Thermo Scientific Neslab Dimax User manual

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NESLAB DIMAX
DI Maximum Cooler
Thermo Manual P/N U00858 Rev. 12/28/05
Installation-Operation-
Basic Service

Thermo Fisher Scientific
25 Nimble Hill Road
Newington, NH 03801
Tel : [phone] or
[phone]
Fax : [phone]
www.thermofisher.com/tc
Statement of Copyright
Copyright © 2007 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.
Sales, Service, and Customer Support
25 Nimble Hill Road
Newington, NH 03801
Tel: [phone]
Sales: 8:00 am to 5:00 pm
Service and Support: 8:00 am to 6:00 pm
Monday through Friday (Eastern Time)
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[email protected]
Dieselstrasse 4
D-76227 Karlsruhe, Germany
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Building 6, No. 27
Xin Jinqiao Rd., Shanghai 201206
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Fax : [phone]
[email protected]

- 1 -
DIMAX DI MAXIMUM COOLER
PREFACE
Compliance ............................................................................................ 3
Unpacking .............................................................................................. 3
After-sale Support ................................................................................... 3
SECTION I
Safety
Warnings ................................................................................................ 4
SECTION II
General Information
Description ............................................................................................. 5
Specifications ......................................................................................... 6
SECTION III
Installation
Site ......................................................................................................... 7
acility Water Requirements ................................................................... 7
Electrical Requirements .......................................................................... 7
ield Wiring Requirements ...................................................................... 7
Plumbing Requirements .......................................................................... 9
luids ..................................................................................................... 10
illing Requirements ............................................................................... 10
Microprocessor Controller ....................................................................... 11
LEDs ...................................................................................................... 11
ault Messages ...................................................................................... 16
SECTION IV
Operation
Start Up .................................................................................................. 17
low Transducers ................................................................................... 18
Low luid Level Safety ............................................................................ 18
Autorefill ................................................................................................. 18
Emergency Off (EMO) ............................................................................ 18
Remote Interface .................................................................................... 19
Resistivity Sensor ................................................................................... 20
DeviceNet ............................................................................................... 20
DeviceNet Interface ................................................................................. 21
DeviceNet Messaging ............................................................................. 22
MODULE STATUS LED .......................................................................... 23
NETWORK STATUS LED ....................................................................... 23
SECTION V
Maintenance
Service Contracts ................................................................................... 25
Deionizing Cartridge ................................................................................ 25
Cleaning ................................................................................................. 25

- 2 -
SECTION VI
Service & Tro bleshooting
Algae ...................................................................................................... 26
Checklist ................................................................................................ 26
Service Assistance ................................................................................. 27
SECTION VII
Diagrams
low Diagram .......................................................................................... 28
Wiring Diagrams ..................................................................................... 29

- 3 -
Preface
Compliance Listedto:
UL61010-12ndEdition
CSAC22.2#61010.12ndEdition
Productstested andfound to bein compliancewith therequirementsdefined in
theEMC standardsdefined by89/336/EECaswellasLowVoltageDirective
(LVD) 73/23/EEC can be identified by the CE Mark on the rear of the unit. The
testinghasdemonstratedcompliancewiththefollowingdirectives:
LVD,73/23/EEC ComplieswithIEC/EN61010-1
EMC,89/336/EEC IEC/EN61326-1
Foranyadditionalinformation,refertotheDeclarationofConformitythat
shipped with the unit.
Unpacking 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, or does
not operate properly, contact the transportation company and file a damage
claim. Under ICC regulations, this is your responsibility.
After-saleSupport ThermoElectronCorporationiscommittedtocustomerservicebothduringand
afterthe sale.If youhave questionsconcerning theoperationof yourunit,
contact our Sales Department. If your unit fails to operate properly, or if you
havequestionsconcerningsparepartsorServiceContracts,contactour
CustomerServiceDepartment.Beforecalling,pleaseobtainthefollowing
informationfromtheunit'sserialnumberlabel:
- BOM number _________________________
- Serial number _________________________
- Softwareversion(seepage14) ____________

- 4 -
Section I Safety
Warnings
Make sure you read and understand all instructions and safety 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, contact our Sales Department (see After-sale Support).
Observe all warning labels.
Never remove warning labels.
Never operate damaged or leaking equipment.
Never operate the unit without cooling fluid in the reservoir.
Always turn off the unit and disconnect the line cord from the power
source before performing any service or maintenance procedures.
Always empty the reservoir before moving the unit.
Always turn off the unit and disconnect the line cord from the power
source before moving the unit.
Additional safety warnings are posted throughout the manual. These warn-
ings are designated by an exclamation mark inside an equilateral triangle with
text highlighted in bold. Read and follow these important instructions. ailure
to observe these instructions can result in permanent damage to the unit,
significant property damage, or personal injury or death.

- 5 -
Section II General Information
Description
The DIMAX Liquid to Liquid Heat Exchanger is designed to remove heat
loads from liquid-cooled instruments. The unit uses facility cooling or tap
water as the secondary cooling medium to remove heat from the primaryfluid
in the closed recirculation loop.
The unit consists of a plate heat exchanger, recirculation pump, stainless
steel reservoir, built-in replaceable deionizing cartridge, and a microprocessor
controller. The controller monitors temperature, controls resistivity and
displays all fluid flows.
The unit has 11 return lines. The flow rate in 8 of these lines as well as the
facility flow line is monitored by flow transducers. The unit also has fluid level
sensors designed to protect the unit's pump and your application. A resistivity
sensor monitors resistivity and sends a signal to the controller when replace-
ment is necessary.

- 6 -
25
20
15
10
5
Pressure PSI
10 20 30 40 50 60
low rate (gallons per minute)
Specifications
Temperature Range1
Pumping apacity
Facility Water
Requirements
Reservoir Volume
Gallons
Liters
Unit Dimensions
(H x W x D)
In hes
Centimeters
20
15
10
5
Pressure PSI
10 20 30 40 50
low rate (gallons per minute)
68.0
257
55 x 32½ x 32½
139.7 x 82.6 x 82.6
+20°C to +30°C
1. Lower limit determined by facility water temperature.

- 7 -
Section III Installation
Site
The unit should be placed in a location with easy access to a facility cooling
water and a drain.
or proper ventilation, a minimum clearance of 6 inches ( 15 centimeters) at
the rear of the unit is necessary.
Never place the unit in a location where excessive heat, moisture, or
corrosive materials are present.
Facility Water
Req irements
or the unit to operate at its full rated capacity, the facility water flow rate must
be at least 50 gallons per minute and the facility water temperature must be
between 17°C to 22°C. If the facility water does not meet these requirements,
the cooling capacity will be reduced.
acility water supply should not exceed 100 psi and the maximum pressure
differential between facility water supply and return should not exceed 65 psi.
Electrical
Req irements
Refer to the serial number label on the rear of the unit for the specific
electrical requirements of your unit.
For high-voltage 380-415/480V units only, ensure the voltage selector
switch is in the correct position to meet the power source rating. The
switch is located behind the main circuit breaker panel on the right-
hand side of the unit.
Ensure the voltage of the power source meets the specified voltage, ±10%.
Make sure an adequate ground connection is provided.
Field Wiring
Config ration
The configuration is a 3 phase, 4 wires with PE. Remove the circuit breaker
panel cover to access the DIMAX main circuit breaker (CB1). The Circuit
Breaker is rated for Ring Lugs (RL).
The copper wires of the multi-conductor flexible power cable are terminated
with ring lugs with #10 holes at both ends. Crimp the ring lugs.
One terminal is connected to the branch circuit breaker, and the other to CB1.

- 8 -
Facilities Type Fitting Size Fitting Type Material Pressure Flow omments Monitored return 1" PT Brass ~5 psi >10gpm at <15psi Auxiliary return 1" PT Brass ~5 psi Main Supply 2" PT Brass 25 psi max 50gpm at <15psi
at the mainframe
Auxiliary supply 1" PT Brass 25 psi max acility water In/Out 2" PT Brass 100 psi max 50gpm max Higher pressures-
consult Thermo NESLAB
Autorefill ½" PT Brass 75 psi max Unregulated Higher pressures-
consult Thermo NESLAB
Reservoir Drain ½" PT Brass Atmospheric N/A Reservoir Overflow 1 PT Brass Atmospheric N/A AC Power Input Customer N/A N/A N/A N/A
Supplied
Table 1 acilities Requirements

- 9 -
The multi-conductor cable has 3 current carrying conductors and 1 non-
carrying conductor (Ground). Each cable conductor is made of stranded
copper, and is at least size AWG 12.
The multi-conductor flexible jacketed cable is type S, SO, ST and STO with
insulation rated for a minimum of 600 V, 75°C (140° ).
The multi-conductor cable enters the DIMAX through a flex-type, non-metallic,
¾ inch diameter strain relief. 3-4 inches of the insulated jacketed should
remain un-stripped for slippage purposes.
Each conductor is connected to the DIMAX main circuit breaker using the ring
lug. Torque each screw to 20 in-lbs.
The Ground conductor should be approximately 6 inches long in order to reach
the ground bus through the ring lug. Torque the screw as well to 20 in-lbs.
Pl mbing
Req irements
Before installing the unit to an instrument that previously used tap water as a
cooling fluid, flush the instrument several times to remove any rust or scale
that has built up. The manufacturer of the instrument should be able to
recommend a cleaning fluid for their equipment.
The plumbing connections are located on the right side of the unit and are
labelled ACILITY WATER OUT (2" PT), ACILITY WATER IN (2" PT), MAIN
SUPPLY (2" PT), AUXILIARY SUPPLY 1 - 3 (1" PT), RETURN LINES 1 - 8
(1" PT), AUXILIARY RETURN LINES 9 -11 (1" PT), AUTORE ILL (½" PT),
and OVER LOW (1" PT).
Connect the SUPPLY line to the inlet of your application. Connect the eight
MONITORED RETURN LINES and the three UNMONITORED AUXILIARY
RETURN LINES to the applicable lines (monitored or unmonitored). Connect
the ACILITY WATER IN to the cooling water supply and the ACILITY
WATER OUT to the cooling water drain or return.
lexible tubing, if used, should be of heavy wall or reinforced construction.
The ACILITY WATER IN is subjected to the maximum pressure of the
facility cooling water. Hose connections should be securely clamped and rated
to withstand the maximum pressure of the system. acility water supply
should not exceed 100 psi. Avoid running tubing near radiators, hot water
pipes, etc. If substantial lengths of tubing are necessary, insulation
may be required to prevent loss of cooling capacity.

- 10 -
The units pump is capable of generating up to 40 psi. The SUPPLY plumbing
should be rated to withstand that pressure.
Tubing and insulation are available from Thermo. Contact our Sales Department
for more information (see Preface, After-sale Support).
It is important to keep the distance between the unit and the instrument being
cooled as short as possible, and to use the largest diameter tubing practical.
Tubing should be straight and without bends. If diameter reductions must be
made, they should be made at the inlet and outlet of the instrument being
cooled, not at the unit.
If substantial lengths of cooling lines are required, they should be pre-filled with
cooling fluid before connecting them to the unit.
Fl ids
Never use flammable or corrosive fluids with this unit.
Do not use automobile anti-freeze. ommercial anti-freeze contains
silicates that can damage the pump seals. Use of automobile anti-
freeze will void the manufacturers warranty.
The selected fluid must have a viscosity of 50 centistokes or less at the lowest
operating temperatures.
DEI water is the recommended fluid for operation.
NOTE: The DEI cartridge is intended for maintaining resistivity only. If tap water
is used the cartridge will not last very long and will take a long time to come up
to resistivity.
Filling Req irements
The reservoir must be filled with a minimum of 16 gallons to ensure the pump
head remains submerged.
The unit has a nominal evaporation rate of up to 2.5 gallons per day. Ensure
the autorefill system is installed.
Autorefill will activate if the level is below 20 gallons and de-activate above 22.5
gallons.
The total reservoir capacity is 68 gallons (257 liters). To prevent siphoning, all
tank return lines are located at the top of the tank.

- 11 -
Microprocessor
Controller
The controller has four different loops. An alphanumeric LCD display presents
numeric readings of various operating conditions within the chiller. Display
function is selected by pressing the appropriate keys to move through a menu
of available information.
Various controller loops allow the operator to display and/or alter different
parameters of the controller. When the controller is first powered up it goes
through a short self test and then enters the Operator Loop, displaying the
reservoir fluid temperature.
The various controller loops can be accessed from the Operators Loop by
pressing and holding the key combinations shown on the next four pages.
NOTE: Should you desire to return to the Operators Loop and abort any
changes, keep pressing LAST or NEXT until the display reads SAVE? Press
NO.
The YES key increments the value. The NO key decrements the value.
Pressing both keys for over three seconds accelerates the changing value.
The display will flash as soon as either key is depressed, and will continue to
flash until the ENTER key is pressed to accept the new value. The new value
will not be used by the controller until the ENTER key is depressed and the
display stops flashing.
If the NEXT key is pressed while the value is flashing, the new value will not be
accepted. The display will stop flashing and the original value will be displayed.
In this case the NEXT key can be used to abort data entry. The display will not
sequence unless the NEXT key is depress again.
LEDs
The yellow AULT indicates a unit fault. The LCD display will indicate the
specific fault, see ault Messages on page 16.
The green CARTRIDGE OK indicates the resistivity is above the low level
setpoint. The red REPLACE CARTRIDGE indicates the resistivity is below
the setpoint.
The bi-color MODULE STATUS LED indicates whether or not the device has
power and is operating properly. Reference page 23 for devicenet LED status.
The bi-color NETWORK STATUS LED indicates the status of the communica-
tion link. Reference page 23 for devicenet LED status.

- 12 -
Operators Loop
When the controller is first powered it goes through a short self test and then
enters the Operators Loop, displaying the temperature of the fluid in the
reservoir, the resistivity of coolant leaving the chiller, the facility water flow
rate and any fault message.
By pressing the NEXT key the controller will step through the menus shown.
Figure 2 Operators Loop
TEMPERATURE displays the temperature of the coolant leaving the chiller in
°C. RESISTIVITY is the resistivity of the coolant leaving the chiller in meg-
ohms/cm. ACILITY WTR is the facility water flow rate in gallons per minute.
The most current fault message is also displayed.
LOWS displays the flow rate in each of the eight process return lines (1 - 8)
and the facility water return line ( ) in gallons per minute.
NOTE: low rate may be present but O will be displayed for any line if that
line's alarm is set to zero using the Setup Loop discussed on page 14.
STATUS displays the unit, pump and DI loop on time in hours.

- 13 -
Setup Loop
The setup loop allows the operator to change the DI setpoints and flow alarm
limits.
To enter this loop you must be in the operators loop and displaying the tem-
perature. Depress and hold the ENTER key while pressing the NEXT key.
Scroll through the SETUP menu using the NEXT or LAST key, press ENTER to
go to the desired sub-menu. Scroll through the sub-menu options using the
NEXT or LAST key, change the values using the YES or NO key. Leave the
sub-menu using the NEXT or LAST key. The display will indicate the save
prompt, press YES or NO.
NOTE: To disable the flow alarm for return lines which are off, set the flow
alarm to zero. At least one flow sensor must be set greater than zero for the
pump to come on.
Figure 3 Setup Loop

- 14 -
onfiguration Loop
The configuration loop allows you to configure frequency, enable the buzzer
and verify software version number.
To enter this loop you must be in the operators loop and displaying the
temperature. Depress and hold the ENTER key. While holding the ENTER
key enter the key sequence NO-YES-NO.
Scroll through the CON IGURE menu using the NEXT or LAST key, press
ENTER to go to the desired sub-menu. Scroll through the sub-menu options
using the NEXT or LAST key, toggle the options using the YES or NO key.
Leave the sub-menu using the NEXT or LAST key. The display will indicate
the save prompt, press YES or NO.
Figure 5 Configuration Loop

- 15 -
alibration Loop To enter this loop you must be in the operators loop and displaying the temperature. Depress and hold the ENTER key. While holding the ENTER key enter the key sequence YES-NO-YES. Use this loop to calibrate the RTD, resistivity, the range of the resistivity out signal (V/Mohm), the range of the temperature out signal (100mV/°C) and the high and low flow calibration parameters. Scroll through the CALIBRATE menu using the NEXT or LAST key, press ENTER to go to the desired sub-menu. Scroll through the sub-menu options using the NEXT or LAST key, change the values using the YES or NO key. Leave the sub-menu using the NEXT or LAST key. The display will indicate the save prompt, press YES or NO.
Figure 4 Calibration Loop
3) RESIST OUT?

- 16 -
Fa lt Messages
ault messages are displayed in the Operators Loop and the alarm will sound.
The faults are proiritized. When a fault is cleared and RESET is pressed, the
next prioritized fault is displayed. The messages below are listed from highest
to lowest priority.
NOTE: Use the controller's MUTE button to silence the alarm.
LOW LEVEL UTOUT
Displayed when the tank level is less than 16 gallons. The message clears
after the fault is cleared and the RESET button is depressed.
MOTOR OVERLOAD
Displayed when the motor overload trips. The message clears after the fault is
cleared and the RESET button is depressed.
RTD FAIL
Displayed when the temperature is over 100°C (RTD open circuit). The mes-
sage clears after the fault is cleared and the RESET button is depressed.
WARNING LOW LEVEL
Displayed when the tank level is less than 20 gallons. The message clears
after the fault is cleared and the RESET button is depressed.
HIGH TEMPERATURE
Displayed when the temperature is over 40°C. The message clears after the
fault is cleared and the RESET button is depressed.
LOW FLOW
Displayed when a return line flow drops below the alarm setpoint. The message
clears after the fault is cleared and the RESET button is depressed.
REPLA E ARTRIDGE
Displayed when the resistivity drops below the low setpoint for more than one
hour. The message clears after the fault is cleared and the RESET button is
depressed.
RESISTIVITY HIGH
Displayed when the resistivity is greater than the high setpoint for more than
eight hours. The message clears after the fault is cleared and the RESET
button is depressed.
EMO
Displayed when the EMO button is depressed. The message self-clears when
the EMO is returned to the normal position.

- 17 -
Section IV Operation
Start Up
Connect the unit to a power source, refer to Section III Installation. See unit
serial tag for power supply requirements.
Before starting the unit, check all plumbing connections and make sure the
circulating system (the DIMAX, your application, and the tubing that connects
them) has been properly filled with cooling fluid. The reservoir level must be
above the low level switches.
Close the main circuit breaker (CB1). The white POWER AVAILABLE light will
illuminate, and the controller initializes and displays the Operators Loop. If a
fault is present, it will be displayed. NOTE: Certain faults prevent the pump
from starting, see ault Messages on previous page.
or units with the G I option, be sure the G I is in the ON position before
closing the circuit breaker and turning on the unit.
Depress the PUMP ON/O button on the controller to start the pump. At
least one flow sensor must be set greater than zero for the pump to come on.
The unit may need additional fluid after the pump starts.
NOTE: If the pump performance is marginal on initial start up the electrical
phase may be wrong. Open the top of the unit and observe the pump's rotation.
If it is wrong, shut the unit down and disconnect it from its power source. Swap
any two AC line conductors.
Depress the PUMP ON/O button on the controller to stop the pump. Turn
the unit off by opening CB1.
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- 18 -
Flow Transd cers
low transducers are connected to return lines one through eight as well as the
facility water inlet line. The transducers monitor the flow rate of the cooling fluid
returning from your application and the facility water flow. lows are displayed
on the controller's Operators Loop. If any flow rate drops below the setpoint,
entered in the controller's Setup Loop, a flow error message appears and a flow
alarm sounds.
NOTE: If the setpoint is set to zero, the flow alarm is disabled.
Low Fl id Level Safety
If the reservoir fluid level drops to 20 gallons, a fault message is displayed on
the controller, the TROUBLE LED illuminates, and a remote signal alarm is
generated. The alarm has to be reset once the fault is cleared. If the level
drops below 16 gallons, the alarm sounds and the pump is de-energized.
A torefill
The unit has a nominal evaporation rate of up to 2.5 gallons per day. Ensure
the autorefill system is installed.
If the reservoir fluid level drops below 20 gallons, the autorefill solenoid will
activate and fill the reservoir to approximately 22.5 gallons.
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.
Activation of the EMO button will remove power from the main contactor coil
stopping operation of the unit.
Resetting of the EMO button will not restart the unit. After all hazards have
been removed and the EMO is reset, the unit must be reset by pushing the
PUMP ON button on the control panel.