Date 12/06/2024
UPDATED GUIDANCE
USE OF TAP WATER IN ATC CHILLERS
Page 1
Earlier documentation may have indicated that the use of tap water in ATC chillers was permissible under certain conditions. Based on further evaluation and our ongoing commitment to system reliability, we now advise against the use of tap water in any ATC chiller models. This updated recommendation reflects a more comprehensive understanding of global water quality variation.
WHY THIS MATTERS
Water quality can vary widely by region and application. Tap water may contain:
• High mineral content (e.g. calcium, magnesium)
• pH imbalance
• Biological matter (e.g. algae, bacteria)
• Chemical additives (e.g. chlorine, fluoride)
These factors can contribute to:
• Internal corrosion
• Degradation of seals and materials
• Biological fouling
• Reduced heat transfer performance
As such, continued use of unapproved fluids, including untreated tap water, may affect long-term performance in some instances.
CURRENT RECOMMENDATION
To support the ongoing reliability and efficiency of ATC chillers, we recommend using only ATC-approved fluids.
PREFFERED FLUID
Hexid - Providing corrosion protection, freeze protection, algae inhibition, and effective thermal performance.
If Hexid is not available in your region, please contact ATC for guidance.
SUPPORT
For questions regarding coolant compatibility or fluid selection for your specific system, please contact ATC Technical Support.
Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
+44 (0) 1530 839 998
Service@thermalexchange.co.uk
Support@app-therm.com
Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
+44 (0) 1530 839 998
Service@thermalexchange.co.uk
Support@app-therm.com
Date 1/APR/2021 Author(s) MJH
Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
+44 (0) 1530 839 998
Service@thermalexchange.co.uk
Support@app-therm.com
Date 1/APR/2021 Author(s) MJH
Control method House water modulation House water modulation House water modulation
Temperature sensor PT100 PT100 PT100
Stability achieved by PID controller PID controller PID controller
Power supply requirement
Design flowrate 5L/min 10L/min 17L/min
Pressure relief valve Internal, 1-10bar (20-150psi)
Fluid fittings 1/2" BSPPF
Sound pressure level 45dBA@1m
Tool-less access No
Anti-backfill protection Yes
Overtemperature protection Yes
Out of temperature range Yes, visual, on controller
Low fluid level alarm Yes, visual, lamp
Run-dry protection Yes
Low flow warning Yes, visual, lamp
Overcurrent protection Fused, 2* T6.3A H250V
Rated duty cycle Continuous
Compatible heat transfer fluids
Date 1/APR/2021
SAFETY NOTICES
For your safety, we draw your attention to the following warning and caution marks throughout the manual 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
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 8 bar during operation.
Warning; Water and electricity in close proximity to one another. Always ensure the unit is isolated before service. The product is protected from overcurrent by mains fusing. Never bypass this component.
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.
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Date 1/APR/2021 Author(s) MJH
Specific technical product information is provided in the following series of annexes.
Annex A-1 191122 Unpacking - Weighing over 18kg
Annex B-4 220908 Site & Environmental Requirements for XF004, 008, 015
Annex C-2 201007 Installation - XF-Series
Annex D-3 201007 Fluid handling procedures - Generic
Annex D-4 201007 Fluid handling procedures - Anti-backfill mechanism
Annex E-5 200207 KR3 Basic programming guide
Annex E-5D 211123 KR3 Program XF004, 8, 15
Annex F-3 201007 PD pump using discrete PRV
Annex G-7 201008 XF-Series, generic initial troubleshooting
Annex H-2 200909 End-user maintenance - water-cooled units with water as fluid
Annex I-5 201008 Maintenance for technicians - X-series units
Annex J-3 200120 X-series EU DoC
Annex J-5 200706 Conflict Minerals compliance statement
Annex J-7 200715 REACH compliance statement
Annex J-8 200827 POPs compliance statement
Annex K-1 200623 Standard warranty terms of ATC
Annex M-8 220908 Recommended spares, XF004,008,015 & NSs
Annex R-3 200203 SDS Hexid A4 v6.3
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.
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”.
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
Recommendations for
Women
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.
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
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SITE & ENVIRONMENTAL REQUIREMENTS FOR XF004
This guide applies to XF004, XF008 and XF015 water-to-water heat exchangers and 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 on sales@app-therm.com or using the phone numbers in the head of this document.
GUIDANCE
1
3
Storage temperature range. Without process fluids, -20°C to +70°C.
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.
Operating temperature range With appropriate process fluids, -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.
Electrical supply. XF004, XF008 and XF015-based products (including non-standard numbers) can accept
Mains supply via an earth leakage detecting residual current device (RCD) is recommended. 7 Clearance. Clearance is required as follows;
a) Ensure the on/off 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 top and side panels to be removed.
d) It is possible to site multiple machines of the same type side-by-side. 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.
8 Plumbing. Tubing, piping or hose must be clean and compatible with the fluid to be used. The product is compatible with deionized water, tap water and water-glycol mixtures such as Hexid A4 and A6. Ensure the connected pipework is suitable for handling the flowrate of the fitted pump at a system pressure ≥6bar.
9 Indoor use only. Altitude up to 2000m above sea level. Ensure the unit has adequate ventilation.
10 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.
Caution; Do not replace detachable mains cords with inadequately rated cords. Contact ATC for appropriately rated products.
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
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Date 9/MAR/2022
INSTALLATION FOR WATER-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 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 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
4
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.
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
2
3
Standard units are supplied with 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.
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.
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.
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.
The weakest seal is normally the tank lid, and this is typically where fluid will escape the unit.
Ideally, the product will be located higher or level with the product water-line. If this is not possible, a nonreturn solenoid valve kit can be installed as an optional standard assembly.
4 Please raise any questions with the sales team on sales@app-therm.com
FILLING A SYSTEM
a) Check all application valves are open, including solenoid valves and variable position valves.
i) The product will require an open water circuit to pump into
ii) Any obstructions can increase the time, or entirely prevent the bleeding of air from the system.
b) Remove the cap from the tank lid on the top of the product.
i) Fill the tank to just underneath the bottom of the filling port.
c) Turn your attention to the main power switch.
i) Immediately after toggling this switch assuming that the power cord is connected and turned on at the wall the product will begin to pump water
ii) Leave the product to run until it cuts out on the level switch interlock.
iii) Turn the unit off at the mains switch
iv) Fill the tank again to lift the level switches.
v) Start the product again until the unit cuts out again.
Caution; Do not run the pump dry. Do not deadhead the pump.
d) Repeat steps at c) until the chiller tank water level (if visible) doesn’t drop, and the chiller doesn’t cutout on its level switches.
e) With the unit now running;
i) Leave the cap off the tank for >30mins to allow air to escape, or very loosely screwed on to prevent water splashing out of the tank if the unit has a ‘flow through’ design.
f) Check the application and tubing for signs of leaks whilst the chiller is running.
i) Replace the tank lid fully when satisfied the system is full and bled of air.
a) Isolate the unit. Have a suitable bucket or drain on-hand.
i) Remove the tank lid to allow air into the system.
ii) Disconnect hoses individually. Be aware hoses as well as the unit are filled with fluid.
iii) Consider using the red transport plugs to block product ports to give yourself time to empty hoses before continuing to empty the product.
b) Local rules affect where fluid can be disposed of.
i) Ensure hazardous products do not enter the water course and are reclaimed from the unit for professional disposal.
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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.
Physical navigation buttons, up, down, return and enter.
8888.8 is the actual read value on input sensor.
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.
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.
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.
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”.
The configuration parameters are collected in various groups. Every group defines all parameters related with a specific function (control, alarms, output functions).
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
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”).
Enter button; When the upper display is showing a group and the lower display is blank, this key allows to enter in the selected group. When the upper display is showing a parameter and the lower display is showing its value, this key allows to store the selected value for the current parameter and access the next parameter within the same group.
16 Up button; Allows to increase the value of the selected parameter.
17 Down button; Allows to decrease the value of the selected parameter.
18
Pushing both Return and Enter buttons moves back to the previous group. Press return first to start. The selection of the group is cyclic (on a carousel), so it is possible to move back around to the group you require.
Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
+44 (0) 1530 839 998
Service@thermalexchange.co.uk
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Date 23/NOV/2021 Author(s) MJH
Internal part number EA798 (mains) or 61-591 (24Vdc)
Manufacturer part number KR3
Program purpose
n/a
1) Provide a relative band alarm to control lamp on front panel (and if fitted, the VFC for temperature range).
2) Provide a PID-controlled analogue output to maintain setpoint.
3) Set all other values to safe limits.
o2Ac rEU
diF1 o3F nonE
diF2 o3.AL n/a di.A o3Ac n/a o4F nonE o4.AL n/a o4Ac n/a
Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
+44 (0) 1530 839 998
Service@thermalexchange.co.uk
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Date 23/NOV/2021 Author(s) MJH
Group ‘tin’
n/a
n/a
n/a
Pr.G1 n/a
Pr.t1 n/a
Pr.b1 n/a
n/a
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’
t.Job 0
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
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Date 7/OCT/2020 Author(s) MJH
Operating Manual; Pressure & Flow Adjustment Annex F-3
POSITIVE DISPLACEMENT PUMPS & DISCRETE PRESSURE RELIEF VALVE
This arrangement comprises a positive displacement pump (most commonly a rotary vane type) with a springloaded pressure relief valve to provide better overpressure setting control with minimal flow losses compared to fixed orifice bypasses/reliefs This annex describes ATC’s default settings and how to adjust the system
It is important to understand the basic principle that all else being equal, higher flow results in a higher demand for pressure. The motor generates the power required to turn the pump head and create that pressure. The more restrictive a water circuit is, the higher the pressure required to maintain flowrate. Positive displacement pumps are designed to generate high pressure and are mechanically tight - their RPM dictates flowrate See image;
1) Pump discharge – fluid leaves the pump head and enters the gauge-tee assembly. It passes the temperature sensor at the tee, and when the pressure relief is inactive, fluid heads towards no. 2.
2) Outlet to process – fluid heads out of the product to the application. Whatever restrictions lie downstream, fluid leaving this point has not passed through the pressure relief valve.
3) Pressure gauge connection – connection to a pressure gauge on the front panel of the product. This displays the pressure in the water circuit, at the pump outlet, not the application which will be lower.
4) Pressure Relief Valve (PRV) – spring tension in the body of the PRV determines whether fluid travels through point 2 or passes through to point 7.
5) PRV adjustment knob – rotate clockwise to increase maximum delivery pressure. Rotate anti-clockwise to limit maximum delivery pressure.
6) PRV adjustment locknut – release this locknut to adjust no.5. Ensure it is tightened once adjustments are made. If it is not, vibration may cause the adjustment knob to move on itself.
7) Bypass flow outlet – where the pressure requirement to overcome restrictions downstream of no.2 rises to be higher than the setting at no.5, the spring inside no.4 will compress and allow liquid to start bleeding through to no.7. It is important to understand that the nature of the spring means there can be no black and white point for pressure relief setting – the spring will slowly compress and bleed flow until all flow passes through no.7. When fully bypassing, all flow stays inside the chiller to protect the application.
Service@thermalexchange.co.uk
SETTING THE PRESSURE RELIEF VALVE (BYPASS)
Unless otherwise agreed at point of sale, the default setting for this type of pump and PRV arrangement is 3.33bar (50psi). In the absence of external calibrated pressure gauges, it’s possible to use the chiller itself to set this value;
8) Isolate the chiller – always isolate before performing work.
9) Disconnect from the application if already connected – review the draining procedure in Annex D.
10)Connect the chiller’s process inlet to process outlet – a short run of hose around 1-2m (3-6ft) will be adequate.
11)Start the chiller and follow the fill process from Annex D – fluid will now be running through a short loop with very low pressure required to overcome the restriction.
12)With the chiller running, very slowly kink the short run of hose fitted above – this simulates a blocked application – this is known as ‘deadheading’ the pump. Without PRV, the pump motor would stall or hoses might blow off. Watch the pressure gauge climb as you apply the kink.
13)The pressure gauge will eventually stop climbing with the hose fully kinked – note the value; this is the setting of the PRV where all flow is bypassed.
14)Refer to points 5) and 6) above to adjust if required – contact ATC if you’re unsure over whether your desired setting is reasonable for the product you have.
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Date 2/MAR/2021
Author(s) MJH, LW
Unit not running
Noisy operation
Fluid lines becoming fouled / containing biological matter
Fluid seen leaking from system
Poor cooling capacity (undercooling)
Excess cooling capacity (overcooling)
Operating Manual; Troubleshooting Annex G-7
Check the tank is filled past the level switch to ensure it can run.
Check temperature of fluid and pump motor. In the case of these reaching temperatures that could cause damage the unit will switch off.
Check MCB state (XF-Series), mains inlet fuses (XR-Series) any internal fuses (both XF- & XR-Series) to ensure excessive current in-rush has not blown a fuse in the unit.
Air in the system the has not purged
Bearing failure in rotating machinery causes noise
Pay attention to specific components to identify the source of noise.
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 may be incompatible with the materials used in chiller construction. Contact ATC to ensure the fluid is compatible.
Rapid changes in system temperature can cause some materials to change shape at a faster rate than 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.
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.
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.
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PERIODIC MAINTANENCE FOR WATER-COOLED PRODUCTS
This guide may apply to your unit if you have a water-condensed refrigerated unit, or a water-cooled water-towater heat exchanger. These units do not rely on large/multiple cooling fans to reject heat to air, but instead reject heat into a house/primary/building/city water supply.
Caution: Failure to carry out service at the specified intervals may permanently damage your equipment.
Caution: If the mains wiring becomes damaged, contact ATC or a qualified electrician who will be able to supply a replacement of the correct specification.
Soft cloths and IPA are recommended for cleaning metallic surfaces. If any spillages have occurred, best practice is to allow the water to evaporate off and wipe up remaining glycol residue with a cloth. Always clean with power supply isolated.
Print this sheet out and display close to the product to maximize the visibility of maintenance requirements.
39
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Date 2/MAR/2021 Author(s) MJH
MAINTENANCE FOR TECHNICIANS; GENERIC NON-REFRIGERATED UNITS
This guide may apply to your product if you have an X-Series (X, XF, XR) or A-Series product. The guidance below is designed to be non-specific and to raise awareness of potential dangers for a trained engineer carrying out service work
Warning; during operation component temperatures can exceed +70°C, take care when opening unit.
Warning; After switching off, the cooling fan blades continue to rotate (A-Series only). Do not attempt servicing whilst the blades are rotating.
Warning; All products contain water and electricity in close proximity. Ensure the unit is isolated before service. Never bypass overcurrent protection on the mains supply. Never bypass fuses or circuit breakers.
1 Following service or repair by a trained technician, ensure any electrical connections that may have been disturbed are given the ‘tug-test’
2 Ensure earth bonding conductors are re-attached.
3 Ensure the correct fuses are in place
4 Ensure the mains cord being used is to specification and is free from damage
5 Subject the unit to a PAT test to ensure the unit is safe before running.
6 Ensure there are no leaks inside or outside the unit.
7 Using the wiring schematic for guidance, simulate faults to check each interlock’s function.
Applied Thermal Control Ltd
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Date 6/APR/2022 Author(s) MJH Page 19 / 32
Document layout; Governed by Machinery Directive 2006/42/EC, Annex II.
Applied Thermal Control Ltd, 39 Hayhill Industrial Estate, Barrow-upon-Soar, Loughborough, LE12 8LD, UK.
AUTHORISATION TO COMPILE THE TECHNICAL FILE
Mitchell Howard, address as above
Generic denomination; X-Series
Function; Water Heat Exchanger
DESCRIPTION & IDENTIFICATION
Model; All with ‘X’, ‘XR’ and ‘XF’ prefix.
Type; Water cooled heat exchanger.
Serial number; Commercial name; As above.
Not applicable
QMS International Ltd, Muspole Court, Muspole Street, Norwich, NR3 1DJ, UK ASCB Registered; 201409-2
Applied Thermal Control declares that the machinery described above fulfils all the relevant provisions of the directives and standards below.
Directive
Machinery Directive 2006/42/EC (inclusive
Low Voltage Directive 2014/35/EU)
EMC Directive 2014/30/EU
RoHS Directive 2011/65/EU (RoHS 2)
RoHS Directive (EU) 2015/863 (RoHS 3)
Harmonised Standards applied
EN ISO 12100:2010 (MD)
BS EN 61010-1:2010+A1:2019 (LVD)
IEC 61000-6-2:2005
IEC 61000-6-4:2006 +A1:2011
EN IEC 63000:2018
Pressure Equipment Directive (2014/68/EC) Out of Scope. Sound Engineering Practice (SEP) applied.
PERSON EMPOWERED TO DRAW UP DECLARATION
Robert Poniatowski, CEO
Signed in Barrow-upon-Soar, UK, date 6/APR/2022
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Date 03/FEB/2021 Author(s) MJH
CONFLICT MINERALS COMPLIANCE STATEMENT
Applied Thermal Control (ATC) adheres to and embraces the ethical values that support our everyday activities. As an expression of these principles and ethical values, ATC adheres to the principle of responsible sourcing of components containing precious and non-precious metals and metal salts in compliance with applicable laws and regulations.
The metals considered are Tantalum (Ta), Tungsten (W), Tin (Sn) and Gold (Au). ATC actively sources components from suppliers known to be reputable and could demonstrate compliance upon request with the Conflict Minerals acts and guidelines.
ATC uses Gold and Tin in electrical components, on PCBs and in rotating machinery, as governed by technical requirements of products. These metals could potentially originate from conflict mineral sites. As many of our suppliers do not purchase these metals direct from smelters, both they and ATC must rely heavily on information that will be provided by their suppliers to determine the source and chain of the metals in those products.
ATC is committed to working with its customers and supply chain to meet the customer’s specification and requirements with regards to traceability, sourcing requirements and restrictions. ATC commits that, to the best of our knowledge, our suppliers are complying with the conflict minerals act as stated in their documentation. These statements are reviewed, and updates obtained as required.
Mitchell Howard, Technical Manager Signed in Coalville, UK, date 6/JUL/2020
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
+44 (0) 1530 839 998
Service@thermalexchange.co.uk
Support@app-therm.com
Date 03/FEB/2021 Author(s) MJH
WHAT IS THE REACH REGULATION 1907/2006?
REACH is a regulation of the European Union, adopted to improve the protection of human health and the environment from the risks that can be posed by chemicals, while enhancing the competitiveness of the EU chemicals industry. REACH places the burden of proof on companies. To comply with the regulation, companies must identify and manage the risks linked to the substances they manufacture and market in the EU. They have to demonstrate to ECHA how the substance can be safely used, and they must communicate the risk management measures to the users. If the risks cannot be managed, authorities can restrict the use of substances in different ways. In the long run, the most hazardous substances should be substituted with less dangerous ones. REACH stands for Registration, Evaluation, Authorization and Restriction of Chemicals. It entered into force on 1/JUN/2007.
REACH ‘ARTICLE’ COMPLIANCE CONSIDERATIONS
Substances under Annex XVII are restricted either in full (not to be used at all) or for specific uses (can be used in some uses but cannot be used in identified uses).
Applied Thermal Control has contacted all our suppliers and to the best of our knowledge, none of the articles that we sell intentionally contain any of the Annex XVII substances currently on the candidate list in concentrations of >0.1% by weight.
REACH ANNEX XIV COMPLIANCE
Substances under Annex XIV require authorization to use in the EU after sunset date, require communication to downstream recipients when over threshold (0.1% w/w at article level) and require notification to ECHA when SVHC over threshold and imported over 1000kg annually and use not already registered.
Applied Thermal Control has contacted all our suppliers and to the best of our knowledge, none of the articles that we sell intentionally contain any of the Annex XVII substances currently on the candidate list in concentrations of >0.1% by weight.
SVHC LIST COMPLIANCE
Substances of Very High Concern (SVHC) require communication to downstream recipients when over threshold (0.1% w/w at the article level), notification to the European Chemicals Agency (ECHA) when SVHC over threshold and when imported over 1000kg annually and use not already registered.
Applied Thermal Control has contacted all our suppliers and to the best of our knowledge, none of the articles that we sell intentionally contain any of the Annex XVII substances currently on the candidate list in concentrations of >0.1% by weight.
Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
+44 (0) 1530 839 998
Service@thermalexchange.co.uk
Support@app-therm.com
Date 03/FEB/2021 Author(s) MJH
WHAT IS THE POPs REGULATION 2019/1021?
POPs stands for persistent organic pollutants. In Europe, the global Stockholm Convention is implemented through POPs legislation. POPs are organic substances that persist in the environment, accumulate in living organisms and pose a risk to our health and the environment. They can be transported by air, water or migratory species across international borders, reaching regions where they have never been produced or used. International risk management is necessary as no region can manage the risks posed by these substances alone.
The European Parliament (and Council) issued regulation 2019/1021 on 20/JUN/2019, and further amended (regulation 2020/784) on 8/APR/2020
Pesticides;
Aldrin, Chlordane, DDT, Dieldrin, Endrin, Heptachlor, Hexachlorobenzene, Mirex, Toxaphene
Industrial Chemicals; Hexachlorobenzene, Polychlorinated Biphenyls (PCBs)
Industrial Chemical Byproducts; Hexachlorobenzene byproducts; Polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans (PCDD/PCDF), and PCBs.
Perfluorooctanoic acid (PFOA), its salts and PFOA-related compounds.
POPs COMPLIANCE STATEMENT
We certify that to the best of our knowledge, based upon up-to-date information from our suppliers, all products supplied by Applied Thermal Control are fully POPs compliant in accordance with regulations and amendments above mentioned. DECLARATION
Mitchell Howard, Technical Manager Signed in Barrow-upon-Soar, UK, date 27/AUG/2020
Applied Thermal Control Ltd
39 Hayhill Industrial Estate
Barrow-upon-Soar, Loughborough
LE12 8LD, United Kingdom
+44 (0) 1530 839 998
Service@thermalexchange.co.uk
Support@app-therm.com
Date 03/FEB/2021 Author(s) MJH
WHAT IS THE POPs REGULATION 2019/1021?
POPs stands for persistent organic pollutants. In Europe, the global Stockholm Convention is implemented through POPs legislation. POPs are organic substances that persist in the environment, accumulate in living organisms and pose a risk to our health and the environment. They can be transported by air, water or migratory species across international borders, reaching regions where they have never been produced or used. International risk management is necessary as no region can manage the risks posed by these substances alone.
The European Parliament (and Council) issued regulation 2019/1021 on 20/JUN/2019, and further amended (regulation 2020/784) on 8/APR/2020
Pesticides;
Aldrin, Chlordane, DDT, Dieldrin, Endrin, Heptachlor, Hexachlorobenzene, Mirex, Toxaphene
Industrial Chemicals; Hexachlorobenzene, Polychlorinated Biphenyls (PCBs)
Industrial Chemical Byproducts; Hexachlorobenzene byproducts; Polychlorinated dibenzo-p-dioxins and polychlorinated dibenzofurans (PCDD/PCDF), and PCBs.
Perfluorooctanoic acid (PFOA), its salts and PFOA-related compounds.
POPs COMPLIANCE STATEMENT
We certify that to the best of our knowledge, based upon up-to-date information from our suppliers, all products supplied by Applied Thermal Control are fully POPs compliant in accordance with regulations and amendments above mentioned. DECLARATION
Mitchell Howard, Technical Manager Signed in Barrow-upon-Soar, UK, date 27/AUG/2020
a) For how long is my ATC product warrantied?
ATC provides a comprehensive return to base 2-year parts, 1-year labor warranty from delivery as standard on all new equipment, provided it has been installed and operated in accordance with the manual.
b) Where will ATC fulfill the product warranty?
ATC’s standard warranty terms are Return to Base (RTB) – issues with chillers are often easily solvable over the phone or email, or by reviewing ATC’s technical guidance on the web and in the product manual. On occasion, at the discretion of ATC, goods may be serviced on site FOC or a service loan unit may be supplied. Warranty cover excludes the cost of travel by engineers and loan unit rental charges. Obtaining onsite service for a product, even in full warranty, is a chargeable service.
c) Who is liable for shipping charges in the event of warranty failure?
During the first year of the warranty period, freight costs for shipping to ATC are for the customer’s account. Freight costs for shipping from ATC are for ATC’s account. During the second year of the warranty, freight costs to and from ATC are for the customer’s account
d) I’m experiencing problems with my chiller. It’s within warranty – what do I do next?
Contact ATC to discuss the issue you are having. The contact details in the header of this document are an ideal place to start. Be sure to have your model number and serial number on-hand to aid those attempting to solve remotely.
e) Telephone support couldn’t fix my chiller – what do I do next?
An RMA form must be completed. This allows both the end-user and ATC to clarify your details, to set the party responsible for shipping costs, and to set a different return address if desired. Shipping advice is provided, and the end-user must sign a declaration that states the unit is safe to handle. Return the form by email for fastest response.
f) What happens if my chiller failed outside warranty or requires non-warranty repair work?
A purchase order will be requested to cover an initial inspection – this will only be invoiced if the inspection shows there is no fault. If packaging is required, i.e. a crate, a separate charge will be levied. If the end user prefers ATC to arrange a collection, a shipping charge may be levied.
g) Our process must continue running – can we have a loan unit whilst our chiller is in repair?
ATC hold several standard air-cooled chillers at the factory for the sole purpose of offering for loan – these are available on a first-come, first-serve basis. Models up-to 3kW capacity are available.
Recommended spares include all rotating machinery (i.e. motors, fans), all sacrificial elements (i.e. fuses) and parts that users interact with (dials, fittings). Pricing is available from sales@app-therm.com.
HEXID A4 HEAT TRANSFER FLUID
Conforming to Directive 1907/2006/EC
SECTION 1: IDENTIFICATION OF THE SUBSTANCE/MIXTURE AND OF THE COMPANY/UNDERTAKING
1.1. Product Name Hexid A4
1.2. Supplier Applied Thermal Control Limited 39 Hayhill Industrial Estate, Barrow upon Soar, Leicestershire, LE12 8LD. United Kingdom. www.app-therm.com
1.3. Telephone Number +44(0)1530 839998
1.4. Email sales@app-therm.com
1.5. Emergency Telephone Number +44(0)1530 839998
1.6. Intended/Recommended Use Heat Transfer Fluid
SECTION 2: HAZARDS IDENTIFICATION
2.1. Classification of the substance or mixture
The product is not classified as dangerous according to Regulation (EC) No. 1272/2008. This mixture is not classified as dangerous according to Directive 1999/45/EC.
SECTION 3: COMPOSITION/INFORMATION ON INGREDIENTS
3.1. Chemical Nature Water (CAS 7732-18-5), not classified. Propylene glycol (CAS 57-55-6) (REACH 01-2119456809-23) (EINECS 200-338-0) not classified. Fluorescein (trace) and biocide (trace) not classified.
3.2. Food Grade
SECTION 4: FIRST AID MEASURES
General advise No special precautions required. Treat symptomatically.
4.1 Eye Contact
Rinse thoroughly with plenty of water, also under the eyelids. Remove contact lenses after a few minutes and continue rinsing. If symptoms persist, call a physician.
4.2. Skin Contact
Wash off immediately with plenty of water. If skin irritation persists, call a physician.
4.3. Inhalation
4.4. Ingestion
Remove to fresh air. If symptoms persist, call a physician.
Rinse mouth with water. Never give anything by mouth to an unconscious person. If symptoms persist, call a physician.
SECTION 5: FIREFIGHTING MEASURES
5.1. Extinguishing media
Use extinguishing measures that are appropriate to local circumstances and the surrounding environment. Water spray, foam, dry powder or CO2. Alcohol-resistant foam
5.2 Unsuitable extinguishing Media
High volume water jet. Do not use a solid water stream as it may scatter and spread fire.
5.3 Specific hazards during firefighting
In fire conditions, toxic decomposition products may be formed (see also section 10). In combustion, emits fumes, smoke, carbon dioxide (CO2) and carbon monoxide (CO). Heating will cause a pressure risewith severe risk of bursting and explosion, Violent steam generation or eruption may occur upon application of direct water to hot liquids.
5.4. Advice for firefighters
HEXID A4 HEAT
TRANSFER FLUID
Conforming to Directive 1907/2006/EC
In the event of fire, wear self-contained breathing apparatus. Wear personal protective equipment. Promptly isolate the scene by removing all persons from the vicinity of the incident if there is a fire. Keep containers cool by spraying with water if exposed to fire. Collect contaminated fire extinguishing water separately. This must not be discharged into drains. Burning fluids may be extinguished by dilution with water
SECTION 6: ACCIDENTAL RELEASE MEASURES
6.1. Personal precautions
Use personal protective equipment. Avoid contact with skin and eyes. Keep unnecessary and unprotected personnel from entering the area.
6.2. Precaution to protect the environment
Do not flush into surface water or sanitary sewer system. Avoid subsoil penetration.
6.3 Clean-up procedures
Contain the spillage, soak up with non-combustible absorbent material, (e.g. sand, earth, diatomaceous earth, vermiculite) and transfer to a container for disposal according to local / national regulations (see section 13). Keep in suitable, closed containers for disposal. Dike the area of spill to prevent spreading and pump liquid to salvage tank. Treat recovered material as described in section 13 Disposal considerations.
SECTION 7: HANDLING AND STORAGE
7.1. Precautions for safe handling
Keep container tightly closed. Handle in accordance with good industrial hygiene and safety practice. Spills of these organic materials on hot fibrous insulations may lead to lowering of the auto-ignition temperatures possibly resulting in spontaneous combustion.
7.2. Conditions for safe storage
Keep only in the original container.
SECTION 8: EXPOSURE CONTROLS/PERSONAL PROTECTION
8.1. Control parameters
Component: Propane-1,2-diol CAS-No. 57-55-6
Other Occupational Exposure Limit Values EH40 WEL, Time Weighted Average (TWA):, Total vapour and particulates.150 ppm, 474 mg/m3
EH40 WEL, Time Weighted Average (TWA):, Particulate.10 mg/m3
ELV (IE), Time Weighted Average (TWA):, Total vapour and particulates.150 ppm, 470 mg/m3
ELV (IE), Time Weighted Average (TWA):, Particulate.10 mg/m3
HEXID A4 HEAT TRANSFER FLUID
Conforming to Directive 1907/2006/EC
8.2. Exposure controls/Appropriate engineering controls
Local exhaust. If this product contains ingredients with exposure limits, use process enclosures, local exhaust ventilation or other engineering controls to keep worker exposure below any recommended or statutory limits.
Personal protective equipment
Respiratory protection
Filter Type
Suitable respiratory protective device Combination filter: A-P2
Combined particulates and organic vapour type
Hand protection Category short time exposure Break through time> 10 min
Protective index Class 1 When prolonged exposure is expected: Break through time> 120 min
Protective index Class 4 Observe the information of the glove manufacturers on permeability. Protective gloves should be chosen according to Workplace Safety Assessment. Gloves recommended according to EN 374 (protection against chemicals).
Material Chemical resistant gloves made of butyl rubber or nitrile rubber category III according to EN 374.
SECTION 9: PHYSICAL AND CHEMICAL PROPERTIES
9.1
SECTION 10: STABILITY AND REACTIVITY
10.1. Reactivity
Stable under recommended storage conditions. No dangerous reaction known under conditions of normal use.
10.2. Chemical stability
HEXID
A4 HEAT TRANSFER FLUID
Conforming to Directive 1907/2006/EC
10.3. Hazardous reactions
Hazardous polymerisation does not occur.
10.4. Conditions to avoid
Generation of gas from decomposition causes pressure in closed systems. Keep away from direct sunlight. Avoid high temperatures. Avoid temperatures exceeding the decomposition temperature. Avoid UV light.
10.5. Materials to avoid
Strong acids, Strong bases, Strong oxidizing agents
10.6. Hazardous decomposition products
Aldehydes, Alcohols, Ether, Organic acids.
SECTION 11: TOXICOLOGICAL INFORMATION
11.1. Toxicity Oral
LD50 : > 20000 mg/kg (rat) This product can present a small hazard if large quantities are swallowed.
11.2. Inhalation
LC50 : 6.15 mg/l (rat; 4 h; vapour) At ambient temperature the exposure to vapours is minimal due to a low volatility rate. Inhalation may cause irritation to the nose, throat, upper respiratory tract and lungs. No deaths occurred
11.3. Dermal
LD50 : > 20000 mg/kg (rabbit) Prolonged skin contact is unlikely to result in absorption of harmful amounts. Skin irritation by prolonged exposure is unlikely. Repeated contact may cause flaking and softening of skin.
11.4 Eyes
Slight irritation is possible. Direct contact with eyes may cause temporary irritation. Corneal injury is unlikely.
11.5. Sensitisation
Patch test on human volunteers did not demonstrate sensitisation properties.
11.6. CMR Carcinogenicity
Animal testing did not show any carcinogenic effects. Information given is based on data obtained from similar substances.
11.7. Mutagenicity
No data available.
11.8. Reproductive toxicity
No data available
11.9. Specific Target Organ Toxicity
Single exposure no data available Repeated exposure no data available
11.10. Other toxic properties
HEXID A4 HEAT TRANSFER FLUID
Conforming to Directive 1907/2006/EC
Repeated dose toxicity. In rare cases, repeated excessive exposure to propylene glycol may cause central nervous system effects. Aspiration hazard Due to its physical properties, the substance does probably not pose any aspiration hazard.
11.11. Other relevant toxicity information
Handle in accordance with good industrial hygiene and safety practice.
11.12. Experience with human exposure
Health injuries are not known or expected under normal use.
HEXID A4 HEAT TRANSFER FLUID
Conforming to Directive 1907/2006/EC
SECTION 12: ECOLOGICAL INFORMATION
12.1. Acute toxicity
Fish - LC50 : 40613 mg/l (Oncorhynchus mykiss; 96 h) (static test)
Daphnia and other aquatic invertebrates - LC50 : 18340 mg/l (Ceriodaphnia Dubia (water flea); 48 h) (static test)
Algae - ErC50 : 19000 mg/l (Pseudokirchneriella subcapitata (green algae); 96 h) (Growth inhibition)
Bacteria - NOEC : > 20000 mg/l (Pseudomonas putida; 18 h)Chronic toxicity
Aquatic invertebrates - NOEC : 13020 mg/l (Ceriodaphnia Dubia (water flea); 7 d) (semi-static test)
12.2. Persistence and degradability
Biodegradability 81 % (anaerobic; Exposure Time: 28 d)(OECD 301 F)
Readily biodegradable 96 % (anaerobic; Exposure Time: 64 d)(OECD 306.)
12.3. Bioaccumulative potential
BCF - 0.09 estimated Low bioaccumulative potential
12.4 Mobility
Estimated Koc < 1, indicating very high soil mobility.
12.5. PBT and vPvB assessment
Not a PBT or vPvB substance or mixture
12.6. Other adverse effects
Do not flush into surface water or sanitary sewer system. Avoid subsoil penetration. This substance is not in Annex I of Regulation (EC) 2037/2000 on substances that deplete the ozone layer.
SECTION 13: DISPOSAL CONSIDERATION
13.1. Waste treatment methods
Disposal together with normal waste is not allowed. Special disposal required according to local regulations. Do not let product enter drains. Contact waste disposal services.
13.2. Contaminated packaging
Empty contaminated packaging thoroughly. They can be recycled after thorough and proper cleaning. Packaging that cannot be cleaned are to be disposed of in the same manner as the product.
13.3. European Waste Catalogue Number
No waste code according to the European Waste Catalogue can be assigned for this product, as the intended use dictates the assignment. The waste code is established in consultation with the regional waste disposer.
HEXID A4 HEAT TRANSFER FLUID
Conforming to Directive 1907/2006/EC
SECTION 14: TRANSPORT INFORMATION
Not dangerous goods for ADR, RID, IMDG and IATA.
14.1. EEC Regulations
UNNO None Class None Packing Group None
Road & Rail Transport (ADR & RID) None IMDG Not Applicable ICOA None
SECTION 15: REGULATORY INFORMATION
15.1 Classification Not classified as hazardous to users.
15.2. CAS No. 57556
15.3. Risk or Safety phrases None
15.4. Labelling None
SECTION 16: OTHER INFORMATION
Key literature references and sources for data taken from supplier information and data from the "Database of registered substances" of the European Chemicals Agency (ECHA) were used to create this safety data sheet. Other information - The information provided in this Safety Data Sheet is correct to our knowledge at the date of its revision. The information given only describes the products with regard to safety arrangements and is not to be considered as a warranty or quality specification and does not constitute a legal relationship. The information contained in this Safety Data Sheet relates only to the specific material designated and may not be valid for such material used in combination with any other material or in any process, unless specified in the text.