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Thermo / Neslab ThermoFlex 1400 Recirculating Chiller

1. 5 991 5195 1 07 dnjes y 0 SS ld 74 p y SI yun y suonoeJ09 UCD SUOI 99J109 oj deis eui 12 10uueo puooes e Sue oul pesseJd si deis dnjas Aue 310 97435 Thermo Scientific Compliance WEEE RoHS Pretace CSA Approved Laboratory equipment electrical File 105974 C 000 CLASS 8721 05 CAN CSA C22 2 No 61010 1 04 SA C US CLASS 8721 05 ANSI UL Standard 61010 1 CSA approval for the ThermoFlex3500 amp ThermoFlex5000 is pending Products tested and found compliant with the requirements defined in the EMC standards defined by 89 336 EEC as well as Low Voltage Directive LVD 73 23 EEC can be identified by the CE Mark on the rear of the unit The testing has demonstrated compliance with the following directives e LVD 73 23 EEC IEC EN 61010 1 e EMC 89 336 EEC IEC EN 61326 1 For any additional information refer to the Declaration of Conformity that shipped with the unit This product is required to comply with the European Union s Waste Electrical amp Electronic Equipment WEEE Directive 2002 96 EC It is marked with the following symbol Thermo Fisher Scientific has contracted with one or more recycling disposal companies in each EU Member State d
2. d try n Ro ko dre edis 5 6 P1 and P2 Pump Pressure Relief with Flow 5 6 An LA enne EE ERRA 2950 vis fee E O oe 5 11 EIS EC CEG CG RI 5 11 Section6 Preventive Maintenance cccssssssessessesessesesesecseseeseseeseseeees 6 1 Preventive Maintenance 6 1 Pad ra rere tee 6 2 e penn ETT 6 2 26 37 6 4 DIB MT cT 6 6_ ess 6 8 Section7 Troubleshooting eseeeeeee eene nnn nnns 7 1 MT Te eT er Cre err rr tre 7 1 Sees au ae 1 8 Bul uspnps tbe Controller 7 10 Section8 Additional Information eene 8 1 PD AeA Na pe 8 1 Internal Process Fluid Temperature Sensor rdt1 Calibration 9 3 Optional Process Fluid Flow Transducer FLo Calibration 8 5 8 7 BN teri 8 8 Appendix A Country Specific 230 50 Hz 1 O Requirements Appendix B Global Voltage Configuration Instructions Appendix Analog 1 0 and Remote Sensor Appendix 0 _ Serial Communications WARRANTY N
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5. Process 1 4 FPT Rear View Water cooled only Facility water connections Thermo Scientific Thermo Scientific LERIN Top View Shipping crate dimensions approximate ThermoFlex900 1400 ThermoFlex2500 Theri 21 wide 23 wide 35 tall 36 tall s 40 deep 40 deep Side View ThermoFlex900 1400 ThermoFlex2500 ThermoFlex3500 5000 A i 69 4 28 73 6 cm SM 98 7 B a e 30 9 cm 197 38 4 cm Tie 43 7 C ES 2 4 cm 1 2 5 1 2 5 D NA NA NA NA 22 55 9 cm E 14 9 3 0 cm 16 40 9 cm 18 46 9 cm p 29 4 197 33 3 cm 15 39 B 43 11 2cm NM 15 1 cm 43 11 2cm H Lu 6 4 cm zi 6 4 cm ZU 6 4 cm 1 4 2 g 4 2 cm a MN 5 6 J NA NA NA NA Tu 5 0 cm K 13 4 2 cm 19 7 4 2 cm jJ e 3 4 cm L ae 3 9 Bin 1 3 1 cm 1 3 1 cm M 65 4 ZI 69 4 cm 36 92 7 cm N pe 10 0 cm 9 12 7 6 15 2 0 e 27 2 Pa 32 5 cm 12 30 5 P 2 9 3 0 Le 3 2 0 2451 5 62 4 26 67 3 30 77 78 0 R 3 8 6 cm 3 9 2 cm d 8 7 cm 18 47 0 cm 20 E 51 0 cm 2417 62 2 cm T Ire 43 7 cm ae 48 8 294 59 7 U 36 0 Ire 43 8 cm 48 8 V 20 50 8 cm 22 55 9 2D 67 0 cm n Add 1 8 3 cm for SEMI units e Thermo Fisher Scientific reserves the right to change specifications without notice NESLAB
6. 745492 2 or equivalent Communication cables are available from Thermo Fisher Contact us for additional information All commands must be entered in the exact format shown in the tables on the following pages The tables show all commands available their format and responses Controller responses are either the requested data or an error message The controller response ust be received before the host sends the next command The host sends a command embedded in a single communications packet then waits for the controller s response If the command is not understood or the checksums do not agree the controller responds with an error command Otherwise the controller responds with the requested data If the controller fails to respond within 1 second the host should resend the command D 2 NESLAB Thermo Thermo Scientific Appendix D NOTE All byte values are shown in hex hex represents the binary values that must be sent to the chiller Do not use ASCII The framing of the communications packet in both directions 15 Checksum region Lead char Addr MSB Addt LSB Command n d bytes 4 1 d byte n Checksum OxCA OxCC Lead char 0xCA RS 232 0xCC RS 485 Device address is 1 RS 232 Addr msb Most significant byte of slave address RS 232 0 Addr lsb Least significant byte of slave address RS 232 1 Command Command byte see Table of Commands d bytes Number of data bytes to follo
7. Pumping Capacity P 1 P 2 7 100 6 80 5 A 4 60 8 3 a 40 2 _ 20 1 5 10 15 20 LPM 1 2 3 4 5 GPM Flow Rate Pumping Capacity P 3 P 4 Bar PSID 100 6 Pressure 20 40 60 80 100 LPM 5 10 15 20 2D GPM Flow Rate e Pump curves are nominal values e Pump performance results were obtained with no restrictions on the return to the system Please note that utilizing either the external or internal DI option will result in a 0 5 gpm reduction of available flow e Specifications obtained at sea level using water as the recirculating fluid at a 20 C process setpoint 25 C ambient condition at nominal operating voltage Other fluids fluid temperatures ambient temperatures altitude or operating voltages will affect performance e Thermo Fisher Scientific reserves the right to change specifications without notice NESLAB ThermoFlex 2 5 section 2 ThermoFlex900 5000 Dimensions Inches Centimeters Front View Process discharge fluid connection M and L P 1 P2 pump units with a flow transducer 1 2 FPT Process fluid discharge connections D and J P 3 pumps 3 4 FPT and P 1 P2 pumps 1 2 FPT Process fluid return connection Fand P3 P 4 pumps 3 4 FPI Fandl P 1 P2 pumps 1 2 FPT Section 3 for additional plumbing information 2 6 NESLAB ThermoFlex oon
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11. filtered air Typically laboratory or research environment Change set the level using the Setup Loop see Section 4 When the unit exceeds the chosen limit the controller will flash F4KRAG FLLS and if enabled an audible alarm will sound To clear this message ress This will automatically restart the preventive maintenance timer for your filters Each time the unit exceeds the chosen time the controller will remind you that it is time to change your filters If you change your filters before the preventive timer trips you can clear the timer by using the Diagnostic Loop see Section 4 NOTE For air cooled units both the air and fluid filters in the ThermoFlex can be changed while the unit is running For water cooled units only the fluid filter can be changed while the unit is running A NESLAB ThermoFlex 6 1 section 6 6 2 Fluid Filter Bag A Fluid Diffuser NESLAB ThermoFlex A A The reservoir has a fluid bag filter designed to prevent the introduction of particulates into the system Units are shipped with a bag filter in place NOTE The fluid bag filter can be removed with the unit operating A Before using any fluid or performing maintenance where contact with the fluid is likely refer to the manufacturer s MSDS for handling precautions A When it is time to replace the bag gently pull up on the plastic funnel housing to remove it and simply pull the bag out of the unit
12. 10 gpm Q 34 psid 10 gpm 22 psid 15 gpm 59 psid 15 gpm 38 psid ThermoFlex5000 5 C to 40 C 41 F to 104 F 10 C to 40 C 50 F to 104 F 0 1 5000 W 17076 BTU 4400 W 15027 BTU 19 7 2 38 We x 19 x 307 98 7 x 48 8 x 78 0 NA 264 270 303 NA 120 123 138 4 1 gpm 60 psid 3 3 gpm 60 psid 10 gpm Q 34 psid 10 gpm 22 psid 10 gpm 59 psid 10 gpm 38 psid e Specifications obtained at sea level using water as the recirculating fluid at a 20 C process setpoint 25 C ambient condition at nominal operating voltage Other fluids fluid temperatures ambient temperatures altitude or operating voltages will affect performance e Air cooled units retain their full rated capacity at 20 C setpoint in ambient temperatures up to 25 C 77 F For ambient temperatures above 25 C please de rate the cooling capacity 3 for every 1 C above 25 C 77 F up to a maximum ambient temperature of 40 C 104 F Please note that when operating at a process temperature lower than 20 C the de rate percentage may increase due to additional gains from losses to ambient For water cooled units refer to oection 3 e Additional dimensions are shown at the end of this section add 1 8 3 cm to height for SEMI units e Unit weight is for air cooled units Subtract 30 pounds 14 kilograms for water cooled units Add 27 pounds 12 kilograms for global voltage units e Thermo Fisher Scientific reserv
13. Figure 5 2 Internal DI Cartridge Next rotate the cartridge 1 4 turn counterclockwise to remove it Remove the new cartridge from the shipping bag The cartridge has blue and a white connector Lower the cartridge into the unit with the blue connector facing downward Press down on the cartridge lightly to engage and then rotate it 1 4 turn clockwise or until you Hose Fitting feel the filter clock into place Push the hose fitting into the quick disconnect located on the white end of the cartridge Replace the access panel and thumbscrews a Quick Disconnect The Puralite sensor on the back of the unit turns red when the cartridge needs changing Figure 5 3 DI Fittings NOTE The cartridge can be changed with the unit running however since the cartridge runs in a parallel arrangement disconnecting the cartridge adds to the main flow 0 5 GPM for positive displacement pumps The additional flow will cause an increase in system pressure which may cause a high fluid pressure fault A Thermo Scientific Thermo Scientific External 0 Cartridge A Section 5 A partial flow DI filter cartridge is designed to provide between 1 and 3 MOcm water resistivity NOTE The DI option results in a 0 5 gpm reduction of available flow A NOTE The Puralite sensor that comes with the DI cartridge requires a separate power source Do not use a Deionization DI filter cartridge with Inhibited EG or Inhibited PG A DI
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15. Flow Control with ie mE using a 3 way mbed to the auxiliary port on the Flow Readout otu rear of the unit The valve s outlet connection is 1 2 FNPT for P1 P2 pumps 4 FNPT for P3 and P4 pumps Press the controller s down arrow Aga twice to display the controller s FLo display see previous page Turn the valve handle until the desired rate 1s displayed NOTE The valve is sensitive to slight adjustments A P1 and P2 Pump The Pressure Control with Flow Readout works just like the Pressure Pressure Relief with Relief Valve discussed on the previous Flow Readout Pese It allows you to control the pressure going to your application This valve is plumbed into the unit s auxiliary port allowing you to Discharge also monitor the flow rate to your Line Drain application using the controller s FLo Plug display see previous page l is Figure 5 10 Pressure Control The valve s outlet connection is 2 FNPT Anti Dra Units installed below the end user application may allow system fluid to drain back into the chiller and cause spillage The anti drainback valve is designed to prevent any such spillage The valve automatically closes anytime the unit is powered down or if the pump shuts down This option is required if your unit is more than 24 feet below your application or if there is a possibility of flood back due to the occasional opening of the process lines for either
16. analog input pins 6 and 15 The HMI will display 9 50 0 0400 20 00 Use the arrow keys to adjust the display to match the applied input voltage current Allow the analog input to stabilize approximately 10 seconds Enter the measured reference voltage current using the HMI by pressing the enter key The firmware will use this value and the theoretical analog value and those from the low end to calculate a linear gain and offset The display will automatically go to the low calibration message Press enter to calibrate the analog input at the low end Connect 0 50v 0 050mv 4 00ma reference voltage current source to the analog input The HMI will display 0 50 0 050 4 00 Use the arrow keys to adjust the display to match the applied input voltage current Allow the analog input to stabilize approximately 10 seconds Enter the measured reference voltage current using the HMI by pressing the enter key The firmware will use this value and the theoretical analog input value and those from the high end to calculate a linear gain and offset If the gain and offset are acceptable the calibration is accepted and the calibration is now valid at the low end Otherwise the calibration is rejected and a bad calibration error message is displayed Thermo Scientific NESLAB ThermoFlex C 5 Appendix C Analog Output Calibration The analog output uses a 2 point calibration Depending on how the analog
17. low end calibration display repeat the procedure Press the down arrow key until StorE is displayed press the up arrow to accept the calibration press the down arrow key to abort it NOTE After pressing the up arrow button at the StorE prompt wait several seconds before proceeding to ensure that a bad calibration message Er 16 does not appear Premature use of the keypad after pressing may cancel the bad calibration error message A C 8 NESLAB ThermoFlex Thermo Scientific Appendix D NC Serial Communications Protocol NOTE Appendix D assumes you have a basic understanding of communications protocols A Connect your PC to the applicable connector on the rear of the unit Use the Setup Loop see Section 4 to enable serial communications NOTE Once RS232 or RS485 is activated all keypad operations are disabled except for turning the unit off and changing the serial communication s settings GE HE GE eC REED e is used to enable disable and to configure serial communications Range oFF 15232 15485 Default oFF BAud is used to select the speed rate for serial communications Range 9600 4800 2400 1200 600 or 300 bits Default 9600 dATA is used to display the number of bits per communication Range Fixed at 8 StoP is used to indicate the end of the communication packet Range 2 or 1 Default 2 PAr is used as a means to check for communication errors Range even odd or none Defa
18. output is configured 1 Type2 or Type 3 the HMI will display either volts millivolts or milliamps The calibration procedute 15 Start with default high and low endpoints each consisting of a voltage current value and a theoretical DAC value This will permit calibration of either point first Both ends must be calibrated for the entire calibration to be valid Connect a 9 50v 0 400mv 20 00ma reference voltage current meter to the DAC output pins 6 and 7 The HMI will display 9 50 0 0400 20 00 Use the arrow keys to adjust the output to match the display of 9 50v 0 400mv 20 00ma Allow the DAC output and voltage reading to stabilize approximately 10 seconds Enter the measured reference voltage current using the HMI by pressing the enter key The firmware will use this value and the theoretical DAC value and those from the low end to calculate a linear gain and offset The display will automatically go to the low calibration point Use the arrow keys to adjust the output to match the displayed value Allow the DAC output and voltage to stabilize approximately 10 seconds Enter the measured reference voltage current using the HMI by pressing the enter key The firmware will use this value and the theoretical DAC value and 9 those from the high end to calculate a eo i eo linear gain and offset If the gain and offset are acceptable the calibration is
19. the temperature reaches 44 C or below for at least 15 minutes the speed will return to low When in high speed the unit s decibel level increases significantly Thermo Scientific NESLAB ThermoFlex 3 1 Section 3 eZ NESLAB ThermoFlex Air cooled units can be installed with both sides blocked or one side and the rear See illustration below The front of the unit needs a minimum clearance of 24 Air will enter the front of the system and exit through the sides and rear Having two sides blocked can impact the unit s performance due to changes in air flow If your installation requires two blocked sides please ensure that the following requirements are met Process Setpoint Temperature Below 30 C Ambient Below 40 C Before operating the unit in conditions outside any of those listed on this page please contact Thermo Fisher Scientific s Sales Service and Customer Support to review your installation Figure 3 1 Minimum Clearance Thermo Scientific Electrical Requirements A Thermo Scientific Section 3 The unit construction provides protection against the risk of electrical shock by grounding appropriate metal parts The protection may not function unless the power cord is connected to a properly grounded outlet It is the user s responsibility to assure a proper ground connection is provided A The user is responsible to ensure that the power cord provided meets local electrical codes If not contact q
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22. FLO Press 2e and the controller will flash between HiFLo and the flow rate Use 80 to adjust the rate to match the reference flowmeter Decrease the flow to a suitable low end calibration point avoid a zero flow rate Ensure the flow 1s stable Press the key and the controller will lash between LoFLo and the flow tate Use 3 adjust the rate to match the reference flowmeter Press the key and StorE is displayed press o accept both values press xz to abort them NOTE After pressing the GM button at the StorE prompt wait several seconds before proceeding to ensure that a bad calibration message Er 16 does not appear Premature use of the keypad after pressing oy may cancel the bad calibration error message A Thermo Scientific NESLAB ThermoFlex 8 5 Section 8 shaded displays appear only on units equipped with that option indicates press and hold indicates the controller display is alternating between the two displays m Ana Figure 8 4 Flow Transducer Calibration If you have any questions please contact Thermo Fisher Scientific s Sales Service and Customer Support 8 6 NESLAB ThermoFlex Thermo Scientific Section 8 Wetted Materials P1 and P2 Pumps P3 and P4 Pumps 300 Series Stainless Steel 316 Series Stainless Steel Bronze Carbon Carbon Graphite Silicon Carbide Ceramic Fluorocarbon Viton Fluorocarbon Viton Polysulfone Tank
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24. NESLAB ThermoFlex M Ic a1 a2 30 00 cs S Ic a1 a2 30 03 d1 d2 03 cs Ic a1 a2 40 00 cs 5 Ic a1 a2 40 03 d1 d2 d3 cs M Ic a1 a2 48 00 cs S Ic a1 a2 48 03 01 02 d3 cs M Ic a1 a2 50 00 cs S Ic a1 a2 50 03 01 d2 03 cs M Ic a1 a2 60 00 cs 5 Ic a1 a2 60 03 d1 d2 d3 cs M Ic a1 a2 68 00 cs S Ic a1 a2 68 03 01 02 d3 cs M Ic a1 a2 70 00 cs S Ic a1 a2 70 03 01 02 d3 cs M Ic a1 a2 74 00 cs S Ic a1 a2 74 03 01 d2 03 cs M Ic a1 a2 75 00 cs S Ic a1 a2 75 03 01 02 d3 cs M Ic a1 a2 76 00 cs S Ic a1 a2 76 03 01 02 d3 cs Process Alarm Process Alarm Pressure Process Supply Alarm Process Alarm Process Alarm Pressure Process Supply Alarm Process Fluid Setpoint Thermo Scientific Set Status Settings SET KEYSTROKE SET ON OFF ARRAY SET CALIBRATION SET COPY CALIBRATION S Ic a1 a2 84 01 02 03 cs Set Low Alarm Values SET LO FLOW1 SET LO FLOW3 SET LO TEMP1 SET LO ANALOG1 Thermo Scientific Ic a1 a2 80 02 d1 d2 cs S Ic a1 a2 80 02 01 02 cs Ic a1 a2 81 91 S 1 a2 81 01 dncs Ic a1 a2 82 05 91 05 cs S Ic a1 a2 82 07 01 97 cs Ic a1 a2 84 03 01 02 03 cs M Ic a1 a2 BO 02 d1 02 cs S Ic a1 a2 BO 03 01 02 d3 cs M Ic a1 a2 B2 02 d1 d2 cs S Ic a1 a2 B2 03 d1 d2 03 cs M Ic a1 a2 C0 02 d1 02 cs S Ic a1 a2 C0 03 d1 d2 d3 cs M Ic a1 a2 C8 02 d1 02 cs S Ic a1 a2 C8 03 d1 d2 d3 cs Appendix D see Keyst
25. NPT Both connections are cast bronze Connect the FACILITY INLET to your facility water supply Connect the gt FACILITY OUTLET to your facility water return or drain Ensure all connections ate secure and that the proper sealant lubricant for the fitting material is used Figure 3 3 Plumbing Connections Water cooled Units Facility Water Maximum Inlet Pressure must not exceed 150 PSIG Facility Water Maximum Pressure Differential must not exceed 50 PSID under any condition Pressure Differential Inlet Pressure Outlet Pressure Thermo Scientific section 3 The facility water must meet the following conditions for the ThermoFlex1400 units to maintain its full rated capacity 4 5 Facility Temperature C NO Facility Pressure Drop PSID 0 05 1 0 15 20 25 3 0 35 Facility Flow GPM The facility water must meet the following conditions for the ThermoFlex2500 units to maintain its full rated capacity Facility Temperature C Facility Pressure Drop PSID 6 Facility Flow GPM The facility water must meet the following conditions for the ThermoFlex3500 and ThermoFlex5000 units to maintain its full rated capacity Facility Temperature C Facility Pressure Drop PSID Facility Flow GPM Thermo Scientific NESLAB ThermoFlex 3 7 section 3 Fluid Requirements Never use flammable or corrosive fluids with this unit Do not use automotive antifreeze Commercial antifreeze
26. Replacement bags are available from Thermo Fisher Scientific Fluid Bag Filter Funnel Housing Wire Mesh Fluid Diffuser Figure 6 1 Fluid Filter Bag and Diffuser When you remove the bag you will notice a wire mesh fluid diffuser inside the reservoir supply line The diffuser is used to help streamline the flow into the reservoir After several bag replacements turn the unit off and remove the diffuser to inspect it for debris damage The fluid velocity into the reservoir will rapidly increase with the diffuser removed and cause splashing Turn the unit off before removing the diffuser This is especially critical when using ethylene propylene glycol NOTE To prevent particulates from entering the reservoir ensure the fluid bag filter is in place before removing the diffuser A Do not operate the unit unless the diffuser is installed A Thermo Scientific section 6 Reservoir The user is responsible for maintaining reservoir fluid quality Check the uid on a regular interval Start with frequent checks until a regular Cleaning interval based on your application is established If cleaning is necessary flush the reservoir with a fluid compatible with the process fluid and the unit s wetted parts see Section 8 with the fluid is likely refer to the manufacturer s MSDS for handling Before using any fluid or performing maintenance where contact precautions A Reservoir Sight Tube Clean the
27. ThermoFlex section 2 2 1 section 2 2 8 NESLAB ThermoFlex Thermo Scientific Section3 Installation Site Requirements Ambient Temperature Range 10 C to 40 C 50 F to 104 F Relative Humidity Range 10 to 80 non condensing Operating Altitude Sea Level to 8000 feet 2438 meters Overvoltage Category Pollution Degree 2 Because of the decrease in air density maximum temperature for the air entering the ThermoFlex is reduced by 1 C per 1 000 feet above sea level In addition cooling capacity is reduced 1 2 per 1 000 feet above sea level Never place the unit in a location where excessive heat moisture inadequate ventilation or corrosive materials are present A NOTE Fluid temperatures at the application may differ from the chiller due to environmental heat loss gain Heat is also lost through the plumbing when the setpoint is at or below room temperature Applications with long lengths of plumbing may need additional insulation A Units installed below the end user application may enable system fluid to drain back into the chiller and cause spillage Thermo Fisher offers an anti drainback kit to prevent any spillage see Section 5 NOTE ThermoFlex2500 air cooled units are equipped with a two speed fan Should the unit s internal ambient temperature reach 50 C for 30 seconds or reach 53 C the fan speed will switch from slow speed to high speed to maintain internal temperatures within acceptable limits When
28. accepted and the calibration is now valid at the low end Otherwise the calibration is rejected and a bad calibration error message is displayed C 6 NESLAB ThermoFlex Thermo Scientific Appendix C Remote Sensor Connector Pinout Table 3 U In 8 Red 4th wire not connected to the control board Figure C 2 Remote Sensor Connector Thermo Scientific NESLAB ThermoFlex 7 Appendix C Remote Sensor Calibration This procedure requires a running unit and a calibrated reference thermometer Using OPt loop ensure the remote setpoint mode is enabled rSEt NOTE If it is more convenient perform the low end calibration before doing the high end A Do not pick calibration points that are outside the safe operating limits of the fluid in your application For example with water 40 C and 5 C are typical high and low calibration points Place the remote sensor and a calibrated reference thermometer in the high temperature remote reservoir Ensure the fluid temperature is stabilized Press the key and the controller will display rtd H Press again and the controller will flash between rtd H and the temperature Use the arrow keys to adjust the temperature to match the reference thermometer Press the key again to accept the value 20 Place the remote sensor and calibrated reference thermometer in low temperature reservoir At the rtd L
29. after oressino WENN may cancel the bad calibration error message A NESLAB ThermoFlex 8 3 section 8 shaded displays NEM appear only on units equipped with that option indicates press and hold indicates the controller display is alternating between the two displays 2 gt gt Figure 8 3 Internal Temperature Sensor Calibration If you have any questions please contact Thermo Fisher Scientific s Sales Service and Customer Suppott 9 4 NESLAB ThermoFlex Thermo Scientific Section 8 Optional Process Fluid The ThermoFlex has been designed to minimize the need for calibration Flow Transducer FL 0 However if calibration is desired or recommended by our Sales Service i i and Customer Support please use the following procedure Calibration This procedure requires a running unit a calibrated reference flowmeter and an external flow control valve Connect a calibrated reference flowmeter to the outlet line Using an external flow control valve increase the flow to a suitable high end calibration point Ensure the flow is stabilized To enter the Calibration Loop ensure the controller display is displaying the process fluid temperature see the diagram on the next page Press and hold the vie then press the key The display will indicate CAL Press the key and the controller will display rtd1 Press Ax until the controller displays
30. and 14 Dry Relay Contact Reference to pin 11 Closes if either level switch is in the low position for more than 1 second Dry Relay Contact Reference to pin 11 Closes when any configured fault or warning occurs see Table 2 Dry Relay Contact Reference to pin 11 Closes when pump is turned on Opens when pump is turned off Common for analog signals pins 2 7 and 15 Analog Voltage Output 0 10VDC 10mV C or 4 20mA Reference to pin 6 This voltage output is proportional to the reservoir fluid temperature Default scale 0 10V where OV Low Temp Span 10V Hi Temp Span Optional Range 10mV C Ex 200mV 20 C Max Load 10V 5mA or 4 20mA 4mA low temp span 20 mA high temp span maximum output current bmA 10VDC Contact us for details Dry Relay Contact Reference to pin 11 Closes when a low flow occurs while the pump is on Note To allow the pump to get up to speed at startup the pump runs for 3 5 seconds before the low flow sensor is read Dry Relay Contact Reference to pin 11 Closes when any of the configured faults occur see Table 1 Dry Relay Contact Reference to pin 11 Complement of pin 9 open when pin 9 is closed Common for all relay contacts pins 3 4 5 8 9 10 Digital Input Isolated Reference to pin 1 Connect to pin 1 to allow unit to be remotely turned on off through pin 14 REMOTE START Note 1 All relay contacts except for Pin 10 are normally OPEN when p
31. application swaps or unit servicing See Section 8 for additional draining information 5 6 NESLAB ThermoFlex Thermo Scientific Thermo Scientific section 5 SEMI units were evaluated and found compliant with SEMI 82 0703 Product Safety Assessment SEMI 58 0705 Ergonomic Assessment SEMI 514 0704 Fire Risk Assessment Emergency Off EMO A guarded red mushroom shaped push button switch with twist to reset is provided in the front of the unit to turn off the unit in case of an emergency The button head is engraved with EMO in large white filled letters NOTE The EMO is controlled by a safety circuit and is not influenced by the unit s firmware softwate A Activation of the EMO button will remove power from the main contactor coil stopping operation of the unit The controller will display Er 48 Resetting the EMO button will not restart the unit After all hazards have been removed reset the unit by pushing the RESET button on the control panel In the local mode the unit will restart by pressing the START STOP button again In the serial communications mode send the appropriate start command In the analog digital I O mode cycle the on off input Unit Circuit Breaker Interrupt Rating The rear panel mounted unit main power circuit breaker has an Interrupting Capacity AIC of 3 000 amps Lockout Tagout LOTO Before performing Chiller maintenance the energy sources associated with the Chiller system must be l
32. claim Under ICC regulations this is your responsibility Out of Box Failure An Out of Box Failure is defined as any product that fails to operate in conformance with sellers published specifications at initial power up Install the unit in accordance with manufacturer s recommended operating conditions within 30 days of shipment from the seller Any Temperature Control product meeting the definition of an Out of Box Failure must be packed and shipped back in the original packaging to Thermo Fisher Scientific for replacement with a new unit Seller to pay the cost of shipping Customer must receive a Return Material Authorization RMA from Thermo Fisher prior to shipping the unit Thermo Scientific Safety Warnings Thermo Scientific Section 1 Safety Warnings are posted throughout the manual These warnings are designated by an exclamation mark inside an equilateral triangle and text highlighted in bold Read and follow these important instructions Failure to observe these instructions can result in permanent damage to the unit sionificant property damage or personal injury or death The lightning flash with arrow symbol within an equilateral triangle 1s intended to alert the user to the presence of non insulated dangerous voltage within the unit s enclosure The voltage may be of significant enough magnitude to constitute a risk of electrical shock Make sure you read and understand all instructions and safety
33. contains silicates that can damage the pump seals Use of automotive antifreeze will void the manufacturer s warranty A Acceptable fluids are Filtered Single Distilled water 0 95 Ethylene Glycol Water 0 95 Propylene Glycol Water Deionized water 1 3 compensated Check the fluid concentration on a regular basis Changes in concentration can impact system performance Before using any fluid or performing maintenance where contact with the fluid is likely refer to the manufacturer s MSDS for handling precautions A Ethylene glycol EG is hygroscopic it will absorb water from its environment This can affect the freezing point and boiling point of the fluid over time This may result in system failure A When using EG water PG watet top off with EG water or PG water Do not top off with plain water Topping off with plain water can severely affect the freezing point and boiling point of the fluid This may result in system failure A Do not use a Deionization DI filter cartridge with Inhibited EG or Inhibited PG A DI filter will remove inhibitors from the solution rendering the fluid ineffective against corrosion protection Also inhibitors increase fluid conductivity A gt 3 8 NESLAB Thermo Scientific Water Quality and Standards Process Fluid Permissible PPM Microbiologicals algae bacteria fungi 0 Inorganic Chemicals Calcium lt 25 Chloride l
34. filter will remove inhibitors from the solution rendering the fluid ineffective against corrosion protection Also inhibitors increase fluid conductivity A If there is a cartridge in place first undo the hose fitting by pressing on the quick disconnect located on the top white connection The DI Cartridge will overpressure if it is removed from the unit before removing the hose fitting A Remove the new cartridge from the shipping bag The cartridge has a blue and a white connector Lower the cartridge into the bracket with the blue connector Figure 5 4 External DI Cartridge facing downward Press down on the cartridge lightly to engage and then rotate it 1 4 turn clockwise or until you feel the filter click into place Push the hose fitting into the quick disconnect located on the white end of the cartridge The Puralite sensor turns red when the cartridge needs changing NOTE The cartridge can be changed with the unit running however since the cartridge runs in a parallel arrangement disconnecting the cartridge adds to the main flow 0 5 GPM for positive displacement pumps The additional flow will cause an increase in system pressure which may cause a high fluid pressure fault A NESLAB ThermoFlex 5 3 Section 5 5 4 P1 and P2 Pump Pressure Relief Valve Internal Configuration NESLAB ThermoFlex The pressure relief valve located on the top left rear of the unit is used to set the desired s
35. gt M Looking for more information AY Artisan Scientific Visit us on the web at http www artisan scientific com for more information QUALITY INSTRUMENTATION GUARANTEED Price Quotations Drivers Technical Specifications Manuals and Documentation Artisan Scientific is Your Source for Quality New and Certified Used Pre owned Equipment Tens of Thousands of In Stock Items Fast Shipping and Delivery Equipment Demos Hundreds of Manufacturers Supported Leasing Monthly Rentals Consignment Service Center Repairs InstraView Remote Inspection Experienced Engineers and Technicians on staff in our Remotely inspect equipment before purchasing with our State of the art Full Service In House Service Center Facility Innovative InstraView website at http www instraview com We buy used equipment We also offer credit for Buy Backs and Trade Ins Sell your excess underutilized and idle used equipment Contact one of our Customer Service Representatives todayl Talk to a live person 888 88 SOURCE 888 887 6872 Contact us by email sales artisan scientific com Visit our website http www artisan scientific com Label 1 Label 2 Thermo Scientific NESLAB ThermoFlex Recirculating Chillers Thermo Scientific Manual P N U00933 Rev 07 11 08 Installation Operation Basic Maintenance Visit our Web site at http www thermo com tc Product Service Information Applications Notes MSDS Form
36. panel Use a Philips head screwdriver to remove the five screws indicated in the illustration below Slide the panel back approximately one inch then lift slightly from the rear to disengage the panel s two tabs from their slots Install a 16 ID tube on the drain petcock valve located on the lower end of the exchanger Open the valve to allow fluid to drain into an external device When draining is complete close the valve and replace the panel A wet vac is needed on the facility water inlet connection to thoroughly drain any remaining fluid from the lines oor En l peo ALL il 2 VELIT i TLI prij Ea Petcock Valve Figure 8 2 Water Cooled 8 2 NESLAB ThermoFlex Thermo Scientific Internal Fluid Temperature Sensor rdt1 Calibration Thermo Scientific Section 8 The ThermoFlex has been designed to minimize the need for calibration However if calibration 15 desired or recommended by our Sales Service and Customer Support please use the following procedure This procedure requires a running unit and a calibrated reference thermometer NOTE Uninsulated applications may cause the internal temperature and an external reference temperature to differ and to fluctuate If inaccurate calibration is suspected place the reference thermometer as close to the ThermoFlex process outlet as possible A NOTE If it is more convenient perform the low end calib
37. seconds Default 10 seconds Exceeding this limit flashes Lo P1 and if enabled sounds the alarm The unit reaction depends on the alarm configuration see ALr on next page Figure 4 6 Setup Loop All Units Thermo Scientific NESLAB ThermoFlex 4 7 section 4 CONTINUED FROM PREVIOUS PAGE ALr is used to configure the unit s reaction for Gens gt ALT Ar Je exceeding an alarm limit temperature pressure Be and flow optional The selected configuration will apply to all the alarms The unit will either shut down or continue to run In each configuration the controller will display the error code and sound the audible alarm if enabled Range FLt or indC Default FLt Sound is used to turn the audible alarm on off Range on or off Default on StArt is used to enable disable the auto restart Range on ot off Default off is used to set the preventive care cleaning frequency reminder for the unit s air and fluid filters in hours The time selected is based on your operating environment see Section 6 Range off Default 11 L1 1000 hours L2 2000 hours L3 3000 hours Exceeding this limit flashes FLtrS see Section 6 NOTE If your unit is equipped with any of the Optional Features refer to the next page A Save all changes StorE Abort all changes ERE Figure 4 6 Setup Loop All Units When the display indicates StorE pr
38. soft bristle brush or wash it Shake off as much of the excess water as possible before reinstalling Thermo Scientific section 6 o change the filter remove the three screws securing the filter to the To change the filt the th the filter to th grille assembly and then pull on the filter s plastic brace to remove it The easiest way to replace the filter 1s to bow it as shown below and slide one end under the tabs on the grille then under the other end Replace the screws Press the grille back into place For water cooled units tighten the screw at the top of the grille Figure 6 4 Condenser Filter Thermo Scientific NESLAB ThermoFlex 6 5 Section 6 6 6 DI Filter Optional NESLAB ThermoFlex Establish a preventive maintenance schedule for the DI filter cartridge based on your specific application A Puralite sensor is located on the back of your chiller The sensor will illuminate red when it is time to change the DI filter cartridge Figure 6 5 Puralite The unit also has a separate integrated audible alarm that works independently of the Puralite The alarm is based on unit run hours that will alert you when it is time to change your filter This feature is especially helpful if the Puralite sensor is not readily accessible see Setup Loop in Section 4 If you already know how often your DI filter needs changing you can input the number of hours into the Setup Loop s dl t display see Section 4
39. 07 91 d2 d3 04 95 96 d7 cs Master Byte 01 d2 04 05 Slave Byte d1 d2 d3 d4 d5 06 07 Identifier Byte Entered Value m s b Entered Value Entered Value l s b Identifier Byte Pass Fail Byte Qualifier Byte Entered Value m s b Entered Value Entered Value Entered Value l s b Thermo Scientific Notes Indicates the item to calibrate and whether it is the high or low point The calculated value should match this after the calibration is complete This is a 32 bit int which is the value x1000 For example 20 C is d3 Entered Value represented by 20000 Notes Indicates the item to calibrate and whether it is the high or low point 0 Fail 1 Pass Appropriate units precision 3 Returns the most recently accepted calibration point This is a 32 bit int which Is the value x1000 For example 20 C is represented by 20000 NESLAB ThermoFlex 0 11 Appendix D Identifier Byte Bits b 7 m s b b 6 b 0 Notes Low or High 02 Low 1 High 7 bit ID 00h 01h 02h 03h 04h 05h 06h 07h 10h 11h 12h 13h 14h 15h 16h 17h 18h 19h 20h 21h 30h 31h 32h 33h 38h 39h RTD1 RID2 RTD3 RT D4 RID5 RTD6 RID RTD8 ANALOG IN 1 ANALOG IN 2 ANALOG IN 3 ANALOG IN 4 ANALOG IN 5 ANALOG IN 6 ANALOG IN 7 ANALOG IN 8 RESISTIVITY 1 RESISTIVITY 2 FLOW1 FLOW2 ANALOG IN 9 ANALOG IN 10 ANALOG IN 11 ANALOG IN 12 ANALOG OUT 1 ANALOG OUT 2 Example Calibrate th
40. 1 eere SSN e cy pu 1 IH use ejdsip eu e SSOld e zt e 2 01 9 p ur S pini 991 5195 1 4 H T sun Je 10 02 0 6 54915 dN 12215 euj 40 pasn 11 1 Buissaid q 1uiodies ou ued 5 y ejdsip JIM BY 51215 jun y ueuM Mou s dnies 941 55 e jae 330 610510 O aem 55910 e uo pue uis ysel ejdsip eu 559 4 Taus uo 01224 440 10 uo 1594 11y1S SSOlde Taus y snfpe qum OSN e Sex a OL pue ueevieq ejdsip eu e spuooes 01 A10 9e4 spuooes 0 0 0 umop WIT 07 24 ued eu euin jo ujBue eui s Av T3P 13 _ SSdlde Taus y snfpe om osn j e 2 001 IH eu e 559 4 ISd 001 1019e4 154 001 01 p WWI 44 i UBIH
41. 15 VAC 60 Hz 10 20 100 VAC 50 60 Hz 10 20 200 208 230 VAC 60 Hz 10 15 200 230 VAC 50 Hz 10 16 15 13A ThermoFlex2500 Voltage Frequency Phase Branch Circuit Requirements 200 208 230 VAC 60 Hz 10 20 200 230 VAC 50 Hz 10 16A1 15A 13A ThermoFlex3500 5000 Voltage Frequency Phase Branch Circuit Requirements 200 230 VAC 50 60 Hz 10 20A 208 230 Pump 60Hz 10 30A Line Cord Plug 9 15P 9 15P 6 15P 6 15P Line Cord Plug 5 20P 5 20 b 15F 6 15P Line Cord Plug 6 20P 6 20 Line Cord Plug 6 20 6 30 Units selected for 230 VAC operation have a range of 10 to 7 Refer to Appendix for country specific ratings For installation information on Global Voltage units refer to Appendix B Refer to the nameplate label located on the rear of the unit for specific electrical requirements 34 NESLAB ThermoFlex Thermo Scientific Plumbing Requirements Thermo Scientific gt gt section 3 Ensure that the shipping plugs are removed from all fittings before installation A Never connect the process fluid lines to your facility water supply or any pressurized liquid source A To prevent damage to the unit s plate exchanger centrifugal pumps requite a 3 8 gpm 14 9 Ipm minimum flow rate A NOTE To prevent a pump discharge pressure error code ensure your plumbing installation will develop a back pressure greater than 4 PSI A The process fluid plumbing conn
42. 3uvjsuoo ST peo INOA FT yUSTGuI MOT 3urod3os yovas 03 2q 03 JOU yun 23n3e32duu23 32947 e Tsd Jo arum 32s21d K1035vj AOA sso oaq UMOP 1845 put spuooss Qc 991 TAP AA HAOL V 9099 06 Utt 193975 103 tsd GT jo ones 195924 4109328 5 pmp MOAIS owy umop anus T aru y uonoag Iq oxnssoad sso oaq 6 JO 95924 4103281 MOTO anus TA WU 84 X9jjouueu av ISAN jjo pouan sr 3urod3ss JO st JUTOd Jas v 123j UVI 10332 2u T 330ddng 12ui03sn SALG INO 330ddng SALG INO 330ddng SALG INO 12103819 SALG INO 78 900296 225 4 ouop stA 1r o3nsuo 42242 qnop 9224 puo227 set 322npsut y 000224 595 0 01 WHE 599355 Aq JO WILT 2 qesrp st ssooodd y 30 2198 FENSI J ALON Jo pasuvyd jou savy 93nsuo 03 souT Surquun d voNvordde zno ur 3224 G UOD2
43. 4 32940 01 IW savy SIOP 3I0AJ2s23 003 35 aq 501395 uvds Iwy o3ne 55 yry u 404 one uo oanssoad ATddns 42245 SCI JY 33oddng put IDTAIIC SALG INO 32390 2 32947 e OUT THAAT 242 JOU SEM 310432823 23nsu5Te SALG INO 901796 99 75559090 FI 1sn pe 69125 TAI 32945 01 ow savy JOU SIOP MOAIS ou 003 Jas 5010325 ueds oum ONY y yry eui ogne uo oanssoad ATddns 42245 G 225 4 JH ONY JYI e SHE HOUT je ooe d ur dvo put ouung ou qr sr yun uonvgodeao JATSSIOX J suOTIOy osne UOnoeowq DIVMIFOS MIU FT QUON IPOD SInOU UI O3 sol un ou ing 01395 o qvasn pe 12103815 20 uosouo ougejj IWH IY UYIM Aj nyssooons HOI Ome 941 y uonooq oos doo dnjag ur 013395 120103805 oy JO U SOY gunvgodo umnurrurmu 292 Yovos JOU OME 991 JIOAJISII UI UONIPUOD UL SI 91947 uonesodo ewou 10 MOJ 003 249 PMY MOAIS 32238
44. 57 Disable 19 Disable 20 Disable Ve Enable 297 Disable 28 Disable 30 Disable 60 Disable Analog Input 61 Disable Any Fault Enable Status bit s Disable Status Bit Disable 39 40 45 46 47 48 Enable 17 18 23 24 25 26 Enable external sensor opened or shorted Configurable Relay 2 Error Number Factory Default 20 Disable 44 Disable 57 Disable 43 Disable 19 Enable 21 Enable 27 Disable 29 Disable 28 Disable 30 Enable 60 Disable 61 Disable Any Indicator Enable 50 56 Disable 15 41 42 Disable 17 18 23 24 25 26 Enable Code 1 1 Default 2 4 8 16 32 Default 64 128 256 1024 2048 Default 4096 8192 16384 Default 32768 Default Relay Code 1 18465 16 Default 32 Default 64 128 256 512 Default 1024 2048 4096 8192 16384 32768 Default Default Relay Code 2 33328 Thermo Scientific Appendix C Analog Input Calibration The analog input uses a 2 point calibration Depending on how the analog input is configured 1 Type2 or Type 3 the HMI will display either volts millivolts or milliamps The calibration procedure is Start with default high and low endpoints each consisting of a voltage current value and a theoretical analog input value This will permit calibration of either point first Both ends must be calibrated for the entire calibration to be valid Connect a 9 50v 0 400mv 20 00ma reference voltage current source to the
45. 8 deis ees ozuoJg 1529 HSan IeM LLE AA LLE a DJCOCEGEBA ECER SE eh deis 88S dey 5 196 peeu PYM 02 deis ees SS ld e y eBueuo o qum OSN j e gt pue pi n m e dsip eu e SS ld e 4 Taua c 01 uod cgrsu po1oeuuoo 2 uo ui pesn si i SS ld e o qum OSN e um Z pue dois ejdsip eu SS ld e 101224 Taua 10 2 Jexoed e jo pue y pesn SI 4015 SS9Jg e Tajus 94 01 Vm 251 e ana 0096 pue pnyg 1 i ejdsip ou e SS ld e 0096 A1019e4 aua puooes Jed Sq 00 10 009 0021 O0tz 008t 0096 Uoneoiunululoo el49S 10 peeds eui 199Jes pesn si pnyg 7 88 1945 9 y ejdsip si yivp 55914 e Dumes eui 01 m OSN j e gt UOU pue ou e SSOJg e euou 1 A10 0e4 ppo abuey 510419 10 29U9 0
46. 9q 295 uondo uir poddmbo sr yun Fr asn pye OW 19522 usu 4 33o0ddng 12ui03sn SALG INO 330ddng SALG INO UO 3223 310322301d suOTIOYy osne y UOTOVIY 2 uonoes IOUT 39 sarun st OAT JUITINI JO ISvIOA 2 PUN po qeuo Sr JUIOdjas JOWI So vu Y c aqosd o1nje1oduro Jow uad aqosd 210u123 po1joug JTOATISAT IAI MOJ DAI 5 utu 0 WdD 1 0 94 Mop MOT passardap vonnd OWE sam JOIIO SUONVITUNUTUIODS 291574 DIVO 023905 pue e dsrp u22A12q 1 owy L PIATIIOI 1uTod3ss 35 oy Sursn Uni 0 PUN 32238 JOU HUN 32238 00 JPA HUN mys 3TU mys 3TU mys WU 10224 Thermo Scientific Section 7 Checklist Unit will not start For first time use please refer to the quick start instructions included with your unit or the copy in this manual The manual s copy follows the Table of Contents Check th
47. Configuration Thermo Scientific Section 5 Adjusting Screw The pressure relief valve is used to set the desire system back pressure P1 to your application The valve is factory preset to 80 5 psi 550 1 kPa Packing Nut The valve s inlet outlet connections are 2 FNPT lf the unit is not plumbed to an application set the pressure by installing a loop of hose equipped with a shut off valve between the supply and return fittings Start the unit and allow it to prime then close the valve Figure 5 7 Nut and Screw Use the controller s An a display P1 it should display 80 5 psi Figure 5 8 Main Loop Use a screwdriver to turn the adjusting screw counterclockwise to reduce pressure until the controller displays the desired setting NOTE Due to internal back pressure the minimum pressure setting for a deadheaded pump is 40 psi for a P 2 pump and 22 psi for a P 1 these settings prohibit external flow from the unit A If the unit is plumbed to an application ensure the unit is off Then back out the adjusting screw counterclockwise to reduce pressure Turn the unit Ensure that there is back pressure in the system Turn the adjusting screw until the controller displays the desired setting Do not exceed 100 psi A When complete inspect the area around the packing nut for fluid If fluid is present slightly tighten the nut and reinspect NESLAB ThermoFlex 5 5 Section 5
48. ESLAB ThermoFlex Thermo Scientific SASN 5 1 eui 49J9J S y Burwood JO Aue Isd OL Jo e paye suy pue seui uoneoidde Jno duind eAnisod e peddinbe yun JayeM OOA D euejAdoJd 9586 0 69Jnos pinbij pezunsseud Jeje Woo Ao euel ui3 9596 0 Aue 10 Ajddns sayem sseooud JOOUUOD WVW 2 1 salem peziuoreg JUN 14 YIM SPINI JO esn ueseJd SAISON JO e ui eoe d Spin 4 A uo esn JO si yun au i suonneoaJd Ajajes 4 v ees g 4 ees eanBi4 ees i FS eunBi4 ees 1195 0 y esneo III u9tuM e 5141 eui THA31 XVIN d Y 01 JOU 8g 91O0N peueis s euu9 xe zo peddo
49. ESS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE OUR OBLIGATION UNDER THIS WARRANTY IS STRICTLY AND EXCLUSIVELY LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE COMPONENT PARTS AND Thermo Fisher Scientific DOES NOT ASSUME OR AUTHORIZE ANYONE TO ASSUME FOR IT ANY OTHER OBLIGATION Thermo Fisher Scientific ASSUMES NO RESPONSIBILITY FOR INCIDENTAL CONSEQUENTIAL OR OTHER DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OR DAMAGE TO PROPERTY LOSS OF PROFITS OR REVENUE LOSS OF THE UNIT LOSS OF TIME OR INCONVENIENCE This warranty applies to units sold in the United States Any units sold elsewhere are warranted by the affiliated market ing company of Thermo Fisher Scientific This warranty and all matters arising pursuant to it shall be governed by the law of the State of New Hampshire United States All legal actions brought in relation hereto shall be filed in the appropriate state or federal courts in New Hampshire unless waived by Thermo Fisher Scientific gt M Looking for more information AY Artisan Scientific Visit us on the web at http www artisan scientific com for more information QUALITY INSTRUMENTATION GUARANTEED Price Quotations Drivers Technical Specifications Manuals and Documentation Artisan Scientific is Your Source for Quality New and Certified Used Pre owned Equipment Tens
50. I Hi t is the fluid s High Temperature alarm limit Range 4 C to 42 C Default 42 C Exceeding this limit flashes Hi t and if enabled sounds the alarm The unit reaction depends on the alarm configuration see ALr on next page e Lo t is the fluid s Low Temperature alarm limit Range 4 C to 40 C Default 4 C Exceeding this limit flashes Lo t and if enabled sounds the alarm The unit reaction depends on the alarm configuration see ALr on next page Hi P1 is the pump s High Pressure discharge alarm limit e HP T e Range 4 0 PSI to 100 0 PSI Default 100 0 PSI Exceeding this limit flashes Hi 1 and if enabled sounds the alatm dELAY is the length of time the pump can exceed the Hi P1 alarm limit NOTE This feature 15 active only if the unit is configured to shut down with a pressure alarm A Range 0 to 30 seconds Default 0 seconds Exceeding this limit flashes Hi P1 and if enabled sounds the alarm The unit reaction depends on the alarm configuration see ALr on next page EN RE Lo P1 is the pump s Low Pressure discharge alarm limit Range 4 0 PSI to 40 0 PSI Default 4 0 PSI Exceeding this limit flashes Lo P1 and if enabled sounds the alarm is the length of time the pump can exceed the Lo P1 alarm limit NOTE This feature is active only if the unit is configured to shut down with a pressure alarm A Range 0 to 30
51. Polyethylene Brass Plumbing 300 Series Stainless Steel Bronze Fluorocarbon Viton Nickel Polypropylene EPDM Brass Copper Teflon PPS flow transducer Nitrile Funnel Acetac Copolymer Thermo Scientific NESLAB ThermoFlex 8 7 Section 8 Shipment Storage Transporting and or storing the unit in near or below freezing temperatures requires draining see Draining in this Section Store the unit in the temperature range of 25 C to 60 C with packaging and lt 80 relative humidity A N Do not store the unit for more than 90 days A 8 8 NESLAB ThermoFlex Thermo Scientific Thermo Scientific Appendix A Country Specific 230 VAC 50 Hz 19 Requirements Refer to the nameplate label located on the rear of the unit for specific electrical requirements 1 Units shipped to the following locations require a 16 Amp service Afghanistan Albania Algeria Andorra Angola Argentina Armenia Austria Azerbayan Belarus Belgium Benin Bolivia Bosnia and Herzegovina Brazil Bulgaria Burkina Faso Burundi Cambodia Cameroon Cape Verde Central African Republic Chad Chile Comoros Congo Croatia Czech Republic Denmark Djibouti DR Congo Ecuador Egypt Eritrea Estonia Ethiopia Finland France French Guiana Gabon Georgia Germany Greece Guinea Hungary Iceland Indonesia Iran Iraq Israel Italy Coast Jordan Kazakhstan Kyrgyzs
52. S Ic a1 a2 22 03 01 02 03 cs REQ ANALOG1 REQ ANALOG2 Thermo Scientific M Master Sends S Slave Responds M Ic a1 a2 00 00 cs S Ic a1 a2 00 02 v1 v2 cs M Ic a1 a2 02 00 cs S a1 a2 02 d1 dncs M Ic a1 a2 07 00 cs S Ilc a1 a207 nn d1 dn cs M Ic a1 a2 09 00 cs S Ilc a1 a209 nn d1 dn cs M S Ic a1 a2 OF 02 en ed cs M Ic a1 a2 10 00 cs S Ic a1 a2 10 03 01 02 03 cs M Ic a1 a2 20 00 cs S Ic a1 a2 20 03 01 02 03 cs M Ic a1 a2 21 00 cs S Ic a1 a2 21 03 01 02 03 cs M Ic a1 a2 22 00 cs M Ic a1 a2 28 00 cs S Ic a1 a2 28 03 01 02 03 cs M Ic a1 a2 29 00 cs S Ic a1 a2 29 03 01 02 03 cs Appendix D Notes protocol version v1 0 v2 1 Unit SW version in ASCII Display message in ASCII see Request Status Table in this Appendix Response Only ed Error Data en Error Number 1 Bad Command 2 Bad Data 3 Bad Checksum see Error in this Appendix Process Fluid Supply Pressure P1 Process Fluid Supply Temperature RTD1 Refrigeration Suction Temperature RTD2 Refrigeration Ambient Temperature RTD3 Process Fluid Supply Pressure P1 Refrigeration Suction Pressure P2 NESLAB ThermoFlex D 5 Appendix D Request Low Alarm Values REQ LO FLOW1 REQ LO TEMP1 REO LO ANALOG1 Request High Alarm Values REQ HI FLOW1 REQ HI TEMP1 REQ HI ANALOG1 Request PID Settings REQ SETPT1 REQ COOL P TERM1 REQ COOL I TERM1 REQ COOL D TERM1 D 6
53. When your unit exceeds this time the controller will flash DI and the audible alarm if enabled will sound To clear this message and stop the audible alarm press This will automatically restart the preventive maintenance timer for your DI filter If you change the filter before the preventive maintenance timer alerts you you can clear the timer by accessing the Diagnostic Loop dl display see Section 4 If you aren t sure how often to change your DI filter cartridge use the Setup Loop s default time of 448 hours When alerted check the Puralite sensor on the back of the unit to see if it is illuminated If it is not illuminated reset the timer for another 448 hours by pressing and Thermo Scientific section 6 then checking the Puralite periodically If the Puralite has turned red and the controller alarm has not gone off access the Diagnostic Loop unit display see below Check the system run hours this will give you an accurate DI replacement time Adjust the DI filter alarm to match the time needed between filter cartridge changes NOTE It may be necessary to monitor the Puralite three or four times to establish an accurate changing schedule Also DI filter operating time is reduced every time new fluid is added A FLtrS Indicates the total time the filter XXXX has been in use in hours If desired press and hold and then press Wil to reset the value to 0 di Indicates the total time the di filter ata
54. ach or 5A total for all relays combined 1mA minimum switching capacity 48VA 48W Resistive load only Note 2 Jumper configurable default 10mV C Note 3 Sink 0 5mA 5VDC rated for signal level gold contact or TTL device Figure C 1 Analog 0 Connector C 2 NESLAB ThermoFlex NOTE When making your connection to the ThermoFlex Analog I 0 connector in order to comply with the EMC directive Use a shielded I 0 cable Connect the remote end of the cable shield to earth ground Connect cable shield to ThermoFlex end connector A 1 0 15 pin D sub 15 conductor cable with shield Connect shield to earth ground Connect shield to ThermoFlex connector Thermo Scientific This display depends on your unit configuration see Section 4 Thermo Scientific Gi mm SS Appendix C e rELAY is used to configure the code for ox relays 1 and 2 see Tables 1 and 2 on the next page Example To have just the tank overflow drip pan error fault activated for either relay you would enter code 6 e rtd is used to enable disable the remote temperature sensor See Table 3 for pin out information NOTE There 15 no other indication on the unit that the remote sensor is enabled A r Start is used to enable disable the remote start stop NOTE The analog I O remote start stop capability has priority over the controller s start stop as well as any serial communications
55. are orre tea etree actus T T MT 1 1 sya A A E E A 1 1 General Information eese 2 1 TVS A TH T 2 1 2 1 Dci metr c P 3 1 3 1 Ve Ct Ale FR ON enses kes 3 3 _ Ponitini ESO MR 2 5 3 8 Water Quality Standards and Recommendations sss 3 9 Water Ireatment Kit Nortt America 3 11 Compatibility with Recommended 8 3 12 stare 3 14 Operation SD 4 1 4 1 4 2 A 4 2_ AOA OSE LOO E M 4 4 oro m 4 5 BO Mr 4 6 Da CIOS IC rore c 4 10 D ETT 4 11 NESLAB ThermoFlex Contents Section5 Additional Options Accessories 5 1 RR 5 1 O UO mmr a terre rene basi pud dM Upper Tra S 5 2 NER 5 3 P1 and P2 Pump Pressure Relief Valve Internal Configuration 5 4 P1 and P2 Pump Pressure Relief Valve External Configuration 25 8 Flow Control with Flow
56. as a coolant We recommend not using the uninhibited no corrosion additives ethylene glycol It is more corrosive to copper than plain water so it is not recommended unless required for the application Inhibited Ethylene Glycol Water Inhibited glycol can be used to increase the operating temperature range of the fluid but not as a pre mixed anticorrosive solution Industry standards use a pH standard of 8 to determine when the fluid has become corrosive Dowtherm is an ethylene based product that contains dipotassium phosphates in 4 concentration The recommended use of Dowtherm is mixing with distilled or deionized water or water that contains less than 25 ppm chloride and sulfate and less than 100 ppm total hardness of CACO3 The general term inhibited glycol water is too close to meaning inhibited water Inhibited water can have many types of additives including chromate that will quickly foul the cooling system Some inhibitor additives can release the bonding agent in the carbon graphite in the P2 pumps so they are incompatible such as Sodium Hydroxide Uninhibited Propylene Glycol Water Although the use of propylene glycol is similar to ethylene glycol propylene glycol is considered safe to use in the food industry Propylene is less dense than ethylene and will have a tendency to weep through mechanical seals 3 12 NESLAB ThermoFlex Thermo Scientific Thermo Scientific section 3 Inhibited Propylene Glyco
57. at the value contains one decimal point and the units are F i e 98 6 F Examples to set setpoint to 25 C A The precision and units are 1 C a 2 byte integer is used If you already know this skip to step 3 1 Master sends CA 00 01 70 00 8E Request Setpoint 1 2 Slave responds CA 00 01 70 03 01 0014 76 Precision 1 units C value 20 20 x 1 C 20 C Response indicates uses a 2 byte integer nn 03 precision and units are 1 C d1 01 3 Master sends CA 00 01 FO 02 00 19 F3 Set Setpoint 1 to 25 C 4 Slave responds 00 01 F0 03 01 00 19 F1 Precision 1 units C value 250 250 x 1 C 25 C B The precision and units are 0 1 C a 2 byte integer is used If you already know this skip to step 3 1 Master sends CA 00 01 70 00 8E REQ SETPOINT 2 Slave responds 0001 70 03 11 00 C8 B2 Precision 0 1 units C value 200 200 x 0 1 C 20 0 C Response indicates uses a 2 byte integer nn 03 precision and units are 0 1 C d1 11 3 Master sends CA 00 01 FO 02 00 FA 12 Set Setpoint 1 to 25 0 C 4 Slave responds 00 01 FO 03 11 00 FA 00 Precision 0 1 units C value 250 250 x 0 1 C 25 0 0 C See Additional Command Examples in this Appendix D 4 NESLAB ThermoFlex Thermo Scientific Table of Commands Command Request Status REQ ACK REQ UNIT SW VER REQ DISPLAY MSG REQ STATUS ERROR Request Measurements REQ FLOW1 REQ TEMPI REQ TEMP2 REQ TEMP3
58. ations without notice NESLAB ThermoFlex 2 9 section 2 ThermoFlex2500 BIU Hr Watts li it E Cooling Capacity 12000 3500 10000 3000 S 800 750 2000 E 6000 1500 4000 1000 2000 _ 500 C 50 60 70 80 90 100 VE Temperature Setpoint ThermoFlex3500 5000 Cooling Capacity BIU Hr Watts 24000 7000 20000 6000 5000 lt 16000 4000 12000 3000 8000 2000 4000 1000 Temperature Setpoint Specifications obtained at sea level using water as the recirculating fluid at a 20 C process setpoint 25 C ambient condition at nominal operating voltage Other fluids fluid temperatures ambient temperatures altitude or operating voltages will affect performance e Air cooled units retain their full rated capacity at 20 C setpoint in ambient temperatures up to 25 C 77 F For ambient temperatures above 25 C please de rate the cooling capacity 3 for every 1 C above 25 C 77 F up to a maximum ambient temperature of 40 C 104 F Please note that when operating at a process temperature lower than 20 C the de rate percentage may increase due to additional gains from losses to ambient For water cooled units refer to Section 3 e Thermo Fisher Scientific reserves the right to change specifications without notice 2 4 NESLAB ThermoFlex Thermo Scientific Thermo Scientific section 2
59. ay result in a hazardous situation and may void the manufacturer s warranty A Transport the unit with care Sudden jolts or drops can damage the unit s components A Drain the unit before it is transported and or stored in near or below freezing temperatures see Draining in Section 8 Store the unit in the temperature range 25 C to 60 C with packaging and lt 80 relative humidity A The circuit protector located on the rear of the unit is not intended to act as a disconnecting means A Observe all warning labels A Never remove warning labels A Never operate damaged or leaking equipment A Never operate the unit without process fluid in the reservoir A Always tutn off the unit and disconnect the power cord from the power source before performing any service ot maintenance procedures or before moving the unit A Never operate the unit with panels removed A Never operate equipment with damaged power cords A Refer service and repairs to a qualified technician A 1 2 NESLAB ThermoFlex Thermo Scientific Description Specifications Process Fluid Temperature Range Ambient Temperature Range Temperature Stability Cooling Capacity at 20 C 60 Hz 50 Hz Reservoir Volume Gallons Liters Footprint or Dimensions HxWxD Inches Centimeters Unit Weight empty Ib kg Pumps P 1 Positive Displacement 60 Hz 50 Hz P 2 Positive Displacement 60 Hz 50 Hz Thermo Scientific Section 2 General Info
60. d the flow rate value Press the aua key again to display the process fluid temperature 4 indicates the controller display is alternating between the two displays P1 Pump discharge pressure in PSI bar or kPa Fo Jt fx FLo Flow rate in liters or gallons optional feature See Setup Loop in this Section to select desired scales Figure 4 2 Main Loop NESLAB ThermoFlex 4 3 Section 4 4 4 Controller Loops NESLAB ThermoFlex The controller has the capability to display various loops which indicate operating conditions and parameters within the unit The loops are selected and changed by pressing the appropriate keys When the controller is first powered up it goes through a short initialization and then displays the process fluid temperature Use the key combination shown below to scroll through the loops Figure 4 3 Controller Loops Unit running SP is the Setpoint Loop and is used to display and change the setpoint The setpoint is the desired process fluid temperature needed for your application The Setpoint Loop is accessed by pressing the mode key see next page SEtuP is the Setup Loop The Setup Loop allows you to display and or alter different parameters of the controller The Setup Loop is accessed from the Setpoint Loop by pressing the mode key diA is the Diagnostic Loop The Diagnostic Loop allows you to display the operating times for various components within the u
61. des a biocide and corrosion inhibitor capable of treating up to ten gallons of application water and 1s designed to provide protection for a period of six months This kit is compatible with the following fluids Filtered Singled Distilled Water Uninhibited Ethylene Glycol Water Uninhibited Propylene Water Deionized DI Water Reverse Osmosis RO Water Do not use the Thermo Fisher Water Treatment Kit with a DI filtered system the filter will remove a portion of the reagent s active ingredients limiting its effectiveness Thermo Scientific NESLAB ThermoFlex 3 11 Section 3 Compatibility with Filtered Singled Distilled water This fluid is recommended primarily because it has all microorganisms that Recommended cause biological fouling removed through vaporizing and condensing the FI u ds water However distilled water does not remain pure for very long when exposed to the atmosphere Air born spores can contaminate the water and activate aleae growth An effective maintenance plan would include switching out the fluid with newly distilled water every six months The particulates that have been filtered out in the process are also preventive in keeping the system clean of contaminants NOTE Distilling water that contains an additive could increase the concentration of that additive in the water A Uninhibited Ethylene Glycol Water Ethylene glycol is used to depress the freezing point of water
62. e sdwnd 2471 TH uo uonosvas puq 2 0199 6 2 X9 jouueu qv ISAN DNUSIOS owy SALG INO 19VIUO7 e sseddq y 03 popper oq 0 3 po e3sur u22q seu AJLA ssvd q doap asnssosd uonvordde 5gq lt lt sosmbas JOU SI JIOATISIT IAY INSU o 000225 296 fy ou ur u2souo 8013398 o qvasn pe y 901296 225 013325 GOT INOA C doo dnjag sr o3nssoad s dung oT uo spuadap uonovas popoooxo Aquegoduua3 4 savy Aew ywn oya SII IPOD F 22s 03 15349 ssoud Suruuni ps ST FUN IY Ld 97 330ddng 12ui03sn SALG INO o3nsso3dd pue II INWA APIO JO o po12 2uuoo pue uo ST J93 A 23nsu Te Symm 33o0ddng 12ui03sn INO 400296 225 uone nuoA sey 21nsujqe uvy uv SUISN uontoo 1243008 OJUT JE JOY IsSNVYXd JO JOYIOUL UI J9 OOO Suge 901296 298 ISULI 941 JOU ST oinjyeroduray JUZICUIE EYI 2Jnsu Te 0 901296 225 Suruonoung JY uto Joy uo suqop put
63. e 25 C please de rate the cooling capacity 3 for every 1 C above 25 C 77 F up to a maximum ambient temperature of 40 C 104 F Please note that when operating at a process temperature lower than 20 C the de rate percentage may increase due to additional gains from losses to ambient For water cooled units refer to Section 3 e Additional dimensions are shown at the end of this section add 1 8 3 cm to height for SEMI units Unit weight 15 for air cooled units Subtract 30 pounds 14 kilograms for water cooled units e Thermo Fisher Scientific reserves the right to change specifications without notice NESLAB ThermoFlex 2 1 section 2 Specifications Process Fluid Temperature Range Ambient Temperature Range Temperature Stability Cooling Capacity at 20 C 60 Hz 50 Hz Reservoir Volume Gallons Liters Footprint or Dimensions HxWxD Inches Centimeters Unit Weight P 1 P 2 P 3 P 4 empty Ib kg Pumps P 1 Positive Displacement 60 Hz 50 Hz P 2 Positive Displacement 60 Hz 50 Hz P 3 Centrifugal Pump 60 Hz 50 Hz P 4 Centrifugal Pump 60 Hz 50 Hz 2 2 NESLAB ThermoFlex ThermoFlex3500 5 C to 40 C 41 F to 104 F 10 C to 40 C 50 F to 104 F 0 1 C 3500 W 11953 BTU 3050 W 10416 BTU 1 9 1 2 38 j x 19 7 x 307 98 7 x 48 8 x 78 0 264 264 270 303 120 120 123 138 2 1 60 psid 1 7 gom 50 psid 4 1 gpm 60 psid 3 3 gpm 60 psid
64. e controller for error codes see Error Codes in this section Ensure the circuit protector is in the on 1 position For Global Voltage units ensure the unit is properly configured see Appendix B Make sure supply voltage is connected and matches the unit s nameplate rating 10 NOTE Once RS232 RS485 is activated all keypad operations are disabled except for turning the unit off and changing the serial communication s settings Unit shuts down Ensure 0 button wasn t accidently pressed Ensure the circuit protector is in the on 1 position Check the controller for error codes see Error Codes in this section Make sure supply voltage is connected and matches the unit s nameplate rating 10 Restart the unit Clearing Error Codes Note the code in case it cleares before you are done troubleshooting If desired silence the audible alarm by pressing any key If the unit shut down the controller will continue to flash the error code Press enter to clear the display and silence any alarm Refer to Error Codes in this section Once the cause of the shut down is identified and corrected start the unit If the cause was not corrected the error code will reappear If the unit is still running press entet to see if the code clears a limit may have been only temporarily exceeded If the error code does not clear press until the display flashes between the error code and the temperature and then pr
65. e low point of at 20 C using RS 232 D 12 Master Sends CA 00 01 82 05 01 00 00 4E 20 08 Slave Returns CA 00 01 82 07 01 01 31 00 00 4E 20 D4 NESLAB ThermoFlex Process Suction Ambient Water Thermo Scientific Set Analog Out Cal This command is used to do a two point calibration of the analog output Master Sends Slave Returns Byte 01 d2 d3 d4 d5 06 MODE on A CO N Procedure Ic al a2 83 06 91 92 93 94 95 96 cs Ic al a2 83 01 91 cs Master ID 1 ANALOG_OUT1 MODE see table below Entered Value MSB Entered Value Entered Value Entered Value LSB Function Exit oet output to high point voltage Enter actual high point voltage oet output to low point voltage Enter actual low point voltage Calibrate Set output to mid point voltage Appendix D Slave Status 1 0 Entered Value Volts x10000 Volts x10000 Use mode 1 to set the output to the high point voltage 10V Use the previous calibration to calculate the DAC value for 10V After the output settles read it and use mode 2 to send the actual voltage x10000 to the controller Use mode 3 to set the output to the low point voltage OV Use the previous calibration to calculate the DAC value for OV After the output settles read it and use mode 4 to send the actual voltage x10000 to the controller Use mode 5 to calculate the new calibration constants The calibration uses the entered voltage
66. ections are located on the rear of the unit and are labeled gt PROCESS OUTLET PROCESS INLET The connections for units with P1 and P2 pumps 1 2 Female NPT and P4 pumps are 4 FPT The process outlet connection is cast bronze the process inlet connection is stainless steel Outlet connection for units with a flow transducer 1 4 Male NPT Reservoir Drain Plug Figure 3 2 Plumbing Connections 1 of 2 Connect the PROCESS OUTLET to the fluid inlet on your application Connect the PROCESS INLET to the fluid outlet on your application Ensure all connections are secure and that the proper sealant lubricant for the fitting material is used Figure 3 2 Plumbing Connections 2 of 2 NESLAB ThermoFlex 3 5 Section 3 3 6 NESLAB ThermoFlex NOTE P1 and P2 pumps are capable of producing 110 psi Ensure your plumbing is rated to withstand this pressure An external pressure relief valve 1s available see Section 5 A Keep the distance between the unit and the instrument being cooled as short as possible Ensure tubing is straight and without bends If diameter reductions are required make them at the inlet and outlet of your application not at the ThermoFlex Water Cooled Units For water cooled units the facility water plumbing connections are also located on the rear of the unit and are labeled FACILITY INLET and gt FACILITY OUTLET The connections ate also 72 Female
67. el on the rear of the unit Use a 1 4 socket to remove the four screws securing the access panel to the unit The configuration panel has two 3 position toggle switches one for voltage and one for frequency All units are shipped with the toggle switch in the center SHIP position Place each switch to the settings that match the voltage frequency supplied to the unit Reinstall the refrigeration access panel 115 100 Volt units 208 230 208 230 200 Volt units Refrigeration Access Panel for 900 1400 and 2500 units Figure B 1 Global Voltage For 3500 and 5000 units remove the upper access panel NESLAB ThermoFlex 1 Appendix C Analog 1 0 and Remote Sensor 8 7654321 Analog 1 0 Connector Pinout 9 151413 1211 109 Install your analog input output device to the 15 pin female connector on the rear of the unit Analog I O is activated using the Setup Loop see page C 3 PIN NAME 1 2 3 DIGITAL INPUT COMMON Not Used LOW LEVEL Only if option chosen CONFIGURABLE RELAY 2 PUMP ON ANALOG GROUND RESERVOIR TEMP OUT OR EXTERNAL SENSOR TEMPERATURE IF EXTERNAL SENSOR ENABLED LOW FLOW Only if option chosen CONFIGURABLE RELAY 1 Normally Open CONFIGURABLE RELAY 1 Normally Closed RELAY COMMON REMOTE START ENABLE NOTES Note 1 Note 1 Note 1 Note 2 Note 1 Note 1 Note 1 Note 3 DEFINITION Common for digital inputs pins 12 13
68. es the right to change specifications without notice Thermo Scientific Thermo Scientific ThermoFlex900 Cooling Capacity ThermoFlex1400 Cooling Capacity BIU Hr Watts 5000 1400 4000 1200 1000 S 3000 800 2000 500 400 1000 200 BIU Hr Watts 2000 6000 5000 1500 S 4000 E 1000 2 300 S 2 E 000 a 1000 e Specifications obtained at sea level using water as the recirculating fluid at a 20 C process 60 Hz 50 Hz 10 20 30 40 C 00 60 70 80 90 100 a Temperature Setpoint 60 Hz 50 Hz 10 20 30 40 C 100 E 50 60 70 80 90 Temperature Setpoint section 2 setpoint 25 C ambient condition at nominal operating voltage Other fluids fluid temperatures ambient temperatures altitude or operating voltages will affect performance e Air cooled units retain their full rated capacity at 20 C setpoint in ambient temperatures up to 25 C 77 F For ambient temperatures above 25 C please de rate the cooling capacity 3 for every 1 C above 25 C 77 F up to a maximum ambient temperature of 40 C 104 F Please note that when operating at a process temperature lower than 20 C the de rate percentage may increase due to additional gains from losses to ambient For water cooled units refer to Section 3 e Thermo Fisher Scientific reserves the right to change specific
69. ess 4 to save a changes ot press Axa to abort a changes The display will return either the process fluid temperature or if the unit was off when you entered the loop a blank screen 4 8 NESLAB ThermoFlex Thermo Scientific CONTINUED FROM PREVIOUS PAGE ol shaded displays appear only O PT on units equipped with that option ox LA a ES save all changes x Abort all changes Figure 4 7 Setup Loop Optional Features Thermo Scientific section 4 OPt is used to configure the analog in out mode of operation See Appendix C FILL is used to set the time limit the auto refill has for filling the unit s reservoir to the normal operating level Range 0 to 900 seconds Default 45 seconds Exceeding the time limit flashes and the auto refill will shut down di t is used to set the preventive care cleaning frequency reminder for the unit s DI filter cartridge Range 0 to 9999 hours Default 448 hours Exceeding the limit flashes Di see Section 6 HiFLO is used to set the high flow alarm limit Range 0 5 to 20 0 GPM Default 5 0 GPM Exceeding this limit flashes HiFLO and if enabled sounds the alarm The unit s reaction depends on the alarm ALr setting LOFLO is used to set the low flow alarm limit Range 0 5 to 20 0 GPM Default 0 5 GPM NOTE Centrifugal pumps require a minimum flow rate of 3 8 gpm 14 4 Ipm A Exceeding this limit flashes LOFLO and if e
70. ess enter If the code still does not clear refer to Error Codes in this section NESLAB ThermoFlex 7 9 Section 7 7 10 NESLAB ThermoFlex Unit will not circulate process fluid Check the reservoir level Fill if necessary Unit requires gt 5 PSIG application pressure drop If a bypass valve has been installed some restriction may need to be added to the bypass line Check the application for restrictions in the cooling lines Ensure the reservoir bag filter is not clogged The pump motor overloaded The internal overtemperature overcurrent device will shut off the pump causing the flow to stop This can be caused by low fluid debris in system operating unit in a high ambient temperature condition or excessively confined space Allow time for the motor to cool down Make sure supply voltage matches the unit s nameplate rating 10 Inadequate temperature control Verify the setpoint Make sure the condenser air filter is free of dust and debris Ensure your unit s installation complies with the site requirements listed in Section 3 Make sure supply voltage matches the unit s nameplate rating 10 If the temperature continues to rise make sure your application s heat load does not exceed the rated specifications Check for high thermal gradients 1 the application load is being turned on and off or rapidly changing If operating at high altitude note that heat removal capacity decreases 1 2
71. eu e 2 05 101224 Do 07 01 9 S uiodies 1sn pe si dS d5 SS ld e 710 21 yo 0 Aejdsip qum OSN j a gm L1 3499 ysel Aejdsip eu e L1 A1012eJ SS ld s noy 0005 1 s4nou 0002 27 Taus 0001 11 HO S4 pue SHUN y 104 Duiueo o Ju 1 DY 195 oj pesn SI JAYI B 6D uni enunuoo d edIPU inus 11 5 e ejdsip O 55910 e 17 pue 11V Usemjeq ysel ejdsip eu 11 Aiojoe4 _ SSOJge JO us 10 BBS uni enunuoo 314 inus pue 55 o1 sun ay 17y s SS ld en eA y 1sn pe o um 257 e am 0 pue m Kejdsip eu e Spuooes 0 1012eJ spuooes 0 0 0 5 Hur Ld IH 991 ueo dund oui own jo si 192 1xeu y eouenbes 0 SS ld e OY 1sn pe 0
72. event of reduce the galvanic corrosion observed NESLAB ThermoFlex 3 9 section 3 Water Quality Materials Compatibility units with in line partial flow deionization filter 15 00 Not Recommended Increasingly Corrosive 10 00 Operations with Plastic and Stainless Steel Systems Operations with Mixed Metals Copper Brass Stainless Steel CONSULT MATERIALS ENGINEER Resistivity 25 C o 10 20 30 40 50 60 70 80 C Temperature Facility Water Permissible PPM Desirable PPM Microbiologicals algae bacteria fungi 0 0 Inorganic Chemicals Calcium lt 40 lt 0 6 Chloride lt 250 lt 25 Copper lt 1 3 lt 1 0 0 020 ppm if fluid in contact with aluminum iron Iron lt 0 3 lt 0 1 Lead lt 0 015 0 Magnesium lt 12 lt 0 1 lt 0 05 lt 0 03 Nitrates Nitrites lt 10 N 0 Potassium lt 20 lt 0 3 silicate 2b 1 0 sodium lt 20 lt 0 3 sulfate lt 250 lt 50 Hardness 17 0 05 Total Dissolved Solids lt 50 lt 10 NOTE A corrosion inhibitor is recommended if mixed metals are in the facility water loop 3 10 NESLAB ThermoFlex Thermo Scientific Section 3 Water Treatment Kit Thermo Fisher Treatment Kit is available and is designed to minimize the effects of corrosion scale fouling and microbial contamination North America Only It allows the system to continue providing reliable service with optimal efficiency for the life of the unit The kit inclu
73. isposed of or recycled this product through them Further information on Thermo Fisher Scientifics compliance with these Directives the recyclers in your country and information on Thermo Scientific products which may assist the detection of substances subject to the RoHS Directive are available www thermo com WEEERoHS NESLAB ThermoFlex Preface After sale Support Feedback Warranty Unpacking NESLAB ThermoFlex Thermo Fisher Scientific is committed to customer service both during and after the sale If you have questions concerning the unit operation or questions concerning spare parts or Service Contracts call our Sales Service and Customer Support phone number see inside cover for contact information When calling please refer to the labels on the inside cover These labels list all the necessary information needed to properly identify your unit We appreciate any feedback you can give us on this manual Please e mail us at neslabmanuals thermofisher com Be sure to include the manual part number and the revision date listed on the front cover Thermo Scientific NESLAB ThermoFlex units have a warranty against defective parts and workmanship for 24 months from date of shipment See back page for more details Retain all cartons and packing material until the unit is operated and found to be in good condition If the unit shows external or internal damage contact the transportation company and file a damage
74. l Water Same issues as with uninhibited propylene and inhibited ethylene glycol Deionized Water 1 3 compensated Deionized water has had the conductive ions that cause galvanic corrosion between dissimilar metals removed NOTE This is not the normal state of water so if it is too pure deionized water is aggressive to metal The result 1s the leaching of metallic ions from metal surfaces which causes pitting A NEVER use flammable or corrosive fluids with this unit Do not use automotive antifreeze Commercial antifreeze contains silicates that can damage the pump seals Use of automotive antifreeze will void the manufacturer s warranty A NESLAB ThermoFlex 3 13 section 3 Filling Requirements 3 14 NESLAB ThermoFlex A Ensure the reservoir drain plug on the back of the unit is in place and that all plumbing connections are secure Before using any fluid refer to the manufacturer s MSDS for handling precautions A Locate and remove the reservoir cap by unscrewing it counterclockwise Figure 3 4 Reservoir Cap To prevent the introduction of particulates into the system fill the unit with the reservoir bag filter in place Units are shipped with a bag filter in place For information on changing the bag filter see Section 6 The polyethylene reservoir has a sight tube and ball for easy fluid level monitoring S ow y fill the reservoir with clean process fluid through the funnel only failure to comply ma
75. n press WEM to reset the value to 0 see Section di Indicates the total time the di filter cartridge has been in and then press E o reset the value to 0 see Section unit Indicates the unit operating time in hours This value can not be reset Thermo Scientific Thermo Scientific Shut Down Section 4 Press the 0 key on the controller NOTE To protect the unit s compressor the unit will enter a 20 second shut down cycle before the refrigeration system and pump shut down During this time the display will indicate O H The bars will scroll downward indicating the controller is in the shut down cycle A When the display goes blank it is safe to place the circuit protector located on the rear of the unit to the off 0 position Using any other means to shut the unit down can reduce the life of the compressor Always turn the unit off and disconnect it from its supply voltage before moving the unit A The circuit protector located on the rear of the unit is not intended to act as a disconnecting means A NESLAB ThermoFlex 4 11 Section 4 4 12 NESLAB ThermoFlex Thermo Scientific Section5 Options Accessories Auto Refill The Auto Refill provides makeup fluid to replace any fluid lost to evaporation etc It requires a pressurized fluid source connection to the 14 Female Pipe Thread fitting on the rear of the unit ELET Figure 5 1 Auto Refill Fitting The auto refill fluid mu
76. nabled sounds the alarm The unit s reaction depends on the alarm ALY setting SEr is used to configure the serial communications mode of operation See Appendix D drAin is used to open and close the unit s anti drainback valve for draining see Section 5 Range yes no Default no NOTE The valve automatically closes when you exit the drAin display When the display indicates StorE press to save a changes ot press to abort a changes The display will return either the process fluid temperature or if the unit was off when you entered the loop a blank screen NESLAB ThermoFlex 4 9 Section 4 4 10 Diagnostic Loop LIL LM Figure 4 8 Diagnostic Loop NESLAB ThermoFlex been in use in hours If desired press and hold use in hours If desired press and hold e The Diagnostic Loop is used to view or reset the Operating times of various unit components To enter the Diagnostic Loop ensure the controller display is either a blank screen unit off or displaying the process fluid temperature Press the key and the display will indicate SP press again to display SEtuP press again to display ch AD Press to enter the loop or press to return to the process fluid temperature or blank display Use the ama key to sequence down through the loop Use the gory key to sequence up through the loop FLtrS Indicates the total time the air and fluid lters have and the
77. nd low pump discharge pressure alarm limits and time delays Fault reaction to a temperature pressure or flow optional alarm limit continue to run or shut down Audible alarm enabled disabled Auto restart feature enabled disabled Preventive care cleaning frequency reminder for air and fluid filters Optional Features Analog I O feature enabled disabled Auto refill alarm DI filter cartridge preventive maintenance interval High low flow alarm limits Serial communications feature enabled disabled Anti drainback valve position Save abort all changes To enter the Setup Loop ensure the controller display is either a blank screen unit off or displaying the process fluid temperature Press the key and the display will indicate SP press it again to display SEtuP Press the key to continue or press twice to return to the process fluid temperature or blank display Use Ama to sequence down through the loop Use oy to sequence back through the loop up to the display see next To change any parameter B Press the key B Use the s keys to change a displayed value B Press key to confirm the change Thermo Scientific Section 4 De 5 Cr Cano c UnitS are the temperature fluid flow and pressure display scales Units Units degx Scales Defaults BITS Gallons or Liters Gallons M PSI Bar or kPa PS
78. nit The Diagnostic Loop is accessed from the Setup Loop by pressing the mode key NOTE The loops can be accessed and changed without the unit running as long as the circuit protector is in the on 1 position Figure 4 4 Controller Loops Unit not running Thermo Scientific Setpoint Loop 57 Thermo Scientific Section 4 Ensure the controller is either a blank screen not yet initialized or displaying the process fluid temperature Press the key and the controller display will alternate between SP and the setpoint value If no change is required press the key to return the display to the process fluid temperature B Ifa setpoint change is required use the keys The setpoint range is 5 C to 40 C Coy NOTE If the E not used within one minute the controller will time out and return to the process fluid temperature display and any changes will not be accepted A Once the desired value is displayed press the key to confirm the change B The display will return to the process fluid temperature indicates the controller display is alternating between the two displays Uu Figure 4 5 Setpoint Loop NESLAB ThermoFlex 4 5 Section 4 4 6 Setup Loop 526 NESLAB ThermoFlex Use the Setup Loop to adjust verify the following controller settings Scales C or F Liters or Gallons PSI Bar or kPa High and low temperature alarm limits High a
79. ockout and tagged out LOTO Hazard control features added to the system e g safety interlocks EMO are not a substitute for turning off and locking out electrical or fluid energy For units rated 20 Amps or less electrical LOTO 1s accomplished by removing the power cord and closing the locking device on the power receptacle located on the rear of the unit For other units electrical LOTO is the responsibility of the user and can be provided by Using the main disconnect knife switch at system control cabinet Disconnecting main power at the facility power source prior to the system controller cabinet In addition follow all OSHA and local facility LOTO directives NESLAB ThermoFlex 5 7 Section 5 Drip Pan and Drain The unit is equipped with a secondary containment drip pan in case there is a leak The drip pan drain located on the rear of the unit Install the supplied nylon 1 4 turn quick disconnect QD fitting into the drain fitting The QD is barbed for a 1 2 ID hose Since the pan will not hold more than 110 of the reservoir volume connect the drain to guide the fluid to an appropriate spillage location 1 4 Turn Quick Disconnect Drip Pan Drain Fitting Figure 5 11 Drip Pan Drain ThermoFlex900 1400 ThermoFlex2500 ThermoFlex3500 5000 A 3 A 8 8 cm 4 10 1 cm 3 5 11 3 2 7 0 2 6 8 cm 2 7 1 C 6 ES 17 7 cm 6 px 16 7 cm m 24 3 cm 5 8 NESLAB ThermoFlex Thermo Scientific The
80. of Thousands of In Stock Items Fast Shipping and Delivery Equipment Demos Hundreds of Manufacturers Supported Leasing Monthly Rentals Consignment Service Center Repairs InstraView Remote Inspection Experienced Engineers and Technicians on staff in our Remotely inspect equipment before purchasing with our State of the art Full Service In House Service Center Facility Innovative InstraView website at http www instraview com We buy used equipment We also offer credit for Buy Backs and Trade Ins Sell your excess underutilized and idle used equipment Contact one of our Customer Service Representatives todayl Talk to a live person 888 88 SOURCE 888 887 6872 Contact us by email sales artisan scientific com Visit our website http www artisan scientific com
81. ower is off Pin 10 contacts are normally CLOSED when power is off Relay contacts are rated 24V AC DC 2A lt 0 08 Ohm maximum each or total for all relays combined 1mA minimum switching capacity 48VA 48W Resistive load only Note 2 Jumper Configurable Default 10mV C Note 3 Sink 0 5mA 5VDC Rated for signal level gold contact or TTL device Thermo Scientific NESLAB ThermoFlex C 1 Appendix C PIN NAME NOTES 13 REMOTE SETPOINT Note 3 ENABLE 14 REMOTE START Note 3 15 REMOTE SETPOINT Note 2 DEFINITION Digital Input Isolated Reference to pin 1 Connect to pin 1 to allow the setpoint to be changed remotely through pin 15 REMOTE SETPOINT Digital Input Isolated Reference to pin 1 Connect to pin 1 to turn unit on Disconnect to turn unit off Note Pins 1 and 12 must be connected to allow operation from this pin Analog Voltage Input 0 10VDC 10mV C or 4 20mA Reference to pin 6 Apply a DC voltage to this pin to adjust the unit s setpoint Default Range 0 10V where Low Temp Span 10V Hi Temp Span Input Impedance gt 600K Optional Range 10mV C Ex 200mV 20 C Max Input Voltage 10VDC or 4 20mA 4mA low temp span 20 mA high temp span Contact us for details Note 1 All relay contacts except for Pin 10 are normally OPEN when power is off Pin 10 contacts are normally CLOSED when power is off Relay contacts are rated 24V AC DC 2A lt 0 08 Ohm maximum e
82. per 1 000 feet above sea level Also reduce the maximum temperature for the air entering the ThermoFlex by 1 C per 1 000 feet above sea level Verify adjust controller PID values see Section 7 Ensure the unit was shut down properly see Section 4 If not the compressor may be damaged Unit vibration The optional pressure relief valve setting may be the cause If it 15 change the pressure setting 5 psi to eliminate the vibration Please contact Thermo Fisher Scientific Sales Service and Customer Support if you need any additional information see inside cover for contact instructions Thermo Scientific Section 7 Adj usti ng the The controller controls temperature using a Proportional Integral Derivative PID algorithm Should your unit experience temperature Controller control issues adjusting the controller s PID values may correct the P D Va condition NOTE Thermo Fisher recommends that only a qualified technician adjust the PID values Incorrect values will hamper unit performance A Pro proportional value Range 0 0 to 99 9 Factory Preset 10 0 int integral value Range 0 00 to 9 99 Factory Preset 0 50 dEr derivative value Range 0 0 to 9 9 Figure 7 1 Adjusting PID Values Thermo Scientific NESLAB ThermoFlex 7 11 Section 7 7 12 NESLAB ThermoFlex Thermo Scientific Thermo Scientific Draining A Section 8 Additional Information Before using an
83. precautions listed in this manual before installing or operating your unit If you have any questions concerning the operation of your unit or the information in this manual please contact us See inside cover for contact information Never place the unit in a location where excessive heat moisture or corrosive materials are present A The unit construction provides protection against the risk of electrical shock by grounding appropriate metal parts The protection may not function unless the power cord is connected to a properly grounded outlet It is the user s responsibility to assure a proper ground connection is provided A Always turn the unit off and disconnect the supply voltage from its power source before moving the unit A Never connect the process fluid inlet or outlet fittings to your building water supply or any water pressure source A Never use flammable or corrosive fluids with this unit Use of these fluids will void the manufacturer s warranty A Do not use automotive antifreeze Commercial antifreeze contains silicates that can damage the pump seals Use of automotive antifreeze will void the manufacturer s warranty A Before using any fluid or performing maintenance where contact with the fluid is likely refer to the manufacturer s MSDS for handling precautions A NESLAB ThermoFlex 1 1 Section 1 Performance of installation operation or maintenance procedures other than those described in this manual m
84. r 3urod3ss YOvaI Paes 833 5 UVI IT UMOp uonvordde 22s ynys yun JT ALON 941 SuIpoooxo JOU ST onje1odura3 1843 2Jnsu Te SSO 3e 2Q IYI 03 SIUN Surquunjd eu321xo 03 uonev nsur UONIIC 295 san eA PONLO ATIIA e poppe sr vay uou 1urod3os onuoo IA 1 241 vay po1eo o3 pare3odugo1 uo o3n183odugo1 JAMO IY 10 JULISUOD SI 001255 225 NVA dnas popoooxo Aquegoduuo3 4 savy ywn doo ur uasoys 8939 o qeasn pe 3 SFE FI 228 03 22349 5924 Suruuni s st PUN 292 JJ e 51 ssooogg uo spuod p uonov21 yuq 3 01 2 9012956 225 013395 3 OTT INOA AFIIIA e 9 2 X9 jouueu gv ISN 33oddng FJIUIOISN PUL IDTAIIC INO 32t3u0o 501091 JOIIO IPOD ICI 9 UOTIDIC UI SIPON 21410 29S INO uonoog 59 amp essooou 1sn pe 5800195 434 Y yoddng INO p 901296 99 1vssooou J snipe 5500195 14 9
85. ration before doing the high end A Do not pick calibration points that are outside the safe operating limits of the fluid in your application For example with water 40 C and 5 C are typical high and low calibration points Run the unit to a suitable high end calibration point Place a calibrated reference thermometer in the reservoir Ensure the fluid temperature is stabilized To enter the Calibration Loop ensure the controller display is displaying the process fluid temperature see the diagram on next page Press and hold the and then press the key The display will indicate CAL Press the key and the controller will display rtd1 Press again and the controller will display r1 H high end calibration Press again and the controller will flash between r1 H and the temperature Use to adjust the temperature to match the reference thermometer Press the key again to accept the value Press the Aaa key until StorE is displayed press d to accept the new value press ama to abort it Run the unit to a suitable low end calibration point At the r1 L low end calibration display repeat the procedure Press the amu key until StorE is displayed press cem to accept the new value press ama key to abort it NOTE After pressing the gem button at the StorE prompt wait several seconds before proceeding to ensure that a bad calibration message Er 16 does not appear Premature use of the keypad
86. rmation The Thermo Scientific NESLAB ThermoFlex recirculating chiller is designed to provide a continuous supply of fluid at a constant temperature and volume The unit consists of an air cooled or water cooled refrigeration system heat exchanger recirculating pump polyethylene reservoir and a microprocessor controller ThermoFlex900 5 C to 40 C 41 F to 104 F 10 C to 40 C 50 F to 104 F 0 1 C 900 W 3074 BIU 750 W 2561 BTU 1 9 12 21 us x 14 ly x 24 RT 69 4 x 36 0 x 62 4 130 5 99 2 ThermoFlex1400 5 C to 40 C 41 F to 104 F 10 C to 40 C 50 F to 104 F 0 1 C 1400 W 4781 BTU 1170 W 3996 BTU LZ 27 Ta 1 x 24 pm 69 4 x 36 0 x 62 4 130 5 99 2 2 1 gpm 60 psid 1 7 gom Q 60 psid 4 1 gpm Q 60 psid 3 3 gpm 60 psid ThermoFlex2500 5 C to 40 C 41 F to 104 F 10 C to 40 C 50 F to 104 F 0 1 C 2500 W 8538 BTU 2200 W 7513 BIU ES iue 28 E 17 16 26 73 6 x 43 6 x 67 3 1799 195 Specifications obtained at sea level using water as the recirculating fluid at a 20 C process setpoint 25 C ambient condition at nominal operating voltage Other fluids fluid temperatures ambient temperatures altitude or operating voltages will affect performance e Air cooled units retain their full rated capacity at 20 C setpoint in ambient temperatures up to 25 C 77 F For ambient temperatures abov
87. rmo Scientific Section 5 Seismic Tie Downs Install the seismic tie downs to the unit as shown below Then secure the unit to the floor with user supplied hardware 5 16 Nut side View Front View Figure 5 12 Seismic Tie Downs ThermoFlex900 1400 ThermoFlex2500 ThermoFlex3500 5000 A 2 6 8 2 6 8 2 6 8 B 18 47 0 20 51 0 2472 62 2 b 197 48 4 22 56 1 24 61 3 D 20 92 2 23 59 9 25 65 1 Distance between 0 53 Seismic mounting holes NESLAB ThermoFlex 5 9 Section 5 Center of Gravity 1 2 P 2 pump standard unit no fluid in tank Lim Top View oide View Figure 5 13 Center of Gravity ThermoFlex900 1400 ThermoFlex2500 ThermoFlex3500 5000 A 10 27 3 12 30 5 13 A 34 0 cm B 634 17 2 8 a 21 3 cm g 22 9 cm C 135 34 3 cm 13 34 3 cm 16 40 6 cm Weight Distribution ThermoFlex900 1400 ThermoFlex2500 ThermoFlex3500 5000 Left Front 29 5 6 13 4 kg 42 8 05 19 5 kg 56 6 105 25 7 kg Left Rear 28 8 lbs 13 1 kg 43 6 lbs 19 8 kg 66 4 105 30 1 kg Right Front 34 3 Ibs 15 6 kg 46 9 0 21 3 kg 64 9 Ibs 29 4 kg Right Rear 33 4 lbs 15 1 kg 47 7 lbs 21 6 kg 76 1 Ibs 34 6 kg Standard unit 2 pump no fluid in tank 5 10 NESLAB ThermoFlex Thermo Scientific Other Options Other Accessories Thermo Scientific Section 5 There are many other options available for your s
88. roke in this Appendix see Set On Off Array in this Appendix di 0 OFF 1 2 nochange see Calibration in this Appendix Copy calibration data between unit backup and reset calibration memory See Set Copy Calibration in this Appendix Process Alarm Process Fault Process Alarm Pressure Process Supply Alarm NESLAB ThermoFlex D 7 Appendix D SET High Alarm Values SET HI FLOW1 SET HI 1 SET HI ANALOG1 SET SETPT1 SET PID Settings SET COOL P TERM1 SET COOL I TERM1 SET COOL D TERM1 D 8 NESLAB ThermoFlex M Ic a1 a2 DO 02 d1 02 cs S lc a1 a2 DO 03 01 02 d3 cs M Ic a1 a2 E0 02 d1 02 cs S Ic a1 a2 E0 03 d1 02 03 cs M Ic a1 a2 E8 02 d1 d2 cs S lc a1 a2 03 d1 d2 d3 cs M Ic a1 a2 F0 02 d1 d2 cs 5 Ic a1 a2 F0 03 d1 d2 d3 cs M Ic a1 a2 F4 02 d1 d2 cs S Ic a1 a2 F4 03 01 d2 03 cs M Ic a1 a2 F5 02 d1 d2 cs S Ic a1 a2 F5 03 01 02 d3 cs M Ic a1 a2 F6 02 d1 d2 cs S Ic a1 a2 F6 03 01 02 d3 cs Process Alarm Process Alarm Pressure Process Supply Alarm Process Fluid Setpoint Cool P Term Cool Term Cool D term Thermo Scientific Request Status Table Basic nn 4 b0 b1 b2 di 63 b4 65 b6 07 00 b1 D2 d2 b4 b5 06 07 00 b1 D2 93 03 b4 05 06 07 00 dA 01 02 Thermo Scientific Unit Running RID1 open or shorted RTD2 open or shorted open or shorted High Temp fixed fault Low Temp fixed fault High Temp fa
89. rray turns off or disables the feature while sending 1 turns on or enables it Sending a 2 does not change the state of the feature In all cases the array is returned showing the state of each feature after the command has been carried out Sending all 2 s effectively turns this command into a request status command nn 1 01 Unit On Off Set Keystroke This command is used to effect a keystroke remotely as if someone pressed the key on the HMI Value 0 Null 1 Enter 2 Up Yes 3 Down No 4 Mode 5 On Off 6 7 D 10 ThermoFlex Thermo Scientific Set Calibration Appendix D This command is used to do a two point calibration The command contains the identification of the item to calibrate RTD1 ANALOG IN 2 etc whether it is the high or low point and the entered calibration value The controller takes the entered value and the current reading along with the entered value and reading at the other calibration point and calculates calibration constants If successful the pass status byte and the new entered value are returned and the new calculated value matches the new entered value Otherwise the fail status byte and the old entered value are returned and the new calculated value matches the old entered value The return message also includes a qualifier byte that indicates the unit of measure and number of decimal places in the entered value Master Sends Ic a1 a2 82 05 91 02 03 d4 db cs slave Returns Ic a1 a2 82
90. s e mail Voice Info 800 258 0830 Thermo Fisher Scientific 25 Nimble Hill Road Newington NH 03801 Tel 800 258 0830 or 603 436 9444 Fax 603 436 8411 www thermo com tc Statement of Copyright Sales Service and Customer Support 25 Nimble Hill Road Newington NH 03801 Tel 800 258 0830 Sales 8 00 am to 5 00 pm Service and Support 8 00 am to 6 00 pm Monday through Friday Eastern Time Fax 603 436 8411 service tc us thermofisher com Dieselstrasse 4 D 76227 Karlsruhe Germany Tel 49 0 721 4094 444 Fax 49 0 721 4094 300 info tc de thermofisher com Building 6 No 27 Xin Jingiao Rd Shanghai 201206 Tel 86 21 68654588 Fax 86 21 64457830 info china thermofisher com Copyright 2008 Thermo Fisher Scientific All rights reserved This manual is copyrighted by Thermo Fisher Scientific Users are forbidden to reproduce republish redistribute or resell any materials from this manual in either machine readable form or any other form Thermo Scientific Preface Section 1 Section 2 Section 3 Section 4 Contents es 1 UE EE NR m Waifs ES cee bi 01010 il UR ii li nere el ERN E TE ES 1 S
91. s and the actual DAC values to calculate the new calibration parameters Use modes 1 3 and 6 to set the output to OV 5V and 10V respectively to check the calibration Exit Analog Output Calibration using mode 0 Thermo Scientific NESLAB ThermoFlex 0 13 Appendix D Set Copy Calibration This command is used to copy calibration parameters from one location to another The source and destination must be different Use the 7 bit Identifier Byte from the SET CALIBRATION command 01 source 0 1 Backup 2 Unit d2 Destination d3 Calibration ID 7 bit Identifier Byte from SET CALIBRATION command 0 14 NESLAB ThermoFlex Thermo Scientific WARRANTY Thermo Fisher Scientific warrants for 24 months from date of shipment the Thermo Scientific NESLAB ThermoFlex unit according to the following terms Any part of the unit manufactured or supplied by Thermo Fisher Scientific and found in the reasonable judgment of Thermo Fisher to be defective in material or workmanship will be repaired at an authorized Thermo Fisher Repair Depot without charge for parts or labor The unit including any defective part must be returned to an authorized Thermo Fisher Repair Depot within the warranty period The expense of returning the unit to the authorized Thermo Fisher Repair Depot for warranty service will be paid for by the buyer Our responsibility in respect to warranty claims is limited to performing the required repairs or replacemen
92. sight tube by gently pulling up on the plastic funnel housing to remove it see illustration on previous page and then gently pulling out the black sight ball stopper from the tube Use a long soft bristle 1 4 brush Use caution not to scratch the glass For easier replacement wet the stopper first and then use a twisting motion to install it in the sight tube Ball Stopper Sight Tube Figure 6 2 Reservoir Cleaning Thermo Scientific NESLAB ThermoFlex 6 3 Section 6 Condenser Filter gt 6 4 NESLAB ThermoFlex Clean the filter through the grille using a vacuum with a soft bristle brush Remove the one piece grille assembly when it is for a more thorough cleaning To remove it first pull the bottom of the assembly away from the unit and then pull it away from the top Failure to clean replace the condenser filter will lead to a loss of cooling capacity and lead to premature failure of the cooling system A NOTE Water cooled units have an embedded screw located at the top of the grille securing it to the unit Loosen the screw to remove the grille A The condenser framing and fins located behind the grille assembly are vety sharp Use caution when removing the assembly A Water cooled units also have a fan with sharp blades ensure the unit is off before removing the assembly A Screw Water cooled units CAUTION Sharp edges Figure 6 3 Screen Removal Once removed vacuum the filter with a
93. st also meet water quality standards or the valve may fail to operate as designed see Section 3 The auto refill valve input pressure must be lt 80 PSI to ensure the valve functions properly The auto refill operates when all of the following conditions are met e Fluid is available e The unitis turned on The fluid reaches low level condition The auto refill shuts off when The fluid reaches the correct operating level Thermo Scientific NESLAB ThermoFlex 5 1 Section 5 5 2 NESLAB ThermoFlex Internal 0 Cartridge A A partial flow DI filter cartridge is designed to provide between 1 and 3 water resistivity NOTE The DI option results in a 0 5 gpm reduction of available flow A NOTE The Puralite sensor that comes with the DI cartridge requires a separate power source Do not use a Deionization DI filter cartridge with Inhibited EG ot Inhibited PG A DI filter will remove inhibitors from the solution rendering the fluid ineffective against corrosion protection Also inhibitors increase fluid conductivity A t Remove the two thumbscrews securing E the DI access panel to the top of the White Connector unit If there is a cartridge in place first undo the hose fitting by pressing the quick disconnect located on the top white connection Blue Connector The DI Cartridge will overpressure if it is removed from the unit before removing the hose fitting A i
94. start stop message A e SEt is used to enable disable the remote setpoint NOTE When remote setpoint is enabled a flashing dot will appear on the controller s display as shown below xc oxx C AnAin is used to configure the analog voltage input type Type 1 0 10 VDC Default Type 2 10 mV C Type 3 4 20 mA is used to enable disable the digital to analog converter Once enabled the desired output type can be selected Type 1 0 10 VDC Default Type 2 10 mV C Type 3 4 20 mA NESLAB ThermoFlex C 3 Appendix C C 4 Table 1 Error Low Level option Tank Overflow Drip Pan Full option Low Temp High Temp Low Flow option High Flow option Low Resistivity option High Resistivity option High Pressure Low Pressure Unit Fault Pump Unit Shut Off Refrigeration Shut Off Limit Fault option sensor Fault Regardless of alarm setting fault or indicator Table 2 Error Low Level option Tank Overflow Drip Pan Full option Auto Refill Error option Low Temp High Temp Low Flow option High Flow option Low Resistivity option High Resistivity option High Pressure Low Pressure Indicator warning PM Timer option Comm Error sensor Fault external sensor opened or shorted Regardless of alarm setting fault or indicator NESLAB ThermoFlex Configurable Relay 1 Error Number Factory Default 31 Enable 44 Disable
95. t 25 Copper 1 3 0 020 ppm if fluid in contact with aluminum iron Iron 0 3 Lead 0 015 Magnesium 12 Manganese 0 05 Nitrates Nitrites lt 10 as Potassium lt 20 Silicate lt 25 Sodium lt 20 Sulfate lt 29 Hardness 17 Total Dissolved Solids lt 50 Other Parameters 6 5 8 5 Resistivity 0 01 Compensated to 25 C section 3 Desirable PPM 0 6 10 1 0 0 1 0 1 0 03 0 3 1 0 0 3 0 05 10 7 8 0 05 0 1 Unfavorably high total ionized solids TIS can accelerate the rate of galvanic corrosion These contaminants can function as electrolytes which increase the potential for galvanic cell corrosion and lead to localized cotrosion such as pitting Eventually the pitting will become so extensive that refrigerant will leak into the water reservoir As an example raw water in the United States averages 171 ppm of NaCl The recommended level for use in a water system is between 0 5 to 5 0 ppm of NaCl Recommendation Initially fill the tank with distilled or deionized water Do not use untreated tap water as the total ionized solids level may be too high Although the initial fill may be as high as 10 MQcm compensated to 25 C the desired level for long time usage for units equipped with a deionization filter is 1 to 3 compensated to 2570 The above two recommendations will reduce the electrolytic potential of the water and pr
96. t cartridge has been in use in hours If desired press and hold and then press WEW to reset the value to 0 unit Indicates the unit operating time in hours This value can not be reset Figure 6 6 Filter Timer Reset Thermo Scientific NESLAB ThermoFlex 6 7 Section 6 Service Codes The controller also displays Service Codes These codes are based on the component run time and are established to avoid unplanned failures The unit will continue to run Contact Thermo Fisher Scientific s Customer Support when any of these codes are displayed SEr 1 SEr 2 SEr 3 SEr 4 SEr 5 SEr 6 You can press the enter key to clear any service code Note the service code number because once cleared the code will not reappear 6 8 NESLAB ThermoFlex Thermo Scientific LZ Xxe ouJeu 991 330ddng 1210351 SALG INO 3 UONIIC 295 2 42942 o qnop SEM C 901555 35 uondo o nuoo uii poddmbo sr jun mop asn py uonisod 12241100 J0 mys Surquunjd uonvormdde 29412 jessooou 800398 4 pue p uonoog 25s Suns OTT Tg INO o u22q savy Aew jum IPO 243 jr 22s 03 15340 5924 SUTUUNI 9 SI PUN IY JJe 9 UOTIDIC 225 243 29243 L 5
97. tan Latvia Lebanon Liberia Libya Liechtenstein Lithuania Luxembourg Madagascar Mali Mauritania Moldova Monaco Mongolia Morocco Mozambique Namibia Nepal Netherlands Niger North Korea Norway Paraguay Peru Poland Portugal Romania Russia Rwanda Saint Vincent and the Grenadines San Marino Sao Tome and Principe Saudi Arabia Senegal Serbia Slovakia Slovenia Somalia South Africa South Korea Spain Sweden Switzerland Syria Tajikistan Thailand Togo Tunisia Turkey Turkmenistan Ukraine Uruguay Uzbekistan Vanuatu Vatican City Vietnam 5 2 Units shipped to the following locations require a 15 Amp service Australia China Fiji Islands Nauru New Zealand Papua New Guinea Solomon Island Tonga Tuvalu 3 Units shipped to the following locations require a 13 Amp service Abu Dhabi Bahrain Bangladesh Botswana Brunei Cyprus Dominica Gambia Ghana Gibraltar Grenada Hong Kong India Ireland Kenya Kiribati Kuwait Lesotho Malawi Malaysia Maldives Malta Mauritius Myanmar Nigetia Oman Pakistan Qatar Saint Lucia Seychelles Sierra Leone Singapote Sri Lanka Sudan Swaziland Tanzania Uganda United Arab Emirates United Kingdom Yemen Zambia Zimbabwe NESLAB ThermoFlex A 1 Thermo Scientific Appendix B Global Voltage Configuration Instructions Units equipped with the Global Voltage option have a voltage configuration panel located behind the refrigeration access pan
98. tions included with your unit or the copy in this manual The manual s version follows the Table of Contents A Before starting the unit double check all electrical and plumbing connections Have extra recirculating fluid on hand If the unit will not start refer to Section 7 Troubleshooting Place the circuit protector located on the rear of the unit to the on 1 position The display will indicate a series of upward scrolling bas 2 e The bars will scroll upward indicating the controller is initializing the unit The initialization takes approximately 15 seconds e When the bars disappear the controller display will go blank e Press the 0 key on the controller The display will show the process fluid temperature The pump and refrigeration system will also statt If the auto restart is enabled and the unit shuts down as a result of a power failure when power is restored the unit will automatically restart Auto restart is enabled using the Setup Loop see Setup Loop in this Section A NOTE After initial start up check your plumbing for leaks A Thermo Scientific Thermo Scientific Section 4 If desired press the aua key to display the pump s discharge pressure P1 The display will alternate between 1 and the pump s discharge pressure value If the unit is equipped with an optional flow transducer pressing the gt key again will display the flow rate FLO The display will alternate between FLO an
99. ts and no claim of breach of warranty shall be cause for cancellation or recision of the contract of sales of any unit With respect to units that qualify for field service repairs Thermo Fisher Scientific s responsibility is limited to the component parts necessary for the repair and the labor that is required on site to perform the repair Any travel labor or mileage charges are the financial responsibility of the buyer The buyer shall be responsible for any evaluation or warranty service call including labor charges if no defects are found with the Thermo Scientific product This warranty does not cover any unit that has been subject to misuse neglect or accident This warranty does not apply to any damage to the unit that is the result of improper installation or maintenance or to any unit that has been operated or maintained in any way contrary to the operating or maintenance instructions specified in this Instruction and Operation Manual This warranty does not cover any unit that has been altered or modified so as to change its intended use In addition this warranty does not extend to repairs made by the use of parts accessories or fluids which are either incompatible with the unit or adversely affect its operation performance or durability Thermo Fisher Scientific reserves the right to change or improve the design of any unit without assuming any ob ligation to modify any unit previously manufactured THE FOREGOING EXPR
100. ualified installation personnel The unit is intended for use on a dedicated outlet The ThermoFlex has an internal circuit protection that is equivalent approximately to the branch circuit rating This is to protect the ThermoFlex and is not intended as a substitute for branch circuit protection Electrical Service Requirements Standard units ThermoFlex900 Voltage Frequency Phase Branch Circuit Line Cord Requirements Plug 100 VAC 50 Hz 10 15A 5 15P 115 VAC 60 Hz 10 15A 5 15P 200 VAC 50 Hz 10 15A 6 15P 208 230 VAC 60 Hz 10 15 6 15 230 VAC 50 Hz 10 16 15 13A ThermoFlex1400 Voltage Frequency Phase Branch Circuit Line Cord Requirements Plug 100 VAC 50 Hz 10 20A 5 20P 115 VAC 60 Hz 10 20A 5 20P 200 VAC 50 Hz 10 15 6 15 208 230 60 Hz 10 15 6 15 230 VAC 50 Hz 10 16 15 13A ThermoFlex2500 3500 5000 Voltage Frequency Phase Branch Circuit Line Cord Requirements Plug 200 VAC 50 Hz 10 20A 6 20P 208 230 VAC 60 Hz 10 20A 6 20P 208 230 VAC Pump 60 Hz 10 30A 6 30P 230 VAC 50 Hz 10 16A1 15A2 13A3 Refer to Appendix for country specific ratings NESLAB ThermoFlex 3 3 Section 3 Electrical Service Requirements Global Voltage units ThermoFlex900 Voltage Frequency Phase Branch Circuit Requirements 115 VAC 60 Hz 10 15 100 VAC 50 60 Hz 10 15A 200 208 230 VAC 60 Hz 10 15A 200 230 VAC 50 Hz 10 16 15 13A ThermoFlex1400 Voltage Frequency Phase Branch Circuit Requirements 1
101. ult none U id unit id is used in RS485 only Identifies devices connected the the RS 485 port Range 1 to 99 Default 1 This display depends on your unit configuration see Section 4 Thermo Scientific NESLAB ThermoFlex D 1 Appendix D All data is sent and received in binary form do not use In the following pages the binary data is represented in hexadecimal hex format The NC Serial Communications Protocol is based on a master slave model The master is a host computer while the slave is the chiller s controller Only the master can initiate a communications transaction half duplex The slave ends the transaction by responding to the master s query The protocol uses RS 232 RS 485 serial interface with the default parameters 9600 baud 8 data bits 1 stop bit and no parity RS 485 offers a a slave address selection default parameter 1 The unit can be controlled through your computer s serial port by using the unit s standard female 9 pin connection RS 232 COMM RS 485 COMM Pin Function Pin Function 1 No connection 1 No connection 2 IX 2 No connection d 3 No connection 4 No connection 4 No connection 5 GND Signal ground 5 No connection 6 No connection 6 No connection 7 No connection 7 No connection 8 No connection 8 d No connection 9 TX Transmitted data from controller Received data to controller 54321 00000 Hardware Mating Connector 9876
102. ult or warn Low Temp fault or warn High Pressure fault or warn Low Pressure fault or warn Drip Pan fault High Level fault Phase Monitor fault Motor Overload fault LPC fault HPC fault External EMO fault Local EMO fault Low Flow fault AutoRefill fault sense 5V fault Invalid level fault Low fixed flow warn Low pressure fault set at factory Low pressure fault set at factory Unit powering up Unit powering down Appendix D NESLAB ThermoFlex 0 9 Appendix D Error The slave detected an error in the message It received from the master so it returns this command instead of echoing the command sent by the master The slave returns the command it received from the master in the ed byte and an error code in the en byte en Error 1 Bad command not recognized by slave 2 Bad data 3 Bad checksum some errors may not result in any response The slave ignores incoming bytes until it sees the valid lead character and its slave address Then it must receive the correct number of bytes determined by the length byte before it can respond If an incomplete frame 15 received the slave will timeout and clear its input buffer without responding Set On Off Array This command is used to set the state of various features of the unit such as whether the unit is on or off and whether the remote probe is enabled or disabled The number of features and their position in the array is product specific Sending 0 in the a
103. w d byte 1 1 data byte the qualifier byte is considered a data byte d byte n n data byte Checksum Bitwise inversion of the 1 byte sum of bytes beginning with the most significant address byte and ending with the byte preceding the checksum To perform a bitwise inversion exclusive OR the one byte sum with FF hex When a command has no value associated with it e g REQ d bytes will be set to 0 Values such as temperature and flow are sent as either 2 or 4 byte signed integers depending on how they are stored in the controller RAM When the controller sends a value a qualifier byte is sent first followed by a 2 or 4 byte integer the least sionificant byte is sent last The qualifier indicates the precision and units of the value The host does not send the qualifier byte it must send the value using the correct precision units and number of bytes The host first inquires about a value it wants to change then uses the number of data bytes and the qualifier byte it recetves to generate the proper integer to send Thermo Scientific NESLAB ThermoFlex D 3 Appendix D Analog Values Qualifier Byte Precision of measurement Unit of measure index Unit of Measure 0 NONE 1 Temperature in C 2 Temperature in F 3 Flow liters per minute 4 Flow in gallons per minute 5 Time in seconds 6 Pressure in PSI 7 Pressure in bars 8 Resistivity in MW cm E g A qualifier byte of 0x12 indicated th
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106. y fluid or performing maintenance where contact with the fluid is likely refer to the manufacturer s MSDS for handling precautions A Position a suitable pan beneath the drain port at the rear of the unit The drain pan must be shallow under 32 in height and have a volume of approximately 3 gallons Remove 4 Male NPT pipe plug from drain port This will drain the return line reservoir plate exchanger and the suction side of the pump To drain the discharge side of the pump disconnect the 1 2 Female NPT outlet connection the brass fitting on the rear of the unit NOTE Internally the unit does not contain a large quantity of fluid on the discharge side however take care to contain what fluid does drain a wet vac can be employed to minimize the potential for spillage A If the unit is equipped with the flow control or pressure relief with flow control option open the valve or remove the drain plug in order to drain the discharge line If the unit 15 equipped with the anti drainback option enter the Setup Loop and utilize the drAin display to open the valve see Section 4 Opening the valve allows the fluid to drain out of the unit Reinstall 4 Male NPT pipe plug using a sealant suitable for the wetted materials prior to refilling the unit Figure 8 1 1 4 Male Reservoir Drain Plug NESLAB ThermoFlex 8 1 Section 8 Water Cooled Draining water cooled units is accomplished by removing the right side
107. y result in internal spillage NOTE Filling the reservoir above MAX LEVEL fill line will result in a unit over flow error FLO causing the unit to shut down A Reservoir Sight Tube amp Ball Figure 3 5 Reservoir Sight Tube amp Ball Since the reservoir capacity may be small compared to your application and air may need to be purged from the lines have extra cooling fluid on hand to keep the system topped off when external circulation is started Replace the reservoir cap by screwing it clockwise Cap should be hand tight Thermo Scientific Section 4 Operation Basic Controller The controller controls temperature using a Proportional Integral Derivative PID algorithm It is designed with self diagnostic features and an easy to use operator interface Figure 4 1 Basic Controller This key is used to start and stop the unit This key is used to navigate through the controller displays and to increase adjustable values This key is used to navigate through the controller displays and to decrease adjustable values This key has two functions Press it once to make changes Press it again after changes are made in order to continue onto other displays This key is also used to navigate through the controller loops Thermo Scientific NESLAB ThermoFlex 4 1 Section 4 42 NESLAB ThermoFlex Setup Start Up NOTE For first time use please refer to the quick start instruc
108. ystem back pressure to your application The valve is factory preset to 80 5 psi 550 1 kPa Packing Nut Adjusting Screw lf the unit is not plumbed to an application set the pressure by installing a loop of hose equipped with a shut off valve between the supply and return fittings Start the unit and allow it to prime then close the valve Figure 5 5 Nut and Screw Use the controller s ax to display P1 it should display 80 5 psi Figure 5 6 Main Loop Use a screwdriver to turn the adjusting screw counterclockwise to reduce pressure until the controller displays the desired setting NOTE Due to internal back pressure the minimum pressure setting for a deadheaded pump is 32 psi for a P 2 pump and 8 psi for a P 1 these settings prohibit external flow from the unit A If the unit is plumbed to an application ensure the unit is off Then back out the adjusting screw counterclockwise to reduce pressure Turn the unit Ensure that there is back pressure in the system Turn the adjusting screw until the controller displays the desired setting Do not exceed 100 psi A When complete inspect the area around the packing nut for fluid If fluid is present slightly tighten the nut and reinspect NOTE Should the unit start to vibrate the valve setting may be the cause Changing the pressure setting 5 psi will eliminate the vibration A Thermo Scientific P1 and P2 Pump Pressure Relief Valve External
109. ystem that can improve its performance in your application Please contact Thermo Fisher Scientific s Sales Service and Customer Support to assist you with questions that you may have regarding upgrading your ThermoFlex see inside cover for contact information Installation kit includes replacement air and fluid filters Maintenance kit includes a set of hoses adaptor fittings and Teflon tape Fluids Fluid treatment kit Please contact Thermo Fisher Scientific s Sales Service and Customer Support to assist you with questions that you may have regarding accessories for your ThermoFlex see inside front cover for contact information NESLAB ThermoFlex 5 11 Section 5 5 12 ThermoFlex Thermo Scientific Maintenance Timer Thermo Scientific Preventive Section6 Preventive Maintenance The ThermoFlex chiller has an integrated preventive maintenance timer that will alert you when it is time to perform preventive maintenance This unique feature will remind you to change your air and fluid filters Based on the environment in which your chiller is located you can choose from four levels of preventive maintenance off L1 L2 and L3 off Disables the alert L1 1 000 hours default setting Heavy manufacturing environment Airborne particulate created during manufacturing process L2 2 000 hours Typical production environment L3 3 000 hours Clean environment

Thermo / Neslab ThermoFlex 1400 Recirculating Chiller

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