ATC R 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
R05
DOCUMENT DETAILS
Date
23/JUN/2022
Compiled by
MJH
Page
1 / 5
Revision
1
Opening section R05 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
R05
DOCUMENT DETAILS
Date
23/JUN/2022
Compiled by
MJH
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Revision
1
CHANGE LOG
Date
Revision
Page ref
Change
23/JUN/2022
1
All
First release
Opening section R05 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
R05
DOCUMENT DETAILS
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PRODUCT SPECIFICATIONS
Attribute
R05
Weight
25kg
55.1lbs
Heat transfer fluid
volume
2300mL
0.608USGal
Cooling capacity
(Tsetpoint +20°C / +68°F)
(Tambient +20°C / +68°F)
*(Tambient +30°C / +86°F)
500W
1706BTU/h
0.142TR
Temperature stability
0.1±°C
Temperature resolution
0.1±°C
Settable temp. range
+4 to +35°C
Optional temp. range
-10 to +65°C
Power supply
requirement
100-240Vac
50/60Hz
1~ / 2~
1A@240Vac, 2A@115Vac
Sound pressure level
35-64dBa
Controller screen size
4.3” diagonal
Dimensions (W*D*H)
5U 19” rack
500mm / 19.7” deep
Diagnostic functions
PID, compressor and fan
percentage utilization.
Fridge system HP value.
Compressor error states.
Export system log via USB.
Fluid fittings (standard)
1/2" BSPPF
Fluid fittings (option)
Pushfit 12mm
Low fluid level alarm
Visual, 3 level
Controller
Resistive touchscreen,
glove-friendly, pen-friendly.
Tool-less access
No
Overtemperature
protection
Hardware limited
Software settable
Compressor overload
protection
Via PCB function
Overcurrent protection
Fused, 2* T6.3A H250V
Rated duty cycle
Continuous
Compatible heat
transfer fluids
DI water, propylene glycol
mixes, Hexid A4 & A6
Opening section R05 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
R05
DOCUMENT DETAILS
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Revision
1
SAFETY NOTICES
For your safety, we draw your attention to the following warning and caution marks throughout the manual; the
safe operation of an ATC chiller 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.
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; The high integrity refrigeration system 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 refrigeration system automatically invalidates warranty.
Warning; Very cold surfaces and gases, lower than -20°C (-40°F). Severe frostbite hazard.
Warning; Opening the refrigeration system may expose the operator to toxic and corrosive compounds
(HFCs). Take protective measures including suitable eye protection.
Warning; Gases may exceed 15 barg (220psig) during operation.
Warning; Refrigerant is class A1. It does not support combustion but is oxygen depleting. Review
equipment rating label for specific refrigerants and CO2e.
Warning; Water and electricity are in close proximity. Always ensure the unit is isolated before service.
The R-series is protected from overcurrent by mains fusing. Never bypass these components.
Warning; Failure to comply with a ‘warning’ may result in personal injury or death. ATC does not accept
any liability for injury caused through use of this equipment.
Warning; After switching off, the fan blades slow to a stop. Do not open until the fan has stopped
rotating.
Affixed to the chiller’s fan, this symbol printed on yellow background advises of the possible damage to
fingers or other extremities from rotating fan blades. Allow blades to stop before service begins.
Opening section R05 4

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
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R05
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INCLUDED ANNEXES
Specific technical product information is provided in the following series of annexes.
Annex A-1 220310 Shipping & Unpacking - Crane or forklift not typically necessary
Annex B-12 220622 Site & Environmental Requirements for R05
Annex C-6 220309 Installation - Generic air-cooled with 0.5inch fittings
Annex D-1 220623 Fluid Handling & Startup Procedures - Mini & R05
Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4)
Annex F-5 220610 Centrif or turbine pump without relief
Annex G-1 220623 Troubleshooting - Initial help for Mini & R05
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-10 201111 EU Compliance Statement RoHS
Annex J-12 210830 UKCA DoC R-series
Annex J-13 220406 EU DoC R-series
Annex K-1 200623 Standard warranty terms of ATC
Annex M-1 220623 Recommended spares, M-, EM-, R05-Series
Annex R-1 170621 SDS Refrigerant HFC-R134a
Annex R-3 200203 SDS Hexid A4 v6.4
Opening section R05 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-1
DOCUMENT DETAILS
Date
11/MAR/2022
Author(s)
MJH
Page
1 / 1
Revision
1
CRANE OR FORKLIFT NOT TYPICALLY NECCESARY
This guide applies to products that can conceivably be lifted/positioned by one or more persons without the aid of
machinery. Upon reviewing recommendations below, you may opt to use machinery. This is at your discretion.
ATC are not responsible for injury or death sustained through improper handling procedures.
UNPACKING
1
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.
2
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.
3
Please retain all packaging in the unlikely event that the chiller needs to be returned to our local
representatives.
MANUAL HANDLING RECOMMENDATIONS
4
For UL compliance, ATC must make the statement; “as the unit is >18kg, ATC must recommend that 2
persons are used to lift by hand, or a crane”.
5
Your region’s workplace safety regulations may differ. The below information is provided as a guideline only
in the absence of any other regulations. It is based on the United Kingdom’s ‘Manual Handling Operations
Regulations (1992)’.
Lifting items of any weight can cause injury if handled incorrectly, depending on what the load is and the
physicality of the person handling it. Manual handling guidelines suggest that the maximum safe lifting
weight for a woman is 16kg and the maximum safe lifting weight for men is 25kg. These recommendations
change depending on the height the object is lifted to and how the object is carried, outlined in the tables
below.
Recommendations for Men
Height Object is Lifted
Max Weight Held Close to Body
Max Weight at Arm's Length
Head Height
10kg
5kg
Shoulder Height
20kg
10kg
Elbow Height
25kg
15kg
Knuckle Height
20kg
10kg
Mid-Lower Leg Height
10kg
5kg
Recommendations for Women
Height Object is Lifted
Max Weight Held Close to Body
Max Weight at Arm's Length
Head Height
7kg
3kg
Shoulder Height
13kg
7kg
Elbow Height
16kg
10kg
Knuckle Height
13kg
7kg
Mid-Lower Leg Height
7kg
3kg
When two people are lifting an item, the approximate rule is that you should not exceed 2/3rds of the sum of
both individual’s lifting limits. If two men who can carry a maximum of 25kg each are lifting an object
together, then the object should not weigh more than around 33kg. If three people are lifting an object, the
maximum weight of this object should not exceed half the sum of all individual’s lifting limits.
Annex A-1 220310 Shipping & Unpacking - Crane or forklift not typically necessary 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-12
DOCUMENT DETAILS
Doc. Date
22/JUN/2022
Author(s)
MJH
Page
1 / 1
Revision
1
R05 SITE & ENVIRONMENTAL REQUIREMENTS
1
Rack mount –this product is only intended to be used with a ventilated standard 19” rack cabinet. R05 is a
5U high unit, 500mm deep. It must be secured with 4-off end user-supplied M6 bolts for rack cabinet upright
rails. ATC strongly recommends the use of support guides that run from the front upright rail to the back
upright rail of the rack cabinet to support the weight of the chiller.
2
Clean, dust-free environment –R05 units use an internal axial frame fan to provide airflow for cooling the
pump motor, compressor and condenser. Do not block the front or rear vents. The system will shut down if
refrigeration high pressure is triggered.
3
Non-condensing ambient temperature –+5°C to +40°C (+39°F to +104°F). This prevents build-up of
moisture on internal components.
4
Humidity - 80% for ambient temperatures up to +31°C (+88°F), decreasing linearly to 50% relative humidity
at +40°C (+104°F) ambient temperature.
5
Electrical supply
R05
ATC power supply specification
-U
-L
Nominal supply voltage
100-230Vac
24Vdc
Voltage fluctuations
±10%
±5%
Frequency
47Hz to 63Hz
n/a
Mode of supply
1P+N+E / 2P + E
+V, 0V
Current draw at 100Vac
5.8A
12A
Power inlet module
IEC C14
Proprietary
Power inlet rating
10A 250V
25A 600V
Power supply fuse specification
T6.3A
T16A
Power supply fuse location
Inlet module, external access
Internal, DIN-rail mount.
The user must provide protective earth at power inlet. Secondary fuses protecting individual components are
internally-mounted.
6
Clearance –the rack form factor limits clearance considerations to the rear face of the unit. Ensure there is
sufficient room at the rear of the product to remove the power cable without obstruction. Ensure bend radius
of your chosen hose/tube/pipework is not compromised. The front face of the R10 has no vents, but the R20
does –it is a suction vent. Left and right-hand side clearance is dictated by the rack cabinet, but both R10 &
R20 have suction vents on those faces.
7
Plumbing –tubing, piping or hose must be clean and compatible with the fluid to be used. The chiller is
compatible with deionized water and water-glycol mixtures such as Hexid fluid.
8
Indoor use only –altitude up to 2000m.
9
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 other anti-freeze mixtures have the
potential to corrode your application and to damage seals in the chiller.
Annex B-12 220622 Site & Environmental Requirements for R05 7

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 8

Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
[phone]
[e-mail]
[e-mail]
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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 9

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-1
DOCUMENT DETAILS
Date
23/JUN/2022
Author(s)
MJH
Page
1 / 1
Revision
2
FILLING, STARTING & DRAINING OF MINI & R05 PRODUCTS
This annex describes the filling, starting, and draining processes associated with standard Mini and R05 products.
It differs from other ATC chillers/coolers primarily through the user’s interaction with the touchscreen interface.
Read this guide in its entirety before starting the process. You should have hoses connected and made best
efforts to ensure joints are watertight before starting.
FILLING & STARTING
1
Connect the chiller to the electrical supply and switch on at the rear rocker switch. The controller
should begin to load and leave you on the splash screen with ATC logo in the middle.
2
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.
3
Remove the cap from the tank lid. On the Mini, this is at the rear on top. On the R05 this is on the front
panel. Fill the tank to leave 10-20mm (0.4-0.8”) of air between water line and where the lid seals.
4
Turn your attention to the screen on the front of the chiller. Above the settings ‘gear’ icon, you will see
a pump icon. Holding this icon will manually run the pump, and it will ignore any interlock provided by the
level switches. Hold the button until the water line drops to just above the outlet port, then release.
Caution; Do not run the pump dry. Do not deadhead the pump.
5
Repeat the process of filling and manually running the pump. When the level no longer drops when the
pump is run, the unit is filled but we still need to ensure trapped air has been allowed out.
6
Start the chiller by holding the green process start button in the top right. Leave the cap off the tank
for >30mins to allow air to escape. Whilst running, the tank illustration on the user interface ought to stay
green and full.
7
Be aware of the prospect of trapped air becoming compressed in the system. When the chiller is
turned off, the compressed air expands and can push fluid through the tank lid. To avoid this, allow any drop
in level to occur without topping-up early in the 30min air-bleeding cycle. Whilst not foolproof, this is the best
way to avoid backfilling.
8
Check the application and tubing for signs of leaks whilst the chiller is running. Replace the tank lid
when satisfied the system is full and bled of air.
DRAINING
1
On both R05 and Mini, open the ports to gravity-drain the plate heat exchanger and return line. Use
the manual priming button on the touchscreen to empty the tank via the discharge line. Do not run the pump
dry. You may also use a manual siphon tube to empty the tank, although the R05 neck is narrow and should
be measured first. Never turn a chiller upside-down.
Annex D-1 220623 Fluid Handling & Startup Procedures - Mini & R05 10

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-1
DOCUMENT DETAILS
Date
10/DEC/2020
Author(s)
MJH, AMI
Page
1 / 10
Revision
1
XTD043RB-K620G / XTD043RB-K620F (SOFTWARE VERSION 39.4, MINI PROJECT)
Splash Screen
Upon first powering on, the chiller will arrive at this page after a
software loading sequence is complete.
1. Process-start will start fridge and water circuit.
2. Pump priming button runs pump without process starting.
3. Access to settings menu.
4. Service pack refers to software version installed.
5. Serial number is added by ATC during production.
Process View
1. Process stop.
2. Set outlet temperature.
3. Carousel scroll.
4. Settings menu.
5. Actual outlet temperature.
6. System overall utilization.
7. Compressor utilization.
8. High side fridge pressure.
9. Condensing temperature.
10. Fan speed utilization.
11. Fan speed mode.
12. Bypass valve status.
13.Tank level status.
Simple View
1. Actual outlet temperature.
2. Setpoint temperature.
3. Tank level status.
Tolerance Plot
1. Adjusts the plotting resolution to aid visibility.
2. Relative to point 1, the current set resolution.
3. Adjusts the length of time over which data is plotted.
4. Relative to point 3, the current timeframe.
5. Current setpoint, a fixed horizontal line, i.e. a target.
6. A red line will be plot continuously about the black set line.
7. The actual temperature being plotted.
8. Based on the tolerance set at point 2, the upper tolerance.
9. Based on the tolerance set at point 2, the lower tolerance.
1
2
3
4
5
1
2
3
1
2
3
4
5
6
7
8
9
10
11
12
13
1
2
4
5
6
7
8
9
3
Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4) 11

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-1
DOCUMENT DETAILS
Date
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Author(s)
MJH, AMI
Page
2 / 10
Revision
1
Program Mode
1. USB program loading and software management menu.
2. Create new or load existing program.
3. Start loaded program.
4. Scroll right through scheduled setpoints.
5. Scroll left through scheduled setpoints.
6. Adjusts the scale of the X axis to aid visibility of program.
7. Y axis shows the range of setpoint values in program.
8. Vertical line shows programmed change to setpoint temp.
9. Name of loaded program.
10. X axis shows time scale of entire program.
11. Move through carousel onto ‘Engineering View’.
Manage Programs (generate, load from NAND and modify)
Menu accessible via button ‘2’ under ‘Program Mode’.
1. Accept changes and revert to Program Mode above.
2. Save changes to local NAND memory.
3. Back button reverts to Program Mode above.
4. Takes you to ‘Existing Programs’ menu.
5. Name of loaded program in the course of being edited.
6. When line added, tapping the arrows first selects the line,
then allows editing of line time and setpoint temperature.
7. Delete the selected line.
8. Move up to earlier lines where program lines exceed 6.
9. Add a new line. Lines automatically move up if deleted.
10. Move down to later lines where program lines exceed 6.
Save screen
Appears when button ‘2’ from ‘Manage Programs’ is used.
1. Back out to ‘Manage Program’ menu.
Existing Programs in NAND Memory
Menu accessible via button ‘4’ under ‘Manage Programs’.
1. Load highlighted program (reverts to ‘Manage Programs’).
2. Copy highlighted program to new line.
3. Return to ‘Manage Programs’.
4. Delete highlighted program (warning; no confirmation!)
5. Selected program is highlighted grey.
6. When ≥2 programs are in the list, use up arrow to select.
7. When ≥2 programs are in the list, use down arrow to select.
5
4
1
2
3
6
7
10
8
9
5
1
2
3
4
6
6
8
10
7
9
1
1
2
3
4
5
7
6
11
Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4) 12

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-1
DOCUMENT DETAILS
Date
10/DEC/2020
Author(s)
MJH, AMI
Page
3 / 10
Revision
1
Software Management (incl. logs and programs)
1. Error log upload to USB device. Sends a CSV file.
2. Upload programs created on MS Excel.
To generate a CSV template, upload a ‘dummy’ program.
3. Download programs created on-screen into CSV file.
4. Install software update (see Reset Options below).
5. A USB stick is available both uploading and downloading.
6. CSV programs available to download into NAND memory.
7. Software update recognized on USB device.
Reset Options
Menu accessible via button ‘4’ under ‘Software Management’.
1. EEPROM resets all machine settings back to default.
Some software updates will require this to be ticked.
2. EMMC reset deletes all internal memory and log files.
3. Cancel software update.
4. Start update process.
Engineering View
1. When illuminated red, tap to move to error view (below).
2. Scroll up through available parameters.
3. Scroll down through available parameters.
Error View
1. Clear error lists.
2. Scroll up through error list.
3. Return to ‘Engineering View’.
4. Scroll down through error list.
Error Codes
1. Comp. overload/locking.
2. Comp. disconnected.
3. Comp. overcurrent.
4. Comp. abnormal VDC.
5. Comp. overheat.
6. PV PT100 disconnected.
7. Modbus data error.
8. Temp. high level limit.
9. Fluid tank empty.
1
2
3
4
6
7
5
1
2
3
4
1
2
3
1
2
3
4
Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4) 13

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-1
DOCUMENT DETAILS
Date
10/DEC/2020
Author(s)
MJH, AMI
Page
4 / 10
Revision
1
Maintenance Prompt View
1. Move up the parameter list.
2. Move down the parameter list.
3. Date is editable, tap to adjust next check date. When date is
reached, text becomes red.
4. Exclamation mark is shown for overdue. Tap to confirm
check made.
5. Tick mark is shown by black text for maintenance not due.
Passcode Entry
1. Pressing the settings gear icon shows the passcode screen.
Enter 4159 to enter factory settings.
Enter 1234 to enter user settings.
2. Passcode appears in box above keyboard.
3. Select to enter passcode.
Factory Settings (1)
Screen available after successfully entering the passcode.
1. Down arrow scrolls through factory settings pages.
2. Pressing the settings icon again takes you to user settings.
User settings are a cut-back version of factory settings.
3. Return to main carousel.
4. Serial number, commissioning date, default power on, etc.
5. Temperature and pressure display units, etc.
6. Edit the text parameters of various maintenance prompts.
7. Edit temperature and pressure limits before error log.
8. Where capable, modify MODBUS settings.
Factory Settings (2)
Scroll down from ‘Factory Settings’ (1)
Further to ‘Passcode Entry’ above;
1. To access higher level settings, the user settings PIN can
be edited while access has been gained to ‘Factory Settings’.
2. Where standby mode is enabled, this PIN appears to
prevent the user from starting process without PIN entry first.
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Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4) 14

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-1
DOCUMENT DETAILS
Date
10/DEC/2020
Author(s)
MJH, AMI
Page
5 / 10
Revision
1
Factory Settings (3)
Scroll down from ‘Factory Settings’ (2)
1. Modify stop, minimum and maximum compressor speed.
2. Modify fan behavior, speed offset, min and max speed.
3. Modify temperature probe offset.
4. Modify default, minimum and maximum setpoint.
5. Modify input hardware termination positions.
6. Modify output hardware termination positions.
Factory Settings (4)
Scroll down from ‘Factory Settings’ (3)
1. Adjust brightness and screen orientation.
2. View and apply color themes.
3. Adjust real time clock settings.
4. Adjust naming conventions for log and scheduled programs.
5. Adjust controller (and system) behavior.
6. Adjust controller (and system) heating behavior.
Factory Settings (5)
Scroll down from ‘Factory Settings’ (4)
1. Set a new factory PIN for lower level settings access.
2. Reset password if EEPROM reset requests it.
3. Allows adjustment of factory standby PIN.
4. Enable standby mode, (password protected process start).
Machine Information
1. Return to ‘Factory Settings’ main menu.
2. Serial number is added here by factory electronically.
3. Display version, not editable.
4. Commissioning date (factory final test run date).
5. Firmware version, not editable.
6. Select a carousel screen to display upon process start.
7. Software version, not editable.
8. Exit back to main carousel.
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Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4) 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-1
DOCUMENT DETAILS
Date
10/DEC/2020
Author(s)
MJH, AMI
Page
6 / 10
Revision
1
Units of Measure
1. Return to ‘Factory Settings’ main menu.
2. Select Celsius, Kelvin or Fahrenheit for setpoint unit.
3. Select psi or bar for refrigeration condensing pressure.
4. Select Celsius, Kelvin or Fahrenheit for liquid outlet temp.
5. Select Celsius, Kelvin or Fahrenheit for condensing temp.
6. Select whether to display PID with or with a % symbol.
Maintenance Parameters
1. Return to ‘Factory Settings’ main menu.
2. Rename, delete or add new text for reminders.
Limits & Alarms
1. Return to ‘Factory Settings’ main menu.
2. Error log entered when pressure drops lower than setting.
3. Error log entered when pressure runs higher than setting.
4. Error log entered when temperature runs over setting.
Where values are exceeded, a pop-up note appears.
RS485 MODBUS
Only XTD043RB-K620F model can run MODBUS.
1. Return to ‘Factory Settings’ main menu.
2. (Not pictured); single option to enable or disable MODBUS.
3. Set unique address in a multi-system RS485 network.
4. Select start address.
5. Direction of data, select read-write, or read-only.
6. Data transmission rate.
7. Select odd or even.
8. Select half or full; standard ATC wiring is 3-wire half duplex.
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Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4) 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-1
DOCUMENT DETAILS
Date
10/DEC/2020
Author(s)
MJH, AMI
Page
7 / 10
Revision
1
Compressor Settings
This variable speed compressor has been carefully set up by
ATC to work within manufacturer’s limits.
1. Return to ‘Factory Settings’ main menu.
2. Compressor minimum frequency (40Hz is 20% duty).
3. Compressor maximum frequency (200Hz is 100% duty).
4. When a compressor error occurs, the compressor times out
for 60s. This is enforced by compressor control PCB.
5. Frequency issued to instruct the compressor to stop.
Fan Settings
Fan performance is closely linked to overall refrigeration
system health. ATC caution users against making changes.
1. Return to ‘Factory Settings’ main menu.
2. To avoid stalling, the minimum duty default is 17%.
3. To ensure proportional control, the max duty is 45%.
4. Speed offset by fixed value above algorithm requirement.
5. Pulsed control frequency. Set to suit specific fan.
6. Switch between manual and automatic control.
7. Inrush current prevention, if compressor starts at same time.
Calibration (Temperature & Pressure)
In the unlikely event your chiller requires a replacement PT100
or pressure sensor, the previous calibration value(s) may no
longer be valid.
1. Return to ‘Factory Settings’ main menu.
2. Used by the factory to set difference between actual outlet
temperature and that seen by the PT100 probe, in order to
display real temperature.
3. Allows the factory to set pressure offset between
measurement taken from calibrated gauge and that seen by
pressure transducer.
Setpoint Defaults
1. Return to ‘Factory Settings’ main menu.
2. If unit is switched off and on again, with ‘Enable Default’ (2)
active, the default setpoint overrides the last manual setpoint.
3. After power cycling, a default setpoint can be enforced to
prevent chiller moving back to a previous unwanted setpoint.
4. Minimum settable temperature by user.
5. If power is cut when chiller is running (past ‘process start’),
the restoration of power reverts the operating state to that
before the cut.
6. Maximum settable temperature by user.
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Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4) 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-1
DOCUMENT DETAILS
Date
10/DEC/2020
Author(s)
MJH, AMI
Page
8 / 10
Revision
1
Display Settings
1. Return to ‘Factory Settings’ main menu.
2. Rotation of screen through 180 degrees to improve viewing
angle if unit is to be situated above or below eyeline.
3. Set display backlight strength.
Color Theme
1. Return to ‘Factory Settings’ main menu.
2. Scroll through color options.
3. Tap to select color choice.
Date & Time, Real Time Clock
Incorrect setting of this clock will result in log entries and
maintenance prompts referencing date and time incorrectly.
1. Return to ‘Factory Settings’ main menu.
2. Tap each individual setting to make text appear red.
Tap the red arrows either side to adjust value.
Tap the red value to confirm entry.
File Paths
1. Return to ‘Factory Settings’ main menu.
2. For programs created on the controller, a prefix can be
edited to personalize the files.
3. Log files generated can have customized prefix.
It is not recommended to adjust any other values.
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Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4) 18

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-1
DOCUMENT DETAILS
Date
10/DEC/2020
Author(s)
MJH, AMI
Page
9 / 10
Revision
1
PID Cooling Settings (1)
1. Return to ‘Factory Settings’ main menu.
2. Scroll down for more settings.
3. Proportional term adjustment for cooling behavior.
4. Integral term adjustment for cooling behavior.
5. Derivative term adjustment for cooling behavior.
6. Cannot adjust –this is time for a single PID loop.
7. Time elapsed until cooling PID changes to heating mode.
8. Delay counter (7) starts after overshoot exceeds this value.
PID Cooling Settings (2)
1. Return to ‘Factory Settings’ main menu.
2. Scroll up for more settings.
3. Allow heating mode to function via the solenoid valve.
4. ‘Yes’ enables compressor to start running immediately.
5. Integral term removed from PID calculation inside set range.
6. Outside this limit, P-band control is ‘on-off’, i.e. 0 or 100%.
PID Heating Settings (1)
1. Return to ‘Factory Settings’ main menu.
2. Scroll down for more settings.
3. Proportional term adjustment for heating behavior.
4. Integral term adjustment for heating behavior.
5. Derivative term adjustment for heating behavior.
6. Cannot adjust –this is time for a single PID loop.
7. Time elapsed until heating PID changes to cooling mode.
8. Delay counter (7) starts after overshoot exceeds this value.
PID Heating Settings (2)
1. Return to ‘Factory Settings’ main menu.
2. Scroll up for more settings.
3. Allow cooling mode to function via solenoid valve.
4. ‘Yes’ enables compressor to start running immediately.
5. Integral term removed from PID calculation inside set range.
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Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4) 19

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-1
DOCUMENT DETAILS
Date
10/DEC/2020
Author(s)
MJH, AMI
Page
10 /
10
Revision
1
XTD043RB-K620G / XTD043RB-K620F SOFTWARE UPDATE PROCEDURE
1/ Find an empty USB flash drive and ensure that its formatted to FAT32 (they usually are unless
they are changed to something else).
2/ Put the latest version of the file update.ppf and nothing else in the root directory of the flash
drive.
NOTE: the file must not be renamed to anything other than “update” with the extension .ppf
3/ Insert the flash drive into the front of the chiller with the power off.
4/ Turn on the chiller and wait for it to bot to its splash screen.
5/ Start the process running using the Process-start button on the splash screen.
6/ Navigate to the program mode screen by pressing the arrow in the circle button 3 times.
7/ Press the USB button.
8/ Press the update button at the bottom left.
9/ Select RESET EEPROM. And RESET EMMC. And then the tick button, this should begin the update.
NOTE: DO NOT remove the flash drive during the update procedure as this could damage the
controller.
10/ Once complete the chiller will ask to restart and then continue to work as normal once
rebooted, the date and time may need to be changed in the settings menu as well as the serial
number if this has been populated but these are optional, you can then remove the flash drive.
Annex E-1 200707 XTD controller XTD043RB-K620G&F (Mini at SW v39.4) 20