Thermo ThermoFlex 900 User manual

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ThermoFlexThermoFlex
ThermoFlexThermoFlex
ThermoFlex
Recirculating ChillerRecirculating Chiller
Recirculating ChillerRecirculating Chiller
Recirculating Chiller
Thermo Manual P/N U00934 Rev. 07/11/06
Service
Draft

Thermo Electron Corporation
Control Technologies
25 Nimble Hill Road
Newington, NH 03801
Tel : [phone] or
[phone]
Fax : [phone]
www.thermo.com/tc
Statement of Copyright
Copyright © 2006 Thermo Electron Corporation. All rights reserved.
This manual is copyrighted by Thermo Electron Corporation.
Users are forbidden to reproduce, republish, redistribute, or resell any materials from this
manual in either machine-readable form or any other form.
Control Technologies
Sales, Service, and Customer Support
25 Nimble Hill Road
Newington, NH 03801
Tel : [phone]:00 am to 5:00 pm
(Eastern Time), Monday through Friday.
Fax : [phone]
[email protected]
Dieselstrasse 4
D-76227 Karlsruhe, Germany
Tel : [phone]
Fax : [phone]
Hotline: [phone]
Building 6, No. 27
Xin Jinqiao Rd., Shanghai 201206
Tel : [phone]
Fax : [phone]
info. [email protected]

Contents
Section I Safety
Warnings..................................................................................................................3
Section II Theory of Operation
Abbreviations ...........................................................................................................5
RA Process Data Dictionary ....................................................................................5
Flow Diagram (Air-Cooled) ......................................................................................6
Flow Diagram (Water-Cooled).................................................................................7
Components.............................................................................................................8
Section III General Information
Specifications.........................................................................................................13
Performance Curves..............................................................................................14
Section IV Installation
Site Requirements .................................................................................................15
Electrical Requirements.........................................................................................16
Plumbing Requirements ........................................................................................17
Fluids .....................................................................................................................19
Section V Operation
Basic Controller .....................................................................................................20
Prestart...................................................................................................................21
Start Up ..................................................................................................................21
Controller Loops ....................................................................................................23
Setpoint Loop......................................................................................................... 24
Setup Loop.............................................................................................................25
Diagnostic Loop .....................................................................................................29
Adjusting the Controller PID Values ......................................................................30
Shut Down .............................................................................................................31
Section VI Troubleshooting
Operational Error Codes........................................................................................32
Checklist ................................................................................................................41
Flowcharts.............................................................................................................. 43
Section VII Service Function
Entering..................................................................................................................47
Diagnostic Loop .....................................................................................................48
Calibration Loop.....................................................................................................49
Engineering Loop...................................................................................................50
Tune Loop .............................................................................................................. 51
Configuration Loop ................................................................................................52
Master Reset..........................................................................................................53
End Item Number Decoding ..................................................................................54
Section VIII Advanced Service
Removing the Side Panels ....................................................................................57
Draining..................................................................................................................57
Control Board Replacement ..................................................................................58
Pump......................................................................................................................62
Top Assembly......................................................................................................... 64
Pressure Transducer .............................................................................................67
Temperature Sensor ..............................................................................................68
Testing RTD Temperature Sensor .........................................................................69
Temperature Sensor Replacement........................................................................71
RTD1 Calibration ...................................................................................................72
Flow Transducer Calibration..................................................................................74

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Section IX Pressure Transducer Check
PD Pump................................................................................................................76
Suction Pressure ...................................................................................................77
Section X Refrigeration
R134a Refrigeration Charging Data ......................................................................78
Section XI C1 - C3 Service Test
Heat Load Capacity ...............................................................................................78
Section XII Printed Circuit Board Assembly Calibration
Overview ................................................................................................................81
Procedure ..............................................................................................................82
Section XIII Firmware Download
Procedure ..............................................................................................................87
Section XIV Diagrams
Wiring Diagrams ....................................................................................................88
AppendixA
Country Specific Receptacle Ratings Requirements

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Section I Safety
Warnings Warnings are posted throughout the manual. These warnings are desig-
nated by an exclamation mark inside an equilateral triangle and text high-
lighted 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.
The lightning flash with arrow symbol, within an equilateral triangle, is
intended to alert you to the presence of non-insulated "dangerous voltage"
within the unit's enclosure. The voltage may be of significant magnitude to
constitute a risk of electrical shock.
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, please contact our Sales Department.
•Never place the unit in a location where excessive heat, moisture,
inadequate ventilation, or corrosive materials are present.
•The unit construction provides protection against the risk of electri-
cal shock by grounding accessible metal parts. The protection may
be compromised unless the power cord is connected to a properly
grounded outlet. It is the user's responsibility to ensure a proper
earth-grounding connection is provided.
• Always turn the unit off and disconnect the supply voltage from its
power source before moving the unit.
•The circuit protector located on the rear of the unit is not intended to
be used as a disconnecting means.
•Never connect the process fluid lines to your facility water supply or
any pressurized liquid source.
•Never use flammable or corrosive fluids with this unit. Use of these
fluids will void the manufacturer’s warranty.
•Do not use automotive antifreeze. Commercial antifreeze contains
silicates that can damage the pump seals. Use of automotive anti-
freeze will void the manufacturer’s warranty.

- 4 -
•Before using any fluid or performing maintenance where contact
with the fluid is likely refer to the manufacturer’s MSDS for handling
precautions.
• 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.
• Transport the unit with care. Sudden jolts or drops can damage the
refrigeration lines.
• If the unit is to be transported and/or stored in near or below freezing
temperatures it needs to be drained, see Draining in this Section. The
unit can be stored in the temperature range -25°C to 60°C (with
packaging), and <80% relative humidity.
•Observe all warning labels.
• Never remove warning labels.
• Never operate damaged or leaking equipment.
• Never operate the unit without process fluid in the reservoir.
• Never operate the unit with panels removed.
• Never operate the unit with damaged power cords.
• Refer service and repairs to a qualified technician.

- 5 -
Section II Theory of Operation
Abbreviations
In NominalAmperage
Id StartAmperage
Imax Maximum Current
TBD To be defined
TBC To be confirmed
AC Air-cooled
WC Water-cooled
# Number of configuration
MOP Maximum operating pressure
HT High Temperature
STD Standard
CU Condensing unit
RTD Resistance Temperature Detector
RA Process Data Dictionary
Components and signals, names and abbreviations.
Component Name Signal Name Description
T1_RA T1_RAS Measure the evaporating temperature
T2_RA T2_RAS Measure the entering air or facility water
temperature
P1_RA P1_RAS Measure the evaporating pressure
P2_RA P2_RAS Measure the condensing pressure
P3_RA P3_RAS Measure the facility water inlet pressure
P4_RA P4_RAS Measure the facility water outlet pressure
PS1_RA PS1_RAS Overpressure safety switch
COMP Compressor
FAN Fan
LL Stepper Expansion valve

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1 Condenser De-superheating, condensing, sub-cooling refrigerant
2 Evaporator Vaporizing, superheating refrigerant
3 Stepper motor driven Meters liquid refrigerant to the evaporator & creates pressure drop.
expansion valve
4 Compressor Compress refrigerant vapor
5 Hot gas line Meter hot refrigerant gas
6 Filter dryer Eliminates moisture, acid and dust in the refrigerant circuit
7 Service valve Allows access to the hermetic refrigerant circuit for servicing
Note: also included on item (6)
8 Temperature sensor Measures the suction gas temperature
9 Pressure transducer Measures the suction side (evaporating) pressure
10 Receiver Refrigerant storage
11 De-superheating expansion Meters liquid refrigerant to suction side to remove excess superheat
valve DXF (high-temp only) from refrigerant gas exiting evaporator
12 Accumulator (high-temp only) Traps any liquid refrigerant exiting evaporator; provides mixing tank
for refrigerant metered by DTXV
13 Pressure transducer Measures the discharge side (evaporating) pressure (Deluxe only)
14 Temperature sensor Measures the entering air temperature (Deluxe only)
15 Fixed High Pressure Switch Thermoflex 1400 (208/60 units only)
Flow Diagram, Air-Cooled

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Flow Diagram, Water-Cooled
1 Condenser De-superheating, condensing, sub-cooling refrigerant
2 Evaporator Vaporizing, superheating refrigerant
3 Stepper motor driven Meters liquid refrigerant to the evaporator & creates pressure
expansion valve drop.
4 Compressor Compress refrigerant vapor
5 Hot gas line Meter hot refrigerant gas
6 Filter dryer Eliminates moisture, acid and dust in the refrigerant circuit
7 Service valve Allows access to the hermetic refrigerant circuit for servicing
Note: also included on item (6)
8 Temperature sensor Measures the suction gas temperature
9 Pressure transducer Measures the suction side (evaporating) pressure
10 Receiver Refrigerant storage
11 De-superheatingexpansion Metersliquid refrigerant to suction side toremoveexcesssuperheatfrom
valve (DTXV) (high temp only) refrigerant gas exiting evaporator
12 Accumulator (high temp only) Traps any liquid refrigerant exiting evaporator; provides mixing tank for
refrigerant metered by DTXV
13 Pressure regulating valve Meters facility water flow to maintain refrigerant condensing temperature
14 High pressure switch Turns off system in the event of an overpressure occurrence
15 Pressure transducer Measures the discharge side (evaporating) pressure (Deluxe only)
16 Drain valve Drains condenser for shipment purposes
17 Pressure transducer Measures the facility inlet pressure
18 Pressure transducer Measures the facility outlet pressure (Deluxe only)
19 Temperature sensor Measures the entering facility water temperature (Deluxe only)

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Components
Compressor
The compressor is one of the four basic components required in a vapor compression system. It compresses
and circulates the refrigerant. Refrigerant enters the compressor as a low pressure, superheated vapor and is
discharged as a high pressure, superheated vapor. The pressure is elevated to a level that corresponds to a
saturation temperature (known as the condensing temperature) that allows for a state change (vapor to liquid)
in the condenser. The condensing temperature is dictated by the efficiency of the condenser.
The cooling module uses a reciprocating style, high back pressure compressor. A reciprocating compressor is
basically a piston style compressor with inlet and outlet reed valves that control the direction of flow into and
out of the compression cylinder. High back pressure relates to the allowable pressure range.
Process tubes and service ports
Process tubes and service ports provide access to the refrigeration system for evacuating, charging,
recharging and measuring pressure. The process tube is used strictly for improving the charging and
evacuation processes in production.
The service port on the suction side of the compressor uses a Shrader valve for shut-off purposes. The port is
used for the installation site for the suction side pressure transducer. It is also intended as the reclaim,
evacuation and re-charge site for service.
The service port on the dryer uses a Shrader valve for shut-off purposes. The port is used for the installation
site for the discharge side pressure transducer (in the DELUXE unit only). It is also intended as the reclaim,
evacuation and re-charge site for service.
Isolation valves
Isolation valves are used to manually secure a portion of the refrigeration system for service or repair. A
secondary function is to allow a system pressure measurement at a particular point in the refrigeration system.
These devices are only used in systems with refrigerant charges greater than 2.5 kg. The cost of reclaiming
the refrigerant during service work is deemed to be less than the cost of these valves when the charge mass is
less than 2.5 kg (5 lbs).
Discharge pressure sensor
The discharge pressure sensor is only used in the DELUXE units. This sensor is a ratiometric pressure
transducer used to measure refrigerant discharge (compressor outlet) pressure. The purpose of this sensor is
to provide feedback for condenser air filter condition (forAC units), low facility water flow to the condenser (for
WC units), pre-failure notification, field troubleshooting and service diagnosis.
High pressure switch
The high pressure switch (also referred to as the HPC) is a safety device to protect against over-pressurization
of the refrigeration system components beyond their ratings. Should the pressure limit be reached, the switch
opens and disables refrigeration operation. UL regulations require the use of a High Pressure Switch when
system charge is greater than 10 kg (22 lbs) and in all WC units. The setting of this device must be 90% of
lowest working pressure of any of the discharge side components. The switch does not need to have a manual
reset to comply with the UL requirement and therefore was an automatic reset device is used. The controller
will require the user to reset the fault prior to restarting of the refrigeration system.

- 9 -
AC condenser
The AC condenser is one of the four components required in a vapor compression system. It is a heat
exchanger used to reject heat from the discharge refrigerant vapor to the ambient air.As noted above, the
condenser’s efficiency drives the refrigerant saturation temperature for condensation to occur.
The refrigerant pressure is dictated by the efficiency of the condenser and the entering air (ambient)
temperature.Atemperature difference must exist between the refrigerant’s saturation temperature and the
entering air for heat transfer to take place.
Additional heat is rejected once the refrigerant is fully condensed to achieve what is known as sub-cooling.
Sub-cooling is required to prevent a state change prior to the expansion device as a result of the pressure drop
in the refrigerant components between the condenser and expansion device.
Factors that result in an increase in pressure from nominal values are: elevation increases, entering air
temperature increases, debris on the condenser face, and restricted air flow (typically when units as installed
too close to other devices). Excessive discharge pressures can lead to premature compressor failure.
Condenser air filter
The condenser air filter prevents dust and dirt particles from accumulating on the condenser coil.
Ambient air temperature sensor
The ambient air temperature sensor is used in DELUXE units only. It is located in the inlet air stream to the
condenser to monitor condenser sir filter condition in conjunction with the discharge pressure sensor. An
increase in discharge pressure without an increase in suction pressure or entering air temperature will indicate
that either the filter is becoming clogged with debris, the unit is operating at high altitude or a problem with the
fan assembly. The unit must first initialize to eliminate false indications associated with operation at higher
elevations. The failure mode noted here can also be an indication of a fan motor failure, but is believed to be a
lower probability failure than the clogged filter.
Fan assembly
The fan assembly circulates ambient air (cooling medium) through the condenser coil and around its tubes to
absorb heat from the refrigerant.
Receiver
The receiver is a storage tank to hold liquid refrigerant. When the condenser is exposed to lower entering air
(ambient) temperatures, it becomes highly efficient and there is a need to reduce the effective surface area
(number of tubes) to prevent condensing pressure from dropping below a minimum value (usually dictated by
the expansion device). When the entering air temperature increases, the surface area is needed due to the
reduction in condenser efficiency. Without a place to store the excess refrigerant used for the minimum
ambient condition, the discharge pressure will approach or exceed the compressor’s allowable range.
Filter/dryer
The filter/dryer is a device filled with a desiccant or drying agent, with a filter screen at each end used to collect
small amounts of particulate and moisture that may be in the refrigeration system after assembly and
evacuation. Moisture in the refrigeration system can lead to plugging of the expansion device or to acid
formation in the refrigerant oil.

- 10 -
Main liquid line control valve
The main liquid line control valve or expansion device is one of the four basic components of a vapor
compression system. An expansion valve effectively creates a pressure drop that changes the high pressure
liquid exiting the condenser into a low pressure liquid that enters the evaporator.
The valve employed in the platform is known as an electronic expansion valve. The valve is electrically pulsed
to open or closed. Each pulse incrementally adjusts the position of the valve to achieve the desired response.
As a result, the valve can provide a level of diagnostic capability as the number of pulses can be monitored to
determine capacity regulates the flow of liquid refrigerant to the evaporator for cooling and maintaining process
fluid set-point. The limits are set in the software as superheat and maximum operating pressure.
Valve hysteresis and backlash result in the potential inaccuracies in step or pulse counting.As a result, duty
cycle or step counting is not advised in the platform as a main form of control. It can, however, be used to note
if the valve is being over-driven. Overdriving some styles of electronic expansion valves can result in valve
failure.
Hot gas control valve
The hot gas control valve is a mechanical valve that operates much like a relief valve. When outlet (suction)
side pressure drops below the valve’s setting, then the valve open allowing superheated gas to by-pass the
condenser and enter directly to the evaporator. When the valve opens, the superheated (hot) gas is cooled by
the process fluid and thereby heats the process fluid.
The valve’s setting is below the lowest operating temperature seen in the evaporator to prevent condensation
from occurring in the evaporator. Depending on the setting, the valve can be set such that water (when used
as the process fluid) cannot freeze in the evaporator.
The platform uses a preset, mechanical hot gas valve to reduce test labor requirements. The valve has a gas
charge that fixes its setting.As a result, lowering settings than that allowed by the standard temperature range
requires a different valve.
Evaporator
The evaporator is where heat transfer occurs between the process fluid and the cooling module. It is the last of
the four basic components in vapor compression systems. Low pressure liquid enters the evaporator and is
heated by the process fluid until it changes state (boils).
The refrigerant pressure is dictated by the efficiency of the evaporator and the desired process fluid
temperature. Like the condenser, a temperature difference must exist between the refrigerant’s saturation
temperature and the process fluid for heat transfer to take place. Minimizing the temperature difference in the
evaporator allows for higher capacities as the refrigerant has higher density at warmer temperatures.
Maximum evaporating pressures are dictated by the compressor used in the system. The minimum pressure
is set either as a limit of the compressor or the evaporator range limit of the hot gas device.
Factors that result in a decrease in efficiency from nominal values are: fluid changes (i.e. going to ethylene
glycol from water), lower process fluid temperatures, and increase in process flow.
Accumulator
The accumulator is a trap to collect any liquid refrigerant that has spilled out of the evaporator, and prevent it
from reaching the compressor. Liquids are incompressible fluids and therefore result in a myriad of problems
on the compressor when present. It is typically sized to hold about 50% of the total running charge in the
system.
As the platform uses an electronic expansion device with sensor feedback, the BASIC cooling module has the
ability to eliminate the need for this device. However the HIGH TEMPERATURE DELUXE uses a mechanical
de-superheating device. In these configurations, the accumulator serves as a mixing chamber for liquid
injected into the suction line.

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De-superheating expansion valve
The de-superheating expansion valve is used to lower return gas exiting the evaporator to a temperature that
is within the acceptable limits of the compressor. Since the compressor does not do additional work, the
amount of heat removed by this valve results in a reduction of capacity for the module. Only the HIGH
TEMPERATURE DELUXE configuration requires the use of this device.
The valve used in the platform is a preset mechanical expansion valve. It uses a sensing bulb that is attached
to the suction (compressor inlet) line. The bulb has a gas inside it that expands (on increased) or contracts
(on decrease) dependent on the suction temperature.An expansion results in an increase of opening force
on the valve body that opens the valve. Similarly, the valve is driven to close when the gas contracts. The
temperature is controlled by the preset spring inside the valve that works against the bulb force.
Suction pressure sensor
The suction pressure sensor is located on the compressor inlet line to provide feedback for controlling the
main liquid line electronic control valve. This sensor in conjunction with the suction temperature sensor
provides superheat information on the cooling module to determine if the valve should/could be opened or
closed.Additionally, it monitors suction side pressure to prevent (high or low) pressures from exceeding the
limits of the compressor.
Suction temperature sensor
The suction temperature sensor is located on the compressor inlet line to provide feedback for controlling the
main liquid line electronic control valve.As noted above, this sensor, in conjunction with the suction pressure
sensor, provides superheat information on the cooling module to determine if the valve should/could be
opened or closed. The sensor is mounted on the suction line. Some inaccuracy is present in this type of
mount, however refrigerant boundary effects are believed to be negligible given the fact that it’s in the gas
state.Additionally, tube wall thickness is not considered to be significant due to it thickness and it high
conductivity(copper).
WC condenser
The WC condenser is one of the four components required in a vapor compression system. It is a plate heat
exchanger used to reject heat from the discharge refrigerant vapor to the secondary (facility) fluid.As noted
above, the condenser’s efficiency drives the refrigerant saturation temperature.
The refrigerant pressure is dictated by the efficiency of the condenser and the entering facility water
temperature.Atemperature difference must exist between the refrigerant’s saturation temperature and the
entering water for heat transfer to take place.
Additional heat is rejected once the refrigerant is fully condensed to achieve what is known as sub-cooling.
Sub-cooling is required to prevent a state change prior to the expansion device as a result of the pressure
drop in the refrigerant components between the condenser and expansion device.
Factors that result in an increase in pressure from nominal values are: entering facility water temperature
increases and debris on the condenser face. Excessive discharge pressures can lead to premature
compressor failure.
Pressure regulating valve
The pressure regulating valve is a mechanical device that regulates (controls) the flow of cooling medium
(facility water) to the condenser. The valve employs a bellows that is directly coupled to the refrigerant
discharge (outlet) pressure via a capillary tube. This pressure port applies pressure to the bottom of the
bellows that works against a spring force.As condenser pressure rises, the valve is driven to open provided
the spring force is overridden.As the condenser pressure drops, the valve is driven closed by the spring. The
spring force effectively dictates the nominal condensing pressure. As the valve is a two port (inlet and outlet),
it stops facility flow when closed.

- 12 -
Facility water inlet and outlet pressure sensors
The facility water inlet and outlet pressure sensors are only used in the DELUXE units. These devices
measure facility inlet and outlet pressure so that a differential pressure can be calculated. This differential
pressure will correlate to a flow rate through the system. Since the pressure regulating valve can adjust its
position based on the demands of the condenser, the differential is ignored unless the discharge pressure
continues to rise. The differential calculation can also be used to detect if user is exceeding differential
pressure limits of the pressure regulating valve.
Facility temperature sensor
The facility temperature sensor is used in DELUXE units only. It is located in the inlet facility stream to the
condenser to monitor condenser sir filter condition in conjunction with the discharge pressure sensor. An
increase in discharge pressure without an increase in suction pressure or entering air temperature will indicate
that either the condenser or pressure regulating valve is becoming clogged with debris. The unit must first
initialize to eliminate false indications associated with operation with secondary fluids other than water.

- 13 -
• 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.
• Thermo Electron reserves the right to change specifications without notice.
Section III General Information
Specifications
ThermoFlex 900 ThermoFlex 1400
Process Fluid Temperature Range + 5°C to +40°C +5°C to +40°C
+41°F to +104°F +41°F to +104°F
Ambient Temperature Range + 10°C to +40°C +10°C to +40°C
+ 50°F to +104°F +50°F to +104°F
Temperature Stability +/- 0.1°C +/- 0.1°C
Cooling capacity at 20°C
60 Hz 900W (3072 BTU) 1400W (4778 BTU)
50 Hz 750W (2560 BTU) 1170W (3996 BTU)
Reservoir Volume
Gallons 1.9 1.9
Liters 7.6 7.6
Unit Weight
lb 126 126
kg 57.2 57.2
Pumps
PD 1 - Positive Displacement
60 Hz 2.1 gpm @ 60 psi
50 Hz 1.7 gpm @ 60 psi
PD 2 - Positive Displacement
60 Hz 4.1 gpm @ 60 psi
50 Hz 3.3 gpm @ 60 psi
Compliance
NRTL Certified to CSA
and UL Standards; CE Marked

- 14 -
ThermoFlex 900
Cooling Capacity
Pumping Capacity
ThermoFlex 1400
Cooling Capacity
• Pump performance results were obtained with no restrictions on the return to the system.
• 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.
• Thermo Electron reserves the right to change specifications without notice.
Performance Curves
60 Hz
50 Hz
10 20 30 40 °C
25 50 75 100 °F
Temperature Setpoint
6000
5000
4000
3000
2000
1000
CoolingCapacity
2000
1500
1000
500
BTU/Hr WATTS
60 Hz
50 Hz
10 20 30 40 °C
25 50 75 100 °F
Temperature Setpoint
5000
4000
3000
2000
1000
CoolingCapacity
1400
1200
1000
800
600
400
200
BTU/Hr WATTS
LPM
GPM
Flow Rate
5101520
123 45
100
80
60
40
20
Bar PSI
Pressure
7
6
5
4
3
2
1
ABC
D

- 15 -
Site Requirements Ambient Temperature Range* 10°C to 40°C (50°F to 104°F)
Relative Humidity Range 10% to 80% (non-condensing)
OperatingAltitude* Sea Level to 8000 feet (2438 meters)
OvervoltageCategory II
PollutionDegree 2
Never place the unit in a location where excessive heat, moisture,
inadequate ventilation, or corrosive materials are present.
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 to be insulated accordingly.
Units installed below the end-user application may enable system fluid to
drain back into the chiller and cause spillage. Thermo offers an anti-drainback
kit to prevent any spillage, see Section V.
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.
NOTE: 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
If your setpoint and/or ambient temperatures are above these numbers please
contact Thermo Electron's Sales, Service and Customer Support to review
yourinstallation.
Section IV Installation
*Because of the decrease in air density, maximum temperature for the air entering the
ThermoFlex must be 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.

- 16 -
Electrical
Requirements The unit construction provides protection against the risk of electrical
shock by grounding appropriate metal parts. The protection may be
compromised unless the power cord is connected to a properly
grounded outlet. It is the user's responsibility to ensure that a proper
earth-grounding connection is provided.
Electrical Service Required:
ThermoFlex 900
Voltage Frequency Phase Receptacle Rating
100 VAC 50 Hz 1Ø 15A
100 VAC 60 Hz 1Ø 15A
115 VAC 60 Hz 1Ø 15A
230 VAC 50 Hz 1Ø *16A1, 15A2, 13A3
208-230 VAC 60 Hz 1Ø 15A
ThermoFlex 1400
Voltage Frequency Phase Receptacle Rating
100 VAC 50 Hz 1Ø 20A
100 VAC 60 Hz 1Ø 20A
115 VAC 60 Hz 1Ø 20A
208-230 VAC 60 Hz 1Ø 15A
230 VAC 50 Hz 1Ø 16A*
Refer to the nameplate label located on the rear of the unit for specific
electrical requirements.
* Refer to Appendix A for country specific requirements.

- 17 -
ThermoFlex
Application
Fluid Flow
Fluid Flow
Plumbing
Requirements Ensure that the shipping plugs are removed from all fittings before
installation.
Never connect the process fluid lines to your facility water supply or
any pressurized liquid source.
1/4" Male NPT Reservoir Drain Plug
The process fluid plumbing connections are located on the rear of the unit
and are labeled (PROCESS OUTLET) and (PROCESS INLET).
The connections are ½" Female NPT. The process outlet connection is cast
bronze, the process inlet connection is stainless steel.
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.
NOTE: PD pumps are capable of producing 110 psi. Ensure your plumbing is
rated to withstand this pressure. An external pressure relief valve is available,
see Section V.
Keep the distance between the unit and the instrument being cooled as short
as possible. Tubing should be straight and without bends. If diameter reduc-
tions must be made, they should be made at the inlet and outlet of your
application, not at the ThermoFlex.

- 18 -
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
FACILITY OUTLET. The connections are also ½" Female NPT. Both
connections are cast bronze.
Connect the FACILITY INLET to your facility water supply. Connect the
FACILITY OUTLET to your facility water return or drain. Ensure all
connections are secure and that the proper sealant/lubricant for the fitting
material is used.
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)
The facility water must meet the following conditions for the unit to maintain
its full rated capacity.
Facility Pressure Drop PSID
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
Facility Flow - GPM
Facility Temperature °C
45
40
35
30
25
20
15
10
5
0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
Facility Flow - GPM
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
Water-cooled units only