Thermo Scientific System I Owner's manual

Visit our Web site at:
http://www.thermoscientific.com/tc
Product Service Information, Applications
Notes, MSDS Forms, e-mail.
Voice Info: [phone]
Thermo Scientific
System I
Heat Exchanger
Thermo Scientic Manual P/N 013564
Rev. 03/04/2013
Installation
Operation
Basic Maintenance

Visit our Web site at:
http://www.thermoscientific.com/tc
Product Service Information, Applications
Notes, MSDS Forms, e-mail.
Voice Info: [phone]
Thermo Scientific
System I
Heat Exchanger
Thermo Scientic Manual P/N 013564
Rev. 03/04/2013
Installation
Operation
Basic Service

Thermo Fisher Scientic
25 Nimble Hill Road
Newington, NH 03801
Tel : [phone] or
[phone]
Fax : [phone]
www.thermoscientic.com/tc
Statement of Copyright
Copyright © 2013 Thermo Fisher Scientic. All rights reserved.
This manual is copyrighted by Thermo Fisher Scientic.
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)
Fax: [phone]
service.tc.us@thermosher.com
Dieselstrasse 4
D-76227 Karlsruhe, Germany
Tel : [phone]
Fax : [phone]
info.tc.de@thermosher.com
Building 6, No. 27
Xin Jinqiao Rd., Shanghai 201206
Tel : [phone]
Fax : [phone]
info.china@thermosher.com

Table of Contents
PREFACE Compliance ............................................................................................ 2
WEEE/RoHS.......................................................................................... 2
After-saleSupport................................................................................... 3
Unpacking .............................................................................................. 3
Warranty................................................................................................. 3
Out of Box Failure................................................................................... 3
Feedback ............................................................................................... 3
SECTION I
Safety Warnings ................................................................................................ 4
SECTION II
GeneralInformation Description ............................................................................................. 5
Specifications ......................................................................................... 5
SECTION III
Installation Site......................................................................................................... 6
FacilityWaterRequirements................................................................... 6
ElectricalRequirements.......................................................................... 6
PlumbingRequirements .......................................................................... 7
Fluids ..................................................................................................... 7
WaterQualityStandardsandRecommendations.................................... 8
FillingRequirements ............................................................................... 9
PumpPurging......................................................................................... 9
SECTION IV
Operation StartUp .................................................................................................. 10
TemperatureAdjustment......................................................................... 10
SECTION V
Special Features LowLevelFluidMonitor........................................................................... 11
HighTemperatureMonitor....................................................................... 11
EXTERNALINTERLOCKContacts.......................................................... 11
SECTION VI
Maintenance and
Service ServiceContracts ................................................................................... 12
Cleaning ................................................................................................. 12
Algae ...................................................................................................... 12
PumpStrainer ........................................................................................ 12
PressureReliefValveAdjustment ........................................................... 13
PumpLubrication.................................................................................... 13

- 2 -
SECTIONVII
Troubleshooting Checklist................................................................................................. 15
ServiceAssistance ................................................................................. 16
TechnicalSupport .................................................................................. 16
SECTIONVIII
Diagrams FlowDiagram ......................................................................................... 17
DimensionalDrawings ............................................................................ 18
SECTION IX
Warranty

- 2 -
Preface
Compliance
Products tested and found to be in compliance 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:
LVD, 73/23/EEC Complies with IEC/EN61010-1
EMC, 89/336/EEC IEC/EN61326-1
For any additional information, refer to the Declaration of Conformity that shipped with the unit.
WEEE/RoHS
This product is required to comply with the European Union’s Waste Electrical & 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, and this product should be disposed of or recycled through them. Further
information on Thermo Fisher Scientific’s 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 at:
www.thermofisher.com/WEEERoHS

- 3 -
After-saleSupport
Thermo Fisher Scientific 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, contact our Customer
Service Department. Before calling, please obtain the following information:
- BOM number
- Serial number
-Softwareversion
The BOM and serial number are on a label on the rear of 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 contact the transportation company and
file a damage claim. Under ICC regulations, this is your responsibility.
Warranty
Units have a warranty against defective parts and workmanship for one full year from date of
shipment. See back page for more details.
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. The unit must be installed 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.
Feedback
We appreciate any feedback you can give us on this manual. Please e-mail us at
[email protected]. Be sure to include the manual part number and the revision date
listed on the front cover.

- 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.
Never operate equipment with damaged line cords.
In addition to the safety warnings listed above, warnings are posted through
out the manual. These warnings are designated by an exclamation mark
inside an equilateral triangle with text highlighted in bold. Read and follow
these important instructions. Failure 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 System I Liquid to Liquid Heat Exchanger uses building recirculating
or tap water as the secondary cooling medium to remove heat from the
cooling fluid in the closed recirculation loop.
The unit consists of a heat exchanger, recirculation pump, PVC reservoir,
and an analog temperature controller.
Specifications
Temperature Range +5°C to +35°C
Temperature Stability ±1.0°C
Cooling Capacity
50 Hz or 60 Hz at +20°C 14 kW/47768 BTU
Heat Removal
Pumping Capacity
60 Hz 3.0 gpm @ 60 psi (11.4 lpm @ 4.1 bar)
50 Hz 2.5 gpm @ 42.6 bar (9.4 lpm @ 2.9 bar)
Reservoir Volume
Gallons 1.0
Liters 3.8
UnitDimensions
(H x W x D)
Inches 25½ x 14¼ x 20½
Centimeters 64.7 x 36.2 x 52.1
Unit Weight
Pounds 90
Kilograms 43.5
20
16
12
8
4
1 2 3 4 5 6 Flow Rate (gpm)
Heat Removal (kilowatts)
0.5 3.5 7.5 12.5 18 25 Pressure Drop (psi)*
5 10 15 20 Flow Rate (lpm)
+10°C T
Specifications obtained using water as the recirculating fluid and using water as a coolant on
secondary loop, at nominal operating voltage. Other fluids, process temperatures, ambient
temperatures, altitude, or operating voltages will affect performance. Specifications subject to
change. Heat load removal is based on a 10°C difference between the temperature of the
cooling water supply (house water) and the cooling fluid as it leaves the System unit.
*Pressure drop indicates the minimum pressure differential pressure between the facility
water inlet and outlet to achieve the corresponding facility water flow rate
(Pressureinlet - Pressureoutlet = Pressuredrop).

- 6 -
Section III Installation
Site
The unit should be placed in a location with easy access to a cooling water
source and a drain. Never place the unit in a location where excessive heat,
moisture, or corrosive materials are present.
FacilityWater
Requirements
Limit the facility water inlet to outlet pressure differential across the
System I to less than 65 psid.
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 not meet
these standards, the cooling capacity will derate. The chart is based on a 10°C
difference between the temperature of the cooling water supply (facility water)
and the cooling fluid as it leaves the System I.
As the heat load increases, the required flow rate of the cooling water supply
increases. For example, if the heat load is 8 kilowatts, only 3.25 gallons per
minute at 8.5 psi is required to remove the heat. However, if the heat load
is 14 kilowatts, about 5.5 gallons per minute at 21.5 psi is required.
Electrical
Requirements
Refer to the serial number on the rear of the unit for the specific electrical
requirements of your unit.
Ensure the voltage of the power source meets the specified voltage, ±10%.
Make sure an adequate ground connection is provided.

- 7 -
Plumbing
Requirements
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 scalethat
has built up. The manufacturer of the instrument should be able torecommend
a cleaning fluid for their equipment.
The plumbing connections are located on the rear of the unit and are
labelled COOLING WATER and RECIRCULATING WATER. The top fittings
are inlets and the bottom fittings are outlets. The COOLING WATER
connections are ¾ inch FPT. The RECIRCULATING WATER connections
are ½ inch MPT.
Connect the COOLING WATER connections to the cooling water supply.
Connect the RECIRCULATING WATER connections to the instrument being
cooled.
Flexible tubing, if used, should be of heavy wall or reinforced construction.
All tubing should be rated to withstand 80 psi at +35°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 Fisher. 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.
Fluids
Refer to the Water Quality and Recommendations on the next page.
The selected fluid must have a viscosity of 50 centistokes or less at the
lowest operating temperature.
Filtered tap water is the recommended fluid for normal operation.
Never use flammable or corrosive fluids with this unit.

- 8 -
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 corrosion such as pitting. Eventually, the pitting could become so extensive that
leaking will occur between the process water and facility water diminishing the System's heat transfer
capability.
High water hardness (Calcium and Maganese) can also produce scaling. Scaling will inhibit heat transfer
between the process and facility side by building up a deposit layer on metal surfaces. 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/deionized water. Do not use untreated tap water as
the total ionized solids level may be too high.
The desired level for long time usage is 1 to 3 MOhmcm (compensated to 25°C).
The above recommendations will reduce the electrolytic potential of the water and prevent or reduce the
galvanic corrosion observed.
Water Quality Standards
and Recommendations Permissible (PPM) Desirable (PPM)
Microbiologicals
(algae, bacteria, fungi) 0 0
Inorganic Chemicals
Calcium <40 <0.6
Chloride 250 <25
Copper <1.3 <1.0
Iron <0.3 <0.1
Lead <0.015 0
Magnesium <12 <0.1
Manganese <0.05 <0.03
Nitrates\Nitrites <10 as N 0
Potassium <20 <0.3
Silicate <25 <1.0
Sodium <20 <0.3
Sulfate <250 <50
Hardness <17 <0.05
Total Dissolved Solids <50 <10
Other Parameters
pH 6.5-8.5 7-8
Resistivity 0.01* 0.05-0.1*
* MOhmcm (Compensated to 25°C)
15.00
10.00
3.00
1.00
0.10
0.05
Resistivity (MOhmcm @ 25°C)
Not Recommended, Increasingly Corrosive
Operations with Stainless Steel Systems
Operations with
Mixed Metals
Copper/Brass/
Stainless Steel CONSULTMATERIALSENGINEER
10 20 30 40 50 60 70 80
Water Quality Considerations
°C

- 9 -
Filling
Requirements
The reservoir access cover is located on top of the unit. Remove the reservoir
access cover and locate the reservoir plug (square nut). Remove the plug and
fill the reservoir to the bottom of the fill hole flange. Keep extra cooling fluid on
hand until the entire system (the System I, the instrument being cooled and
the tubing that connects them) is filled.
Do not replace the reservoir plug until the unit is circulating fluid through the
instrument being cooled (see Section IV, Start Up).
Pump Purging
PD-2 pumps may require pump purging.
Pump purging is necessary to purge air trapped in the pump head cavity.
When the unit is started, if there is no flow in the RECIRCULATING
SUPPLY tube, or if the flow is restricted (see Section II, Pumps to review the
pump flow and pressure specifications), purging is necessary.
Place a container under the SUPPLY connection. Start the unit. Loosen
the hose clamp on the SUPPLY connection and partially remove the hose
from the connection. Do not completely remove the hose from the
SUPPLY connection. Allow the air to escape. After a few moments,
cooling fluid should flow from the connection.
If fluid does not flow on its own accord, attach a short piece of tubing to the
connection and apply suction to start flow.
Once flow is established, reconnect the tubing on the SUPPLY connection.
The pump is now purged and the unit is ready for operation.

- 10 -
Section IV Operation
Start Up
Before starting the unit, check all electrical and plumbing connections and
make sure the circulating system has been properly filled with cooling fluid.
To start the unit, place the POWER ON/OFF switch in the ON position and
momentarily press and hold the PUSH TO START button. The recirculation
pump will start.
If the unit does not continue to run when the PUSH TO START button is
released, check the reservoir fluid level. The float switch in the reservoir prevents
the unit from operating if the fluid level is below the operating level. If the fluid
level is low, “top off” the reservoir and restart the unit.
Once the System I continues to circulate cooling fluid through the instrument
being cooled, replace the reservoir plug. Tighten the plug “hand tight”;
excessive pressure can damage the PVC reservoir.
Temperature
Adjustment
A control valve, located in the COOLING 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 is discontinued
when the unit is shut off.
To adjust the temperature of the cooling fluid, turn the calibrated
TEMPERATURE dial and position the desired temperature as close as
possible to the reference line.
The RECIRCULATING TEMPERATURE gauge on the front of the unit
indicates the temperature of the fluid in the reservoir.
The temperature controller opens and closes the control valve in the COOL-
ING WATER INLET to maintain the desired temperature. The green and
amber lights on the control panel indicate the status of the valve. When the
green light is on, the valve is open and heat is being removed from the
cooling fluid. When the amber light in on, no cooling is occurring.
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.
When tap water is used as a cooling water source, a slight “bucking” may occur as
the valve opens and closes. The amount of “bucking” depends on the pressure
differential between the COOLING WATER INLET and the COOLING WATER
OUTLET/DRAIN. By lowering the pressure differential to 12 psi, the amount of
“bucking” can be minimized. The “bucking” is not harmful to the System I.

- 11 -
Section V Special Features
Low Fluid
Level Monitor
The low fluid level monitor is connected to a float switch in the reservoir. Alow
fluid level fault occurs when the cooling fluid in the reservoir drops below the
operating level.
In the event of a low fluid level fault, the unit will shut down, the red HIGH
TEMP/LOW LEVEL lamp will light, and the EXTERNAL INTERLOCK
contacts will open. The cause of the fault must be identified and corrected
before the unit can be restarted.
High Temperature
Monitor
The high temperature monitor (HTC) is connected to a sensor that monitors
the cooling fluid temperature as it exits the heat exchanger. The monitor
protects the system from exposure to excessively hot cooling fluid. A
temperature fault occurs when the cooling fluid temperature exceeds the set
temperature limit.
In the event of a high temperature fault, the unit will shut down, the red
HIGH TEMP/LOW LEVEL lamp will light, and the EXTERNAL INTERLOCK
contacts will open. The cause of the fault must be identified and corrected
before the unit can be restarted.
The monitor is located on the rear of the unit. It is factory preset at 38°C
(100°F).
The maximum setting should not exceed +60°C (140°F).
A slotted adjustment screw is located in the center of the monitor. A tem-
perature range scale is located next to the adjustment screw. The tempera-
ture scale is in °F, a temperature conversion chart is located on the
monitor's cover.
To adjust the monitor, turn the adjustment screw until the pointer on the
temperature scale corresponds to the desired limit. A temperature limit 5°F
higher than the operating temperature is recommended.
EXTERNAL
INTERLOCK Contacts
A set of relay contacts is connected to a receptacle on the front panel labelled
EXTERNAL INTERLOCK. The contacts are rated for 15A/250V. 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 normally open: they are
closed during normal operation and open when the unit is turned off or when
a fault occurs.

- 12 -
Section VI Maintenance and Service
For personal safety and equipment reliability, the following procedures
should only be performed by a qualified technician. Contact our
Service Department for assistance (see Preface, After-sale Support).
Service Contracts
Thermo Fisher 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).
Cleaning
Periodically inspect the reservoir. If cleaning is necessary, flush the reservoir
with a cleaning fluid compatible with the circulating system and the cooling
fluid.
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.
Pump Strainer
A wire mesh screen (under hex nut) is located in the pump suction line. If
debris is drawn into the system, the strainer will prevent the material from
being sucked into the pump and damaging the pump vanes.
After initial installation, the strainer may become clogged with debris and
scale. Therefore, the strainer must be cleaned after the first week of installa-
tion. After this first cleaning, a monthly visual inspection is recommended.
After several months, the cleaning frequency will be established. Before
cleaning the strainer, disconnect the line cord from the power source and drain
the reservoir.
PD-2 pumps have a wire mesh screen located
under the large hex nut on the pump suction
line.
Remove the appropriate nut. Remove the
strainer from the unit and rinse it with water.
When the screen is clean, replace it in the
strainer cavity, tighten the hex nut and replace the panel. Refer to Section III,
Filling Requirements for instructions on replacing the cooling fluid.
Strainer

- 13 -
Pressure Relief
Valve Adjustment
The adjustable pressure relief valve establishes the maximum operating
pressure of the unit. If the pressure of the fluid leaving the pump exceeds the
valve setting, the relief valve will bypass the fluid within the unit to relieve the
pressure. The relief valve does not determine the actual operating pressure; the
operating pressure of the system is determined by the back pressure of the
connected equipment and the setting of the flow control.
If adjustment is necessary, contact our Service Department.
For applications requiring maximum pressure less than 55 psi, an External
Pressure Reducer (EPR) is available. An EPR allows an operating pressure of
10 to 50 psi. Contact our Sales Department for more information (see Preface,
After-sale Support). Before calling please obtain the following information:
BOMnumber
Serialnumber
Pump Motor
Lubrication Some units with PD pumps may require pump motor lubrication. Refer to the
pump identification label on the rear of the unit for the specific pump in your
unit.
Motors used to drive the pump are
manufactured by several companies.
These motors use sleeve type bearings
with large oil reservoirs. Oiling instruc-
tions are generally posted on each
motor. In the absence of legible lubri-
cation instructions, add approximately
30 to 35 drops of SAE 20 non-
detergent oil to each bearing on the
following schedule (SAE 20 = 142 CS
viscosity):
DutyCycle Oiling Frequency
Continuous Each year
Intermittent Each 2 years
Occasional Each 5 years
Fill Holes (Typical)

- 14 -
Section VII Troubleshooting
Checklist Unit will not run (POWER ON/OFF switch is in ON position, HIGH
TEMP/LOW LEVEL light is not lit).
Make sure the voltage of the power source meets the specified voltage,
±10%. Refer to the serial number on the rear of the unit for the specific
electrical requirements of your unit.
Unit runs when PUSH TO START button is pressed, but stops when
button is released.
Press and hold PUSH TO START button for longer period of time.
Check for proper reservoir level. The float switch in the reservoir prevents the
unit from operating if the fluid level in the reservoir is below the operating level.
If the fluid level is low, “top off” the reservoir and restart the unit.
Make sure the high temperature monitor is set higher than the temperature
of the cooling fluid.
Unit runs for a short period, then stops (HIGH TEMP/LOW LEVEL light
is lit).
Check the fluid level in the reservoir. If it is low, check the system for leaks.
Make sure the TEMPERATURE dial is set for a temperature lower than the
high temperature limit setting (see Section V, High Temperature Monitor).
Make sure the heat load is not greater than the cooling capacity of the unit
(see Section II, Cooling Capacity).
Make sure the cooling water supply meets the requirements outlined in
Section III, Facility Water Requirements.
A possible power interruption has occurred, causing the “latch” relay to
unlatch. Attempt to restart.

- 15 -
Service Assistance
If, after following these troubleshooting steps, your unit 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
Voltageofpowersource
Temperatureat whichtheproblemoccurs
Temperature,pressure,andflowrateofcoolingwatersupply
Technical Support
Our Service Department can provide you with a wiring diagram and 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