Thermo Scientific NESLAB HX Series Installation, Operation, Basic Maintenance
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Thermo Scientific NESLAB HX Series Installation, Operation, Basic Maintenance

Thermo Scientific NESLAB HX Series Installation, Operation, Basic Maintenance

Recirculating chiller
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  • Page 1 Artisan Technology Group is your source for quality new and certified-used/pre-owned equipment SERVICE CENTER REPAIRS WE BUY USED EQUIPMENT • FAST SHIPPING AND DELIVERY Experienced engineers and technicians on staff Sell your excess, underutilized, and idle used equipment at our full-service, in-house repair center We also offer credit for buy-backs and trade-ins •...
  • Page 2 Thermo Scientific NESLAB HX Series Recirculating Chiller Thermo Scientific Manual P/N U00744 Rev. 03/26/08 Installation Operation Basic Maintenance Visit our Web site at: http://www.thermo.com/tc Product Service Information, Applications Notes, MSDS Forms, e-mail. Voice Info: (800) 258-0830 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...
  • Page 3 Thermo Fisher Scientific Sales, Service, and Customer Support 25 Nimble Hill Road 25 Nimble Hill Road Newington, NH 03801 Newington, NH 03801 Tel : (800) 258-0830 or Tel: (800) 258-0830 (603) 436-9444 Sales: 8:00 am to 5:00 pm Fax : (603) 436-8411 Service and Support: 8:00 am to 6:00 pm www.thermo.com/tc Monday through Friday (Eastern Time)

  • Page 4: Table Of Contents

    HX Series Recirculating Chiller Table of Contents PREFACE Compliance ..................... 3 WEEE/RoHS ................... 3 After-sale Support ..................4 Warranty ....................4 Unpacking ....................5 Feedback ....................5 SECTION I Safety Warnings ....................6 SECTION II General Information Description ....................7 Quick Reference Guide ................
  • Page 5 SECTION VI Optional Features Automatic Refill Device ................37 Heater Package ..................38 SENSOR Connector ................40 COMM Connector ................... 40 Remote Box ................... 41 External Pressure Regulator ..............42 Particulate Filters ................... 43 SECTION VII Maintenance & Service Service Contracts ................... 45 Condenser Cleaning ................

  • Page 6: Preface

    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.thermo.com/WEEERoHS...

  • Page 7: After-Sale Support

    STIRRER X.XFLA Label (typical) Warranty Thermo Scientific NESLAB HX units have a warranty against defective parts and workmanship for one full year from date of shipment. See back page for more details. - 4 - Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 8: Unpacking

    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.

  • Page 9: Warnings

    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 for assistance, see back cover.

  • Page 10: General Information

    Section II General Information Description The Thermo Scientific NESLAB HX Series Recirculating Chiller is designed to provide a continuous flow of cooling fluid at a constant temperature and volume. The unit consists of an air-cooled or water-cooled refrigeration system, a fluid reservoir, a fluid recirculation pump, and a temperature controller.
  • Page 11 Indicates the unit's status, page 26. S YS ON FL OW F AULT HEAT LEVEL WARN LEVEL FAUL T COOL AUT O FILL HIGH T EMP LOW T E MP RMT COMM RES IS T IVITY REM SET PT MUT E RMT ON/OFF Press to sequence forward through the controller's menus,...

  • Page 12: Quick Reference Guide

    Quick Start Procedures (Air-Cooled Models) Installation When the unit is shut off, wait five minutes before Position the unit so the intake and discharge are restarting to allow time for the refrigeration not impeded. Inadequate ventilation will cause a pressures to equalize. If the pressures are not reduction in cooling capacity and, in extreme allowed to equalize, the compressor will short- cases, compressor failure.
  • Page 13 Quick Start Procedures (Water-Cooled Models) Installation Position the unit in a clean environment with easy When the unit is shut off, wait five minutes before access to facility cooling water and a drain. The restarting to allow time for the refrigeration facility water requirements must meet those pressures to equalize.

  • Page 14: Specifications

    Specifications HX 75 HX 150 HX 300 Process Fluid Temperature Range +5°C to +35°C Temperature Stability ±0.1°C Unit Dimensions (H x W x D) Inches 36¾ x 23¼ x 18¾ x 26¼ x 21 x 33¾ x 25¼ Centimeters 93.3 x 59.0 x 47.6 103.2 x 66.7 x 53.6 119.1 x 85.7 x 64.1 Reservoir Volume...

  • Page 15: Cooling Capacity

    Cooling Capacity Cooling capacity will vary depending on fluid temperature, ambient temperature, and cooling fluid. Cooling capacities were obtained under the following conditions: air-cooled unit operating at +20°C (+68°F) ambient temperature. cooling fluid with specific heat of 1.0 was used for fluid temperatures from +5°C to +35°C.

  • Page 16: Pump Capacity

    HX 750 A= HX 750, 60Hz B= HX 750, 50Hz Fluid Temperature (°C) Pump Capacity HX units are available with one of three standard pump types: positive displacement (PD), centrifugal (CP), and turbine (TU). Refer to the name plate label on the rear of the case top to identify the specific pump in your unit. PD 2 &...
  • Page 17 Bar PSI 4.7 70 A=CP 25, 50Hz B=CP 25, 60Hz 4.0 60 C=CP 55, 50Hz D=CP 55, 60Hz E=CP 75, 50Hz F=CP 75, 60Hz 3.4 50 2.7 40 D, E 2.0 30 1.3 20 0.7 10 30 Gpm 18.9 37.9 56.8 60.5 94.6...

  • Page 18: Site (Air-Cooled Units)

    Section III Installation Site (Air-cooled Units) The unit should be located in a laboratory or clean industrial environment. Ambient Temperature Range +55°F to +95°F (+13°C to +35°C) Overvoltage Category Pollution Degree The unit will retain its full rated capacity in ambient temperatures to approximately +75°F (+24°C).
  • Page 19 On models HX 150 through HX 750 a stirrer motor is located under the case top. (Models HX 500 and HX 750 have two stirrer motors.) Heat generated by the stirrer motor is discharged through vents in the case top. Do not block the vents.

  • Page 20: Site (Water-Cooled Units)

    Site (Water-cooled units) The unit should be located in a laboratory or clean industrial environment with easy access to a facility cooling water supply and a drain. All units are equipped with castors for easy movement. This allows the unit to be placed in a small area, as long as there is ample space to move the unit for access on all four sides.
  • Page 21 Temperature of cooling water supply +55°F (+13°C) +65°F (+18°C) +75°F (+24°C) +85°F (+29°C) HX 75 Minimum Flow Rate Gallons per minute 0.75* Liters per minute 2.8* 11.4 Minimum Pressure D Minimum PSID 1.5* Minimum Bar 0.10* 0.13 0.24 0.55 HX 150 Minimum Flow Rate Gallons per minute 1.0*...

  • Page 22: Electrical Requirements

    Electrical Requirements 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 your responsibility to assure a proper ground connection is provided.

  • Page 23: Plumbing Requirements

    Plumbing Requirements Air-cooled and water-cooled unit Before installing the unit to an instrument that previously used facility water as a cooling fluid, flush the instrument several times to remove any rust or scale that has built up. Consult the manufacturer of the instrument for a cleaning fluid recommendation.
  • Page 24 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. If the unit is "hard plumbed”...

  • Page 25: Fluids

    Fluids Never use flammable or corrosive fluids with this unit. Do not use automotive antifreeze. Commercial antifreeze contains silicates that can damage the pump seals. Use of automotive antifreeze will void the manufacturer’s warranty. Thermo Fisher recommends using distilled/deionized water with a 0.05 to 0.1 MOhmcm reading.

  • Page 26: Filling Requirements

    Filling Requirements The reservoir access panel is located at the left rear corner of the case top. To open the access panel, slide the latch back (towards the rear of the unit) and lift. The reservoir cover is located below the access panel. Loosen the thumb- screws and remove the reservoir cover.
  • Page 27 Blank page. - 24 - Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 28: Temperature Controller

    Section IV Temperature Controller SYS ON FLOW FAULT HEAT LEVEL WARN LEVEL FAULT COOL AUTO FILL HIGH TEMP RMT COMM LOW TEMP RESISTIVITY REM SETPT MUTE RMT ON/OFF MUTE LAST ON/OFF RESET Controller Keypad The front panel mounted unit/temperature controller allows the operator to start, control, and monitor many features of the unit.

  • Page 29: Status Indicators

    Status Indicators Units are configured in one of two ways. They are configured either to shut down in the case of a fault, Cutout Option (CUTOUT), or, for those customers willing to take the risk of damage to their unit in order to continue providing all available cooling to their application, a Switch Option (WARN).

  • Page 30: Sys Fault Display

    SYS ON indicates unit is running. HEAT indicates heat is being added to the reservoir system to maintain constant temperature. The indicator flashes when the optional heater is inside the proportional band. COOL indicates the refrigeration system is removing heat from the reservoir system to maintain constant temperature.

  • Page 31: Controller Displays

    Controller Displays An alphanumeric display presents numeric readings of various operating conditions within the chiller. Display function is selected by pressing the appropriate keys to move through a menu of available information. When the controller is first powered up it goes through a short self-test and then enters the Operator's Loop, displaying the reservoir fluid temperature.
  • Page 32 TEMPERATURE xxx.xC This displays the temperature of coolant leaving the chiller. SETPT xx.xC This displays the setpoint for temperature control. The chiller’s temperature controller causes the fluid temperature to equal this temperature. If needed, use the YES/NO keys to change the value then press ENTER to accept the new value.
  • Page 33 Setup Loop The Setup Loop allows the operator to change limits; to configure how the unit will react to a fault: shutdown (CUTOUT) or continue to run (WARN); to display the flow rate in GPM or LPM; and to include or exclude the optional external probe display in the Operator's Loop.
  • Page 34 Include/Exclude optional external sensor. If probe is included, ensure it is connected to the unit or an error message will flash when the changes are saved. Include/Exclude beeper. Thermo Fisher recommends only a qualified technician change the PID values. Incorrect PID values hamper unit performance.
  • Page 35 Blank page. - 32 - Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 36: Flow Control

    Section V Operation Flow Control The RECIRCULATING FLOW CONTROL handle, located on the right-hand side of your unit, is connected to a valve that controls the flow rate of the cooling fluid to your application. When the handle is in the full vertical position, the valve is open and all possible cooling fluid is supplied to your application.

  • Page 37: Pressure Gauge

    Place the MAIN POWER ON OFF switch ON. The controller will go through a short self-test and then display the reservoir fluid temperature. LOCAL Start Up Depress the ON/OFF key on the temperature controller. The unit will start and the SYS ON LED will illuminate. To stop the unit, depress the ON/OFF key on the temperature controller.

  • Page 38: Interface Connector

    INTERFACE Connector 15-pin Dsub Female NAME NOTES DEFINITION 12VDC COMMON Common for digital inputs (pins 13 and 14) RESISTIVITY OUT 0-10VDC Analog Voltage Output: Reference to pin 6. This voltage output is proportional to the resistivity of the reservoir fluid: 0.5VDC / M-cm.
  • Page 39 Blank page. - 36 - Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 40: Optional Features

    Section VI Optional Features Automatic Refill Device The automatic refill device is designed to maintain the correct level of cooling fluid in the reservoir. The device consists of a solenoid valve and a reservoir float switch. If the cooling fluid level falls, the float switch drops, opening the solenoid valve and allows makeup fluid to fill the reservoir.

  • Page 41: Heater Package

    Heater Package The heater package option consists of an immersion heater in the unit’s fluid reservoir, a high temperature limit device, a low-level switch, and a solid state zero-crossing relay. A HTC FAULT message on the controller will light if the high temperature limit device is tripped.
  • Page 42 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 your responsibility to assure a proper ground connection is provided.

  • Page 43: Sensor Connector

    SENSOR Connector The unit can be configured to have its temperature controlled from an external location. Temperature is read on the controller's RTMP display. In the Operator's Loop, RTMP is the sensed temperature, TEMP indicates the HX's tank temperature. See page 29. The external probe is connected to a 9-pin male "D-sub"...

  • Page 44: Remote Box

    Remote Box The remote box operates by sending and receiving RS485 serial communica- tion. It is attached to the unit by an RS485 cable with 9-pin D subminiature connectors on the rear of the remote box and the 9-pin COMM port on the rear of the unit.

  • Page 45: External Pressure Regulator

    External Pressure Regulator For applications requiring a maximum pressure less than 55 psi, an External Pressure Reducer (EPR) is available. An EPR allows an adjustable operating pressure of 10 to 50 psi. If the pressure of the fluid leaving the unit exceeds the valve setting the relief valve will bypass the fluid back into the unit to relieve the pressure.

  • Page 46: Particulate Filters

    Nitrogen Purge Units equipped with nitrogen purge valves are designed to accept a constant flow of dry nitrogen into the reservoir. The nitrogen blankets the cooling fluid reducing fluid evaporation. Remove the reservoir cover by removing the screws. Fill the reservoir with fluid. Replace the reservoir cover and screws.
  • Page 47 Blank page. - 44 - Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 48: Maintenance & Service

    Section VII Maintenance & Service Service Contracts Thermo Fisher Scientific offers on-site Service Contracts designed to provide extended life and minimal downtime for your unit. For more information, contact our Service Department (see Preface, After-sale Support). For personal safety and equipment reliability, only a qualified techni- cian should perform the following procedure.

  • Page 49: Algae

    Algae To restrict the growth of algae in the fluid reservoir, we recommend the reservoir cover be kept in place and that all recirculation lines be opaque. This will eliminate the entrance of light, which is required for the growth of most common algae.

  • Page 50: Reservoir Cleaning

    Locate the reservoir stirrer motor (units with plate heat exchangers and HX 75s do not have a stirrer motor; HX 500s and HX 750s have two stirrer motors). Disconnect the motor wires at the plug located on the side of the electrical box cover.

  • Page 51: Pump Strainer

    Pump Strainer Units with PD and TU pumps have pump strainers that require cleaning. Refer to the name plate label on the rear of the case top to identify the specific pump in your unit. If debris is drawn into the recirculating system, the pump strainer will prevent the material from being drawn into the pump and damaging the pump vanes.

  • Page 52: Pump Motor Lubrication

    Pump Motor Lubrication Some units with PD pumps require pump motor lubrication. Refer to the name plate label on the rear of the case top to identify the specific pump in your unit. Several companies manufacture motors used to drive the pump. These motors use sleeve type bearings with large oil reservoirs.

  • Page 53: High/Low Pressure Cutouts

    High/Low Pressure Cutouts Should the unit's refrigeration discharge pressure become too high the high- pressure cutout will activate and shut down the compressor. High pressures can be caused by a lack of cooling water to the compressor or debris in the refrigeration lines.

  • Page 54: Pump Motor Overload Protector (3Ø Units)

    Pump Motor Overload Protector (3Ø Pumps Only) The overload protector prevents the pump motor from exposure to excessive current. If an overload fault occurs, due, for example, to excessive pressure or flow, or excessive ambient temperature, the overload protector will shut off the pump motor.
  • Page 55 Blank page. - 52 - Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com...

  • Page 56: Troubleshooting

    Section VIII Troubleshooting Checklist Unit will not start or cycles on and off HX 300s through HX 750s are equipped with a compressor crankcase heater. The crankcase heater warms the oil in the compressor and prevents refrigerant from mixing with the oil. Before start up, the unit must be connected to its power source for at least 12 hours.

  • Page 57: Service Assistance

    Inadequate temperature control Check/adjust the setpoint in the Operator's Loop. Ensure the unit is not configured for optional external probe operation. Make sure the installation of the unit is in compliance with the conditions described in Section III. Make sure the heat load of the instrument being cooled is not greater than the cooling capacity of the unit.

  • Page 58: Refrigeration Flow (Hx 75 And Hx 150)

    Section IX Diagrams Refrigeration Flow Diagram (HX 75 and HX 150) Capillary Tube Hot Gas Bypass Valve Compressor Solenoid Valve (NC) Evaporator Coil Dryer Reservoir Condenser Refrigeration Flow Diagram (HX 300 through HX 750) Hot gas bypass Accumulator valve Solenoid valve Compressor Solenoid valve (NC)

  • Page 59: Pump Flow (Cp Pumps)

    Pump Flow Diagram (CP Pumps) Flow transducer (Optional) Reservoir Check valve Pump Flow control valve Pressure gauge Outlet Inlet Pump Flow Diagram (PD and TU Pumps) Flow transducer (Optional) Reservoir Relief valve Check valve 1 2 3 1 2 3 1 2 3 1 2 3 Pump Strainer...

  • Page 60: Dimensions

    Dimensions The pullbox comes in two sizes. On HX 300s, 500s and 750s the box is 12" x 16" x 4" (H x W x D) and is usually located on the rear of the unit. For all others it is 6" x 6"...

  • Page 61: Wetted Materials

    Section X Wetted Materials Fluid Path Plumbing CP Pumps 1 Stainless Steel 1 Stainless Steel 2 Brass 2 Buna N 3 Copper 3 Graphite 4 Nylon 4 Ceramic 5 Bronz 6 Silver TU Pumps 7 Antimony 1 Bronze 8 Nickle 2 Monel 9 EPDM 3 Graphite...
  • Page 62 Appendix A Water Quality Recommendations for Recirculating (Process) Water Permissible (PPM) Desirable (PPM) Unfavorably high total ionized solids (TIS) can Microbiologicals accelerate the rate of galvanic corrosion. These (algae, bacteria, fungi) 0 contaminants can function as electrolytes which Inorganic Chemicals increase the potential for galvanic cell corrosion and lead to localized corrosion such as pitting which can Calcium...
  • Page 63 Water Quality Recommendations for Facility Water NOTE: A corrosion inhibitor is recommended Permissible (PPM) Desirable (PPM) if mixed metals are in the facility water loop. Microbiologicals (algae, bacteria, fungi) 0 Inorganic Chemicals Calcium <40 <0.6 Chloride <250 <25 Copper <1.3 <1.0 0.020 ppm if fluid in contact with aluminum...
  • Page 64 Fluid Risk Assessment Thermo Fisher has determined that uninhibited ethylene glycol can degrade and become corrosive to system materials in as early as three months in certain applications. This chart shows the fluid preventative maintenance schedule based on application variables that affect the rate of degradation of uninhibited ethylene glycol.
  • Page 65 Appendix B External Probe Calibration Before using the optional external probe it must be calibrated. To do this you run the unit to its temperature extremes and use the controller's Operator's and Calibration Loops. Install the external probe into the SENSOR 9-pin "D-sub" located on the rear of the unit.
  • Page 66 Appendix C NEScom Programming Software NEScom is a user friendly software that allows you to automate your temperature control process. The software includes a CD, comprehensive Operator’s Manual and a toll-free number to a trained technical staff. NEScom Software allows you to write custom temperature programs for our temperature controllers equipped with an RS-232 interface.
  • Page 67 Appendix D RS-232 Serial Communications Protocol NOTE: This appendix assumes you have a basic understanding of communications protocols. All data is sent and received in binary form, do not use ASCII. In the following pages the binary data is represented in hexadecimal (hex) format. The NC Serial Communications Protocol is based on a master-slave model.
  • Page 68 NC Serial Communications Protocol NOTE: All byte values are shown in hex, hex represents the binary values that must be sent to the chiller. Do not use ASCII. The framing of the communications packet in both directions is: Checksum region Lead char Addr-MSB Addr-LSB Command...
  • Page 69 The master sets parameters in the chiller by sending one of the Set Functions as shown in Table 1. The master does not send a qualifier byte in the data field. The master should be preprogrammed to send the correct precision and units (it could also read the parameter of interest first to decode the correct precision and units needed).
  • Page 70 Table 1 Commands (continued) (All bytes are in hex) FUNCTION MASTER SENDS UNIT RESPONDS Set Setpoint (control point)* CA 00 01 F0 02(d1)(d2)(cs) CA 00 01 F0 03(qb)(d1)(d2)(cs) Set Heat Low Temperature Limit* CA 00 01 C0 02(d1)(d2)(cs) CA 00 01 C0 03(qb)(d1)(d2)(cs) Set Heat High Temperature Limit* CA 00 01 E0 02(d1)(d2)(cs) CA 00 01 E0 03(qb)(d1)(d2)(cs)
  • Page 71 Appendix E RS-485 Serial Communications Protocol NOTE: This appendix assumes you have a basic understanding of communications protocols. All data is sent and received in binary form, do not use ASCII. In the following pages the binary data is represented in hexadecimal (hex) format. The NC Serial Communications Protocol is based on a master-slave model.
  • Page 72 NC Serial Communications Protocol NOTE: All byte values are shown in hex, hex represents the binary values that must be sent to the bath. Do not use ASCII. The framing of the communications packet in both directions is: Checksum region Lead char Addr-MSB Addr-LSB Command...
  • Page 73 The master sets parameters in the bath by sending one of the Set Functions as shown in Table 1. The master does not send a qualifier byte in the data field. The master should be preprogrammed to send the correct precision and units (it could also read the parameter of interest first to decode the correct precision and units needed).
  • Page 74 Table 1 Typical Commands (All bytes are in hex, all examples use unit address #1) FUNCTION MASTER SENDS UNIT RESPONDS READ Read Internal Temperature CC 00 01 20 00 DE CC 00 01 20 03(qb)(d1)(d2)(cs) Read External Sensor CC 00 01 21 00 DD CC 00 01 21 03(qb)(d1)(d2)(cs) Read Setpoint (control point) CC 00 01 70 00 8E...
  • Page 75 Table 2 QUALIFIER BYTE 00 hex 0 precision, no units of measure 01 hex 0 precision, °C 02 hex 0 precision, °F 10 hex 0.1 precision, no units of measure 11 hex 0.1 precision, °C units 12 hex 0.1 precision, °F units 13 hex 0.1 precision, LPM 14 hex...
  • Page 76 Thermo Scientific Product Repair Depot within the warranty period. The expense of returning the unit to the authorized Thermo Scientific Product Repair Depot for warranty service will be paid for by the buyer. Our responsibility in respect to warranty claims is limited to performing the required repairs or replacements, and no claim of breach of warranty shall be cause for cancellation or recision of the contract of sales of any unit.
  • Page 77 Artisan Technology Group is your source for quality new and certified-used/pre-owned equipment SERVICE CENTER REPAIRS WE BUY USED EQUIPMENT • FAST SHIPPING AND DELIVERY Experienced engineers and technicians on staff Sell your excess, underutilized, and idle used equipment at our full-service, in-house repair center We also offer credit for buy-backs and trade-ins •...

This manual is also suitable for:

Neslab hx 75Neslab hx 150Neslab hx 300Neslab hx 500Neslab hx 750

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