Thermo Scientific NESLAB System IV Manual

NESLAB System IV Liquid to
Liquid Heat Exchanger
Thermo Manual P/N U00682
Rev. 11/10/03
Instruction and Operation Manual

System IV Liquid to Liquid Heat Exchanger
Instruction and Operation Manual
Table of Contents
PREFACE
Compliance ............................................................................................ 3
After-sale Support ................................................................................... 3
Warranty ................................................................................................. 3
NES-care ............................................................................................... 3
Unpacking .............................................................................................. 3
SECTION I
Safety
Warnings ............................................................................................... 4
SECTION II
General Information
Description ............................................................................................. 5
Specifications ........................................................................................ 5
SECTION III
Installation
Site ........................................................................................................
Facility Water Requirements .................................................................
Electrical Requirements ......................................................................... 7
Voltage Selection ................................................................................... 7
Plumbing Requirements ........................................................................ 7
Fluids ..................................................................................................... 8
Filling Requirements .............................................................................. 9
Auto Refill Device (Optional) ................................................................. 9
Flow Control ........................................................................................... 9
Auto Restart ........................................................................................... 9
SECTION IV
Operation
Start Up.................................................................................................. 10
Temperature Controller .......................................................................... 11
Tune Loop .............................................................................................. 12

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SECTION V
Maintenance & Service
Service Contracts .................................................................................. 13
Facility Water Strainer ........................................................................... 13
Algae ...................................................................................................... 13
Configuration ......................................................................................... 13
Voltage Selection ................................................................................... 14
External Interlock Contact ..................................................................... 14
Fuses ..................................................................................................... 14
Phase Rotation ...................................................................................... 14
Pump Motor Overload Protector ............................................................ 15
Displaying Software Version .................................................................. 15
SECTION VI
Tro bleshooting
Error Codes ............................................................................................ 1
Service Assistance ................................................................................ 17
Technical Support .................................................................................. 17
SECTION VII
Diagrams
Flow Diagram ......................................................................................... 18
Rear View .............................................................................................. 19
APPENDIX
Water Quality Standards and Recommendations .................................. 20
SECTION VIII
Warranty ............................................................................................................... 21

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Preface
Compliance
Products tested and found to be in compliance with the requirements defined in
the EMC standards defined by 89/33 /EEC as well as Low Voltage Directive (LVD)
73/23/EEC can be identified by the CE label on the rear of the unit. This label
indicates testing has demonstrated compliance with the following directives:
LVD, 73/23/EEC Complies with UL 3101-1:93
EMC, 89/33 /EEC EN 55011, Class A Verification
EN 50082-1:1992
IEC 1000-4-2:1995
IEC 1000-4-3:1994
IEC 1000-4-4:1995
For any additional information refer to the Letter of Compliance that shipped
with the unit (Declaration of Conformity).
After-sale S pport
Thermo Electron Corporation is committed to customer service both during and
after the sale. If you have questions concerning the operation of your unit,
contact our Sales Department. If your unit fails to operate properly, or if you
have questions concerning spare parts or Service Contracts, contact our
Service Department, see back cover. Before calling, please obtain the following
information from the unit's serial number label on the rear of the unit:
- BOM number ________________________________
- Serial number _______________________________
Warranty
Units have a warranty against defective parts and workmanship for one full
year from date of shipment. See back page for more details.
NES-care Extended
Warranty Contract
 Extend parts and labor coverage for an additional year.
 Worry-free operation.
 Control service costs.
 Eliminate the need to generate repair orders.
 No unexpected repair costs.
Other contract options are available. Please contact us for more information.
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 contact the
transportation company and file a damage claim. Under ICC regulations, this is
your responsibility.

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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).
Performance of installation, operation, or maintenance procedures other than
those described in this manual may result in a hazardous situation and may
void the manufacturer's warranty.
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, or
before moving the unit.
Always empty the reservoir before moving the unit.
Never operate equipment with damaged line cords.
Refer service and repairs to a qualified technician.
In addition to the safety warnings listed above, warnings are posted
throughout the manual. These warnings are designated by an exclamation
mark inside an equilateral triangle with text highlighted in bold print. Read
and follow these important instructions. Failure to observe these instruction
can result in permanent damage to the unit, significant property damage, or
personal injury or death.

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Section II General Information
Description
The NESLAB System IV Liquid to Liquid Heat Exchanger is designed to
remove heat from water-cooled instruments.
The unit consists of a heat exchanger, recirculation pump, stainless steel
reservoir and a microprocessor temperature controller.
Specifications
Temperature Range
Temperature tability
Cooling Capacity1
Pumping Capacity2
Reservoir Volume
Gallons
Liters
Unit Dimensions3
(H x W x D)
Inches
entimeters
+5°C to +40°C
±1.0°C
50 gpm at 0 psi
.5
24.
33¾ x 23.0 x 27.0
85.7 x 58.4 x 8.
1. Cooling capacity based on a 10°C difference between the temperature of the cooling water
supply and a 35 gpm process water flow rate; using a 3 horsepower centrifugal pump and
55 psi tap water pressure.
2. CP 100 pump customizing options available.
3. Additional dimensions are shown on page 19.
5 101520253035
120
100
80
60
40
20
HEAT REMOVAL (KW)
FACILITY FLOW RATE (GPM)
35 gpm process water flow

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Section III Installation
Site
The unit should be placed in a laboratory or clean industrial environment with
easy access to a facility cooling water and a drain.
Facility Water
Req irements
Limit the facility water inlet pressure to less than 150 psi (10,2 Bar) and
limit the facility water inlet pressure to outlet pressure differential
across the ystem IV to less than 35 psid (2,4 Bar).
Refer to the Cooling Capacity chart in Section II, Specifications. The flow rate
of the cooling water supply must meet or exceed these requirements for the
unit to operate at its full rated capacity. If the cooling water does meet these
standards, the cooling capacity will be derated. The chart is based on a 10°C
difference between the temperature of the cooling water supply and the pro-
cess fluid entering the instrument being cooled.
As the heat load increases, the required flow rate of the cooling water supply
increases. For example, if the heat load is 0 kilowatts, only 20 gallons per
minute is required to remove the heat. However, if the heat load is 80
kilowatts, 2 gallons per minute is required.
The flow meter on the front of the unit does not measure the flow rate of the
cooling water supply. The flow meter measures the flow rate of the cooling
fluid returning to the instrument being cooled.
The approximate facility side water pressure drop though the unit is shown
on the graph below.
5101520253035
10
8
6
4
2
Pressure Drop (PSI)
Flow Rate (GPM)

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Electrical Req irements
The unit construction provides protection against the risk of electric
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 connec-
tion is provided.
Refer to the serial number label on the rear of the unit to identify the specific
electrical requirements of your unit.
Make sure the voltage of the power source meets the specified voltage, ±10%.
Voltage Selection
If the unit is to be operated from a 220 to 240 volt source, a voltage selector
inside the unit must be reset. See Section VII, Service for instructions on
changing the voltage selection.
Pl mbing
Req irements
The plumbing connections are located on the rear of the unit and are la-
belled FACILITY WATER and RECIRCULATING WATER. FACILITY
WATER connections are 1 inch nominal FPT. RECIRCULATING WATER
connections are 1½ inch nominal FPT. See illustration on page 19.
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.
Connect the FACILITY WATER SUPPLY to the cooling water source.
Connect the FACILITY WATER RETURN to the drain.
Connect the RECIRCULATING WATER SUPPLY to the inlet of the instru-
ment being cooled. Connect the RECIRCULATING WATER RETURN to the
outlet of the instrument being cooled.
Flexible tubing, if used, should be of heavy wall or reinforced construction.
All tubing should be rate to withstand 80 psi at +40°C. Make sure all tubing
connections are securely clamped. 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.
Tubing and insulation are available from Thermo. Contact our Sales Department
for more information (see Preface, After-sale Support).

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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 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
automotive anti-freeze. Commercial anti-freeze contains silicates that
can damage the pump seals. Use of automotive anti-freeze will void the
manufacturers warranty.
We recommend using distilled/deionized water with a 0.05 to 0.1 megohm-cm
reading.
Highly distilled/deionized water, above the 3 megohm-cm region, may
become aggressive and is not recommended for use with units with
wetted parts other than stainless steel. Distilled/deionized water in the
15 megohm-cm region is definitely aggressive and should not be used.
Units operating in these regions should be closely monitored. ee
Water Quality tandards and Recommendations in the Appendix.
If you do not have access to distilled/deionized water we recommend using
filtered tap water. Thermo cannot recommend any custom fluids, these fluids
are too dependent on your particular application.
Below +8°C, a non-freezing solution is required. The selected cooling fluid
must have a viscosity of 50 centistokes or less. A 50/50 mixture, by volume,
of distilled/deionized water and laboratory grade ethylene glycol is sug-
gested.

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Filling Req irements
Remove the top access panel and locate the reservoir. Fill the reservoir with
cooling fluid to within one inch of the top. Since the reservoir capacity is
small compared to the volume of the circulating system, keep extra cooling
fluid on hand until the circulating system is full.
A to Refill
Device (Optional)
The automatic refill device maintains the correct level of cooling fluid in the
reservoir. The device consists of a float switch in the reservoir and a solenoid
valve at the rear of the unit. If the cooling fluid level falls, the float switch will
drop, opening the solenoid valve and allowing make-up fluid to fill the reservoir.
Once the cooling fluid reaches the proper level, the float switch will rise and the
solenoid valve will close.
NOTE: For the solenoid valve to close properly, the minimum supply flow rate
should be 2.2 gallons per minute.
Connect the 3/8 inch OD stainless steel barbed fitting on the solenoid valve
to the make-up fluid source using 5/16 or 3/8 inch ID flexible tubing.
Tubing is available from Thermo. Contact our Sales Department for more
information (see Preface, After-sale Support).
Flow Control
The RECIRCULATING FLOW CONTROL handle is connected to a three-way
valve that controls the flow of the cooling fluid to the instrument being cooled.
The handle is located on the front of the unit.
When the handle is in the + position, the valve is open and all available
cooling fluid is supplied to the instrument being cooled. When the handle is
in the 0 position, the valve is closed and no cooling fluid is supplied to the
instrument being cooled. When the handle is between these two positions,
the flow rate of the cooling fluid is between full flow and no flow. Use the
flow meter to adjust the desired flow rate.
The gauge next to the flow control handle indicates the operating pressure.
A to Restart
Units are equipped with an auto restart feature. If power is lost, the unit will
automatically restart when power is restored. This feature is enabled/
disabled using the controller's Tune Loop, see page 12.

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Section IV Operation
Start Up
Before starting the unit, double check all electrical and plumbing connections
and make sure the circulating system (the System III, your application, and
the tubing that connects them) has been properly filled with cooling fluid.
Turn the RECIRCULATING FLOW CONTROL to 0. Press START/STOP.
The pump starts and the controller displays the reservoir fluid temperature.
The low fluid level monitor in the reservoir prevents the unit from operating if
the fluid level in the reservoir is below the safe operating level. By slightly,
and/or intermittently opening the RECIRCULATING FLOW CONTROL
(toward +) and using extra cooling fluid to keep the reservoir topped off,
the system can be filled without repeated tripping of the monitor.
If the unit shuts down, top off the reservoir and restart it. When the system
is full, the reservoir level will no longer drop when the RECIRCULATING
FLOW CONTROL valve is opened (toward +).
A control valve, located in the FACILITY WATER inlet line, regulates the
flow rate of the cooling water supply as it enters the unit. The valve regulates
the flow rate based on the heat load. Flow through the unit stops automati-
cally when the unit is shut off.
Temperature Controller
To turn the unit off, press START/STOP. The recirculation pump will stop.
The IDLE and COOL lights indicate the control valves status. When the
temperature control valve is wide open (for maximum cooling), the COOL
light is on steady. When the control valve is closed, the IDLE light is on. As
the control valve moves between these extremes, the two lights flash with
varying on-time to indicate the approximate position of the control valve.

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Temperat re Controller
The microprocessor controller controls temperature using a PID (Propor-
tional-Integral-Derivative) algorithm. It is designed with self-diagnostic
features and easy to use operator interface.
NEXT ENTER
Use this key to accept and save changes.
YE ,
This key is used to increase numerical values.
NO,
This key is used to decrease numerical values.
When the controller is powered it displays the reservoir fluid temperature.
Press the NEXT ENTER key to view the setpoint. The display flashes
between P and the actual setpoint number. If desired, use the YE and NO
keys to change the setpoint. The display flashes as soon as either key is
depressed. Once the desired setpoint is displayed, press NEXT ENTER.
When selecting an operating temperature, remember that the lowest achiev-
able temperature is a function of the available flow rate, the temperature of
the cooling water supply and the heat load.
The temperature control system actuates a control valve in the FACILITY
WATER line. The control valve adjusts the flow of the cooling water supply
to produce the desired operating temperature.
NOTE: The controller does not use the new value until the NEXT ENTER
key is depressed and the display stops flashing. The controller will not allow
you to enter a value above the maximum or below the minimum value, or
any illegal value. If you try to enter an illegal value the display will revert to
its original value when the last digit was entered.
If the NEXT ENTER key is not depressed within one minute, the controller
will time out and the new value will not be accepted. The controller will
revert to the previous value.
NOTE: Error codes are addressed in Section VI, Troubleshooting.

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Set pLoop
The controller is used to tune the COOL PID values; configure the unit to
continue to run (Indc) or shut down (FLt) in the event of a fault; set the high
(Hit) and low (Lot) temperature limits; and enable/disable auto restart (Auto).
If a temperature limit is exceeded the controller will display an error code,
see Section VI.
NOTE: Serial Communication (SEr) is not operational. Ensure the display
indicates OFF.
Setup Loop
CooL is used to adjust the controller's PID values. However
Thermo recommends only a qualified technician change the PID
values. Incorrect values will hamper unit performance. Factory set
values are: P = 15; I = 0.3; D = 0.0.
With the controller displaying the fluid temperature press and
hold the NO key and then press the NEXT ENTER key. The
controller will display tunE. Press YES to display CooL.
Press NEXT ENTER to display Stor press YES
to accept all the changes press NO to abort all
changes and restore all the previous values. The
controller will again display the fluid temperature.
Press NEXT ENTER to display the
alarm (ALr) prompt. Press YES to
display Indc and have the unit continue
to run in the case of a fault. Press NO to
display FLt and have the unit shut down
in the case of a fault. The factory preset
is FLt.
Press NEXT ENTER to display the
high temp (Hit) alarm setting. If
desired use the arrow keys to
change the value. The factory
preset value is 55°C.
Press NEXT ENTER to display the
low temp (Lot) alarm setting. If
desired use the arrow keys to
change the value. The factory preset
value is -10°C.
Press NEXT ENTER to display the
auto restart (Auto) prompt. Use
the arrow keys enable/disable this
feature. The factory preset is ON.
Press NEXT ENTER to display the
serial comm (SEr) prompt. The
display should flash NO. If not use
the arrow keys until NO is
displayed.

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Section V Maintenance & Service
For personal safety and equipment reliability, the following procedure
should only be performed by a qualified technician. Contact our
ervice Department for assistance (see Preface, After-sale upport).
Service Contracts
Thermo offers on-site Service Contracts that are designed to provide extended
life and minimal down-time for your unit. For more information, contact our
Service Department (see Preface, After-sale Support).
Facility Water
Strainer
The facility water strainer is the user-installed basket strainer on the
FACILITY WATER inlet. NOTE: The strainer is designed to be used only
with water. Clean the strainer when it becomes visibly clogged or dirty.
Disconnect the power cord from the power source and turn off the facility
cooling water.
Place a container under the strainer to collect any water that spills out of the
basket when it is removed.
Unscrew the clear plastic basket. Remove the screen and rinse it with water.
Replace the screen and the basket.
Algae
To restrict the growth of algae in the reservoir, it is recommended that the
reservoir cover be kept in place and that all circulation lines be opaque. This
will eliminate the entrance of light which is required for the growth of most
common algae.
We recommend the use of Chloramine-T, 1 gram per 3.7 liters.
Config ration
The unit top is secured to the cabinet by four ball stud retainers; one at each
corner. Remove cabinet top by prying upward gently (cover pops off) in
order to perform the following adjustments.
In some cases, the side access panels may need to be removed. The
access panels are secured using screws installed through the bottom of the
cabinet.

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Voltage Selection
Remove the top cover from the cabinet.
The VOLTAGE SELECT toggle switch is located on the right side of the
control box. Two ranges are available: 200-208V and 220-240V. Set the
switch for the appropriate range.
Replace the top cover.
Fa lt Interlock
Contact
A set of contacts is connected to a receptacle on the control panel. The
contacts are rated 10A/240V. This is not a power inlet or outlet. The
receptacle is isolated from the circuitry. Its ground pin is connected to the
chassis. The contacts are closed during normal operation and open when
the unit is turned off or when a fault is detected.
F ses
The main fuses are 20 Amp RK5. The controller fuses are 1 Amp time delay.
Do not replace with an alternate amperage.
ingle Phase Units
Remove the top cover from the cabinet.
The fuses are located on the right side of the control box.
Three Phase Units
Remove the top cover, the right access panel and the control box cover.
The fuses are located inside the control box.
Phase Rotation
Three phase units with three phase pump motors are equipped with a phase
rotation interlock. If the phasing is wrong, the controller will display PHEr and
the unit will not start.
Unplug the unit. Reverse any two power cord wires in the power cord plug.
Never remove the green ground wire.
Plug in the unit. The PHEr display should be off and the unit should start.

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P mp Motor
Overload Protector
Three phase units with three phase pump motors have a pump motor
overload protector.
The overload protector prevents the pump motor from exposure to
excessively high current. If an overload fault occurs, due, for example, to a
heavy work load, the controller will display OL and the unit will shut down.
The overload protector will automatically reset after about two minutes. The
unit must be manually restarted.
Displaying Software
Version
This procedure will display the software version number on the units display.
In the event the unit is not operational, the software version (and the check-
sum) can also be read from the label which is on the microprocessor chip
itself.
The following chart uses an example of software version 000550.93A
begin at the reservoir temperature display 20.3°C
Press and hold NO for at least 10 seconds. 0550
displays software version digits to left of decimal. Note the two leading zeros
do not display.
Press NEXT 93
displays software version digits to right of decimal.
Press NEXT 1
displays software version revision letter (as its equivalent number - display
cannot show letters. A=1, B=2, etc.)
Press NEXT 0000
displays checksum - this can be disregarded
Press NEXT 20.3°C
returns to reservoir temperature display

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Section VI Troubleshooting
Error Codes
The controller also has the capability to display error codes.
Power up Errors
Power up errors are displays until any controller key is pressed. If the error
message persists the problem is likely a keypad or controller board failure.
Display Indication
Er 00 ROM checksum
Er 01 RAM check
Er 02 Keypad failure
Er 03 NOVRAM checksum error
Operating Errors
Operating errors are displays once and then clear after three seconds or
when any controller key is pressed. If error messages Er04 - Er14 persist,
the problem is likely controller board failure. If Er15 is displayed, ensure
serial communications is turned off in the Setup Loop. If Er1 is displayed
the unit needs calibration, contact us for assistance.
Display Indication
Er 04 - 13 Interrupt error
Er 14 Synchronous error
Er 15 Asynchronous error
Er 1 Bad calibration
Latching Errors
In order to restart the unit when a latching error is displayed, the controller's
START/STOP button must be pressed after the condition is cleared.
Display Indication
Lo t Fluid temperature lower than low temp alarm setting.
Hi t Fluid temperature higher than high temp alarm setting.
Er 22 Fluid temperature higher than the high overrange point.
This is a fixed value, factory set at 55°C.
Er 25 RDT1 input shorted.
Er 2 RTD1 input open.
LLF Low level fault switch open for at least three seconds.
PHEr Improper phasing.
OL Pump motor overload.
If any other code appears contact Thermo customer service, see Preface.

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Service Assistance
If, after following these troubleshooting steps, your units fails to operate
properly, contact our Service Department for assistance (see Preface, After-
sale Support). Before calling please obtain the following information:
Part number
Serial number
Voltage of unit
Voltage of power source
Software Version
Technical S pport
Our Service Department can provide you with a complete list of spare parts
for your unit (see Preface, After-sale Support). Before calling, please obtain
the following information:
Part number
Serial number

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Section VII Diagrams
Flow Diagram

-19-
Rear View