - Generic water-cooled with 1.5inch fittings
Annex D-4 201124 Fluid Handling & Startup Procedures - Anti-backfill mechanism
Annex D-8 220610 Fluid Handling & Startup Procedures - XF050 085 120
Annex E-5 210301 KR3 - how to use
Annex E-5P 220527 KR3 Program XF050,085,120 standard
Annex F-5 220610 Centrif or turbine pump without relief
Annex G-5 200219 Troubleshooting - Diagnose PT100 failure
Annex G-11 220610 Troubleshooting - Initial help for XF050 085 120
Annex G-12 210326 Troubleshooting - X-Series modulating control valve functional explanation
Annex H-2 210326 End-user maintenance - water-cooled units with water as fluid
Annex I-5 210302 Maintenance for technicians - Generic non-refrigerated units
Annex J-3 220406 EU DoC X-series
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-10 201111 EU Compliance Statement RoHS
Annex J-19 220610 UKCA DoC X-Series
Annex K-1 200623 Standard warranty terms of ATC
Annex L-12 220610 Volt Free Contacts
Annex M-2 220610 Recommended spares, XF050,085,120 & NSs
Opening section XF050, 085, 120 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-2
DOCUMENT DETAILS
Date
22/JUN/2022
Author(s)
MJH
Page
1 / 1
Revision
3
CRANE OR FORKLIFT WITH CAVEAT (TYPICAL WEIGHT >60kg)
1
Upon receipt, please check that both the packaging and the unit are undamaged. If there is any doubt, it is
vital that both ATC and the carrier are informed.
2
There are no hidden shipping bolts or other fixings.
3
Inspect the packaging for signs of transit damage before signing for the unit. If possible, unpack the unit
before signing. Once the goods are signed for, ATC cannot be held responsible for any transit damage
subsequently found.
4
Remove the unit from its original packaging and ensure that there is no packaging left around cooling ducts.
There is no internal product packaging that requires the product to be opened.
5
As the unit weighs >60kg, it must be lifted with a forklift or a crane. ATC highly recommends that it is not
manually lifted, and that safe slinging and lifting practices are adhered to.
6
The unit sits on two flattened V-shape skids at thefront and
the rear.
There is an 850mm gap in between the skids at the
narrowest point.
A forklift or pallet truck can be used to lift. Both the skids
and the stiffeners can carry the weight of the unit.
If the unit is to be fitted into a small space where it may not
be possible to maneuver a forklift or pallet truck, the unit
can be lifted using an engine hoist or overhead crane.
If hoisting is preferred, it is recommended that slings rated
for the appropriate weight are fed through the skids at the
front and rear and lifted simultaneously from the top.
7
Please retain all packaging in the unlikely event the unit needs to be returned to our local representatives.
8
Always familiarize yourself with safe lifting practices and conduct risk assessments where necessary.
Annex A-2 220609 Shipping & Unpacking - Crane or forklift with caveat 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-14
DOCUMENT DETAILS
Doc. Date
9/JUN/2022
Author(s)
MJH
Page
1 / 2
Revision
1
SITE & ENVIRONMENTAL REQUIREMENTS FOR XF050 XF085 XF120
This guide applies to standard water-to-water heat exchangers with part numbers starting XF050, XF085 and
XF120. It may also apply to a non-standard model if this annex has been selected for the operating manual. It
describes the requirements for all services and conditions necessary for years of trouble-free running. If you
require more detail, please contact ATC on [e-mail] or use 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 and temperatures, -20°C to +40°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. All standard XF050, XF085 and XF120 are three phase coolers.
Mains supply via an earth leakage detecting residual current device (RCD) is recommended.
Current consumption quoted is based on nominal pump sizes P80, P120, P150 respectively.
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
XF050
XF085
XF120
Supply suffix
-3
-4
-8
-3
-4
-8
-3
-4
-8
Voltage range
400Vac
460Vac
208V
400Vac
460Vac
208V
400Vac
460Vac
208V
Voltage tolerance
±5%
±5%
±10%
±5%
±5%
±10%
±5%
±5%
±10%
Frequency
50Hz
60Hz
60Hz
50Hz
60Hz
60Hz
50Hz
60Hz
60Hz
Supply mode
3P+N+E
3P+E
3P+N+E
3P+E
3P+N+E
3P+E
Current (L-L)
7A
TBC
TBC
TBC
TBC
TBC
9.7A
TBC
TBC
Current (L-N)
4A
TBC
TBC
TBC
TBC
TBC
5.6A
TBC
TBC
Overload rating
4-6.3A
TBC
TBC
TBC
TBC
TBC
6-10A
TBC
TBC
Internal PSU fuse
T0.5A
T0.5A
T0.5A
T0.5A
T0.5A
T0.5A
T0.5A
T0.5A
T0.5A
7
House/Primary water supply. House water supply can vary depending on the thermal performance
requirement. As a starting point, ATC XF-series products are engineered to 10’K deltas with nominal
flowrates. Take the XF050; nominal flow of 80L/min on both the house and process circuits will allow the unit
to achieve 50kW capacity with temperatures of +10°C house inlet, +20°C process delivery and +30°C
process return. House flowrates can be lowered only to the extent that house outlet temperature remains at
least 2°K beneath the desired process delivery temperature. Halving flow on either side will yield a doubling
of the return line temperatures. Doubling flow will yield a halving of nominal return line temperature.
8
Clearance. Clearance is required to achieve the following;
a) Ensure the isolator switch on the front face is unobstructed to allow access in case of emergency.
b) Fitting of hoses and electrical supply to the rear of the unit to allow recommended bending radii.
c) Maintenance access points require side panels to be removed.
The exact amount of clearance can be determined by the OEM or end user as process is not affected as it
would be in an air-cooled product. Access for maintenance is the primary consideration.
9
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 planned flowrates without overburdening the process pump.
10
Indoor use only. Altitude up to 2000m above sea level. Ensure the unit has adequate ventilation.
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.
Annex B-14 220609 Site & Environmental Requirements for XF050 XF085 XF120 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-14
DOCUMENT DETAILS
Doc. Date
9/JUN/2022
Author(s)
MJH
Page
2 / 2
Revision
1
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-14 220609 Site & Environmental Requirements for XF050 XF085 XF120 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-9
DOCUMENT DETAILS
Date
9/JUN/2022
Author(s)
MJH
Page
1 / 2
Revision
1
INSTALLATION FOR WATER-COOLED UNITS WITH 1-1/2" BSPPF FITTINGS
This guide applies to the following product groups;
-K-Series, R-Series and G-Series refrigerated units, where heatload is carried away by water supply.
-XR- and XF-Series water-to-water heat exchangers, where heatload is carried away by water supply.
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/cooler have the following characteristics.
1
Short in length –this reduces friction-based pressure drop and additional 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.
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/cooler to
application contains 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 1-1/2” British Standard Pipe Parallel Female (BSPPF) threads (also known
as G threads (ISO228)) by default, for both application/process and house/primary water supply. 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 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-9 220609 Installation - Generic water-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-9
DOCUMENT DETAILS
Date
9/JUN/2022
Author(s)
MJH
Page
2 / 2
Revision
1
BACKFILLING
1
In situations where the chiller/cooler 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 [e-mail].
Annex C-9 220609 Installation - Generic water-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; Fluid Handling & Startup Procedures
Annex D-4
DOCUMENT DETAILS
Date
03/FEB/2020
Author(s)
MJH, LW
Page
1 / 1
Revision
1
LIMITATION OF SINGLE SWITCHING POINT
In a system with a single level switch, there is only one point the water level must be above in order to have the
unit run. As the tank level drains through natural losses, connections/disconnections, etc., the level gets ever
closer to the switching point. In a system where the application and hosing are more flexible, poorly bled of air, or
a small elevation difference exists, it’s not uncommon to see some liquid return to the tank after the unit is turned
off (whether by hand or by interlock). This liquid return (sometimes called drainback) can be enough to re-satisfy
the level switch and re-start the product, thus emptying the tank again and shutting down once more. The product
then enters a cycle of stopping and starting, detrimental to pump health and the electrics that drive it.
ANTI-BACKFILL LEVEL SWITCH ARRANGEMENT
Products with an anti-backfill level switch system are designed to prevent the product from stopping and starting
continuously. A pair of level switches are present in the tank. The first is in the same position as in a single
switching point system. Upon filling, this first lower switch becomes satisfied. Upon continued filling, a second
switch (the upper, or anti-backfill switch) becomes satisfied. As the unit runs, the level slowly reduces –the upper
switch becomes dissatisfied, but the unit doesn’t stop, it keeps going until the lower switch is dissatisfied also
preventing the pump from running dry as it shuts down. As fluid reenters the tank from sources outside the
product, the bottom level switch is re-made, but fluid volume is insufficient to satisfy the upper level switch.
Electrically, the system requires the upper level switch to be re-made before starting again.
PRODUCTS WITH THREE LEVEL SWITCHES
Your product may have three or even four switches. In the event it has more than two, the top switch function is
either an early warning, or an auto-refill point. If it has four switches, the higher one is for auto-refill. Check the
electrical schematic to confirm.
Annex D-4 201124 Fluid Handling & Startup Procedures - Anti-backfill mechanism 11

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-8
DOCUMENT DETAILS
Date
10/JUN/2022
Author(s)
MJH
Page
1 / 1
Revision
1
FILLING, STARTING & DRAINING OF XF050 / XF085 / XF120
This guide describes the filling, starting, and draining processes associated with standard XF050, XF085 and
XF120 models. It assumes the unit is connected to mains and is live. Start with the isolator 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
cooler 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. Ensure the water circuit joints are properly sealed. You should
have a white lamp on (standby) and a green lamp for DC supply voltage OK. You do not need to connect
the house-water side at this point, but be aware there will be no temperature control, and you may see the
temperature range lamp turn off. Be aware that with no active cooling of the primary/house side, the heat
from the pump motor will slowly cause the temperature to rise on the process side.
2
Remove right-hand side panel (viewed from front). Remove the black plastic tank lid (pop-off lid) and
place to the side. Begin filling the tank by pouring in directly. As the level rises, the front panel sight tube will
show you where to stop filling. Both level switches will be covered (and electrically ‘make’) by the time the
‘level full’marker is reached. If you overfill, the overflow line will flood, releasing fluid from the rear overflow
outlet. Expect the level-full lamp to illuminate green on the front panel. Do not put the tank lid back on yet.
3
Turn your attention to the red/yellow overload/isolator handle on the front of the cooler –immediately
after turning this handle to the 12o’clock position, the cooler pump will start and the pipework will begin to
fill. As it fills, the tank level will reduce. The cooler can be allowed to run until it turns off on the level switch,
at which point the green lamp will turn off.
4
Refill the tank to bring the sight tube back to the full mark. Start the cooler again by rotating the handle
around to the 9o’clock position, then immediately back to the 12o’clock position. Continue this process of
filling > running > auto shutdown > filling etc., until the level no longer drops.
5
As the cooler runs, observe the sight gauge on the front of the unit –allow the cooler to run and watch
the water level drop as the air in the system is displaced. Top up as necessary to ensure the unit does not
shut down again. Time to bleed air is highly dependent on system configuration. ATC recommend the
cooler is run for at least 1 hour with the lid removed. Replace lid and side guard once satisfied air is bled.
6
While the cooler runs, review internal and external hoses for signs of leaks.
Caution; Do not run the pump dry. Do not deadhead the pump.
DRAINING
1
Open the left-hand access panel –you will have the pump and tank directly in front of you. The bottom
left-hand corner of the tank has a tee fitting –one end goes to the sight-tube, the other end goes through a
hose to a small service valve that upon rotating through 90° will start to drain the tank.
2
Once the unit is drained, return the drain valve to the ‘stop’ position –any fluid remaining in the tank
will need to be siphoned manually –it is not possible to fully empty the tank.
3
Some fluid will drain from connected hoses –ATC can provide valved quick release connectors to
prevent cooler draining further from the internal hoses. Without quick release connectors, fluid will leave the
unit under gravity. There may still be a small amount of fluid in the system; ATC recommend re-fitting the
red plastic blanking plugs to prevent fluid escaping during movement of the cooler.
4
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-8 220610 Fluid Handling & Startup Procedures - XF050 085 120 12

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Operating Manual; Controller Operation
Annex E-5
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Date
1/MAR/2021
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1
BASIC PROGRAMMING GUIDE KR3 (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-5, i.e. Annex E-5A.
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-5 210301 KR3 - how to use 13

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XF050 / XF085 / XF120 STANDARD PROGRAM PURPOSE
Internal part number
61-591
Manufacturer part number
Ascon Tecnologic KR3
Program purpose
1) Set o/p1 to drive Belimo 0-10Vdc analogue water valve for cooling duty.
2) Set output 2 for temperature out of range alarm. Where not used, these settings can remain.
3) Set remainder of parameters to safe working limits.
XF050 / XF085 / XF120 KR3 PROGRAM
Group inP
Group ‘out’
Group ‘AL1’
Group ‘AL2’
Setting
Value
Setting
Value
Setting
Value
Setting
Value
SEnS
PT1
o1.t
0.10
AL1t
LHdo
AL2t
nonE
dP
1
o1.F
c.rEG
Ab1
n/a
Ab2
n/a
SSc
n/a
A.o1L
n/a
AL1L
-10.0
AL2L
n/a
FSc
n/a
A.o1H
n/a
AL1H
10.0
AL2H
n/a
Unit
°C
o1.AL
n/a
AL1
n/a
AL2
n/a
FiL
oFF
o1.Ac
dir
HAL1
0.5
HAL2
n/a
inE
our
o2F
AL
AL1d
oFF
AL2d
n/a
oPE
100
o2.AL
1
AL1o
n/a
AL2o
n/a
io4.F
nonE
o2Ac
rEU
diF1
oFF
o3F
nonE
diF2
n/a
o3.AL
n/a
di.A
0
o3Ac
n/a
o4F
nonE
o4.AL
n/a
o4Ac
n/a
Group ‘AL3’
Group ‘LbA’
Group ‘rEG’
Group ‘SP’
Setting
Value
Setting
Value
Setting
Value
Setting
Value
AL3t
nonE
LbAt
oFF
cont
PID
nSP
1
Ab3
n/a
LbSt
n/a
Auto
0
SPLL
10
AL3L
n/a
LbAS
n/a
Aut.r
oFF
SPHL
40
AL3H
n/a
LbcA
n/a
SELF
No
SP
20
AL3
n/a
HSEt
n/a
SP2
n/a
HAL3
n/a
cPdt
n/a
SP3
n/a
AL3d
n/a
Pb
5
SP4
n/a
AL3o
n/a
ti
50
A.SP
n/a
td
1
SP.rt
trin
Fuoc
0.50
SPLr
loc
tcH
2
SP.u
inF
rcG
1
SP.d
inF
tcc
2
rS
n/a
Str.t
KM3 only
db.S
KM3 only
od
oFF
St.P
0
SSt
oFF
SS.tH
999.9
Annex E-5P 220527 KR3 Program XF050,085,120 standard 14

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[phone]
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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
nonE
tr.St
n/a
Pr.S1
n/a
diSP
SPo
Pr.G1
n/a
di.CL
0
Pr.t1
n/a
AdE
2.0
Pr.b1
n/a
diS.t
oFF
Pr.E1
n/a
FiLd
oFF
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
!TEST RIG!
cur
n/a
AH.P
999.9
h.Job
n/a
AH.o
!TEST RIG!
t.Job
0
Annex E-5P 220527 KR3 Program XF050,085,120 standard 15

Applied Thermal Control Ltd
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[phone]
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Operating Manual; Pressure & Flow Adjustment
Annex F-5
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Date
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2
CENTRIFUGAL OR TURBINE PUMP WITHOUT RELIEF
This arrangement comprises a centrifugal or turbine type pump without any form of flowrate control or pressure
relief downstream of the pump discharge. Without any relief, it is critical to ensure the pump is not deadheaded. In
systems with low-pressure pumps and no control valves in the connected application, this approach provides a
simple and cost-effective water circuit, albeit one more prone to failure through lack of safety devices. This annex
describes ATC’s default settings and how to adjust the system.
REPRESENTATIVE COMPONENT LAYOUT & FUNCTIONS (IMAGE BELOW FROM EM05)
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 discharge –centrifugal is gravity fed and discharges at 90deg to the inlet.
2
Temperature sensor –may or may not be present on your unit, but temperature is governed at the outlet.
3
Front outlet bulkhead fitting –see Annex C for specific information about connecting to the unit.
4
Front inlet bulkhead fitting (hidden) –as above.
5
Return to Plate Heat Exchanger (hidden) –layouts vary, but in this unit, we return to the PHE. Other
layouts may see a return to tank or return to airblast coil.
6
Tank return –the ‘no relief’ system pictured has returned to tank. Some systems will go straight to pump.
7
Tank suction –the feed to the pump to begin the path again.
Annex F-5 220610 Centrif or turbine pump without relief 16

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
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[phone]
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ADDITIONAL REPRESENTATIVE LAYOUT (IMAGE BELOW FROM XF050)
With the following exceptions, the numbered descriptions apply as per page 1;
2a
Temperature sensor –as per page 1.
2b
Pressure gauge connection –normally routed to front panel.
Annex F-5 220610 Centrif or turbine pump without relief 17

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[phone]
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Operating Manual; Troubleshooting
Annex G-5
DOCUMENT DETAILS
Doc. Date
19/FEB/2020
Author(s)
MJH
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Revision
2
APPLICATION
This guide may apply to your issue if you have a chiller using an Ascon Tecnologic controller, and the display is
currently showing dashes (- - - -) instead of temperature values. Following this guide will provide enough
information to determine if the controller is faulty, or if the PT100 is faulty.
INSTRUCTION
PT100 probes are platinum elements encased in the
stainless sheath pictured right. To ascertain whether
the PT100 is in good health;
1) Power down the chiller and isolate it.
2) Remove the cover(s) of the chiller to gain
access to the probe.
3) Leaving the probe installed in the water circuit,
identify the three small gauge wires (2x red, 1x
white) connected to the controller.
a. The controller schematics pictured below
right show where the wires are
connected to on your chiller.
b. The controller model number will be
visible on either the front of the
controller, or the labels on the controller
inside the chiller.
4) Ensure the wires are firmly in position and the
controller’s terminal block has a good grip.
a. If the wiring has loose strands outside,
remove the wiring from the screw
terminations, cut, strip and re-seat.
b. See if the reseating has cured the issue
by powering the unit back up again.
5) Assuming the display still shows “- - - -“, power
down the unit, isolate and remove the 3 wires
from the controller.
6) Take a multimeter and set it to resistance mode.
Place one probe on the single white wire, and
the other probe on either of the red wires.
7) PT100s read 100Ωat 0°C, and around 107Ωat
+20°C. If you have a reading in this order, then
the PT100 is healthy, and the controller is faulty.
8) If your multimeter reads a value in the MΩ
range, the high resistance indicates either the
wire has been pulled from the platinum element,
or the element itself has fractured, causing a
break in continuity. Naturally, this requires a
probe replacement.
9) It is always useful to have the probe returned to
the us here to return to the manufacturer and
ask for a failure analysis. Please consult with us
to arrange return shipping.
Annex G-5 200219 Troubleshooting - Diagnose PT100 failure 18

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Operating Manual; Troubleshooting & Functional Explanations
Annex G-11
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10/JUN/2022
Author(s)
MJH
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2
GENERIC INITIAL TROUBLSHOOTING FOR XF050-, XF085-, XF120-BASED MODELS
SYMPTOM
POSSIBLE CAUSE
Unit not running
Check all three phases are delivering at least the rated minimum voltage. Check
across L1-to-L2, L2-to-L3 and L3-to-L1. Where your product has a neutral, these
checks can be made L1-to-N, L2-to-N, L3-to-N.
Check the main incoming overload has not been tripped.
Check the pilot light is present on the 24Vdc PSU. Without the PSU, the
interlocks cannot start the pump or control.
If the DC SUPPLY OK lamp is on, ensure the overload handle is turned to the on
position.
Check the tank is filled past the level switch to ensure it can run.
Check the inverter screen (if fitted to your model) for any fault codes.
Noisy operation
Air in the system the has not purged.
Bearing failure in rotating machinery causes noise –try to isolate specific
components to identify the source of noise.
Fluid lines becoming fouled /
containing biological matter
Not using opaque tubing can lead to UV light passing through the tubing,
prompting growth of organisms.
Not following maintenance schedule for cleaning/flushing.
Fluid seen leaking from
system
Fluid may be incompatible with the materials used in chiller/cooler construction.
Contact ATC to ensure the fluid is compatible.
Rapid changes in system temperature can cause some materials to change
shape at a different rate to others and open leak paths. Contact ATC to discuss
alternative materials and parts in water circuit construction if your temperature
range goes beyond the standard for this product range.
Poor cooling capacity
(undercooling)
Excess application thermal heat load. See Annex G-2 for a description on how to
calculate this.
House/primary water temperature has increased from nominal requirement, or
flow has reduced.
Water regulating valve is not opening correctly or blocked by debris restricting
water flow.
Excess cooling capacity
(overcooling)
A reduction in flow of application water can lead to overcooling. Check for
constrictions in the application lines. Review pressure gauge position for values
typically seen in normal satisfactory operation.
Check value that controller presents for outlet liquid temperature. A value
reported that is higher than actual will force the controller to cool without need.
Water regulating valve could be stuck open, allowing excess heat to be removed
from the process water circuit.
Annex G-11 220610 Troubleshooting - Initial help for XF050 085 120 19

Applied Thermal Control Ltd
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[phone]
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Operating Manual; Troubleshooting & Functional Explanations
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Date
26/MAR/2021
Author(s)
MJH
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1
UNITS WITH MODULATING BALL VALVE FOR FLOW CONTROL
This guide may apply to your product if you have a house-water fed chiller that regulates process temperature by
throttling the house water flowrate. This document explains how this works to aid troubleshooting and sales
processes.
CONTROL HARDWARE
1
The modulating control valve assembly comprises a
conventional ball valve with actuator to drive it. The actuator
is driven by a standard modulating signal of 0-10Vdc and
moves to the position defined by the signal from ATC’s
process control. Measuring voltage across terminal ‘U’ and
ground provides a feedback signal for the actuator position.
Mounting or removing the actuator is achieved by a single
screw through the black plastic rotating assembly. The
actuator can be fitted in 90° steps, where 0° must be the
centerline of the valve body. To move fromfully closed to fully
open (90° rotation) or vice versa, should take 15s where
signal is immediately applied to 0V or 10V. The actuator is
overload protected, requires no limit switches and
automatically stops when the end stop is reached.
CONTROL STRATEGY
1
House water enters the product via a
bulkhead fitting. This may be a different
physical size or in a different location on
your product, but it will always enter the
enclosure first.
2
This unit shows an optional house water
minimum pressure switch. Too low a
pressure indicates fault. This switch is
settable. It is upstream of the control
valve (4) to ensure it does not show an
error when the control valve is closed.
3
House water enters the plate heat
exchanger. Through the other side, the
process fluid is running at a constant
flowrate and higher temperature. Design
nominals are +10°K higher than house
water provided for rated capacity.
4
The control valve downstream of the
plate heat exchanger keeps the heat
exchange full and pressurized to ensure
that a partially open control valve doesn’t
spray/atomize incoming house water and
render the system inefficient.
5
Heated house water now leaves at a
similar temperature to the flow heading to
the process. Outlet temperature depends
on the inlet/supply temperature and
thermal load on the unit.
Annex G-12 210326 Troubleshooting - X-Series modulating control valve functional explanation 20