Page 1 Thermo Scientific ThermoFlex Recirculating Chillers (Deluxe Controller) Thermo Scientific Manual P/N U00939 Rev. 08/08/2013 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: (800) 258-0830...
Page 3 Thermo Scientific ThermoFlex Recirculating Chillers (Deluxe Controller) Thermo Scientific Manual P/N U00939 Rev. 08/08/2013 Installation Operation Basic Maintenance Visit our Web site at: http://www.thermoscientific.com/tc Product Service Information, Applications Label 1 Notes, MSDS Forms, e-mail. Voice Info: (800) 258-0830 Label 2...
Page 4 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.thermoscientific.com/tc Monday through Friday (Eastern Time)
Page 5: Table Of Contents
Initial Start Up ....................4-2 Daily Start Up .....................4-3 Process Fluid Temperature Display ..............4-4 SETPOINT ......................4-5 Status Display .....................4-6 MENU Display ....................4-7 Main Menu Tree ....................4-8 Shut Down ......................4-21 ..........5-1 Section 5 Additional Options/Accessories Auto Refill ......................5-1 Internal DI Cartridge ..................5-2 ThermoFlex Thermo Scientific...
Page 6 Checklist ......................7-12 TUNING ......................7-14 ............8-1 Section 8 Additional Information Draining .......................8-1 CALIBRATION ....................8-3 Wetted Materials ....................8-4 Decommissioning/Disposal ................8-5 Shipment/Storage ....................8-5 Appendix A Country Specific 230 VAC, 50 Hz, 1 Ø Requirements Appendix B Voltage Configuration Instructions Appendix C Serial Communications Appendix D Analog I/O and Remote Sensor Declaration of Conformity WARRANTY ThermoFlex Thermo Scientific...
Page 8: Quick Start
Display Indication Range Default UNITS Controller temperature, pres- C or F sure and ﬂow display scales. psi, bar or kPa (Flow display is optional.) gpm or lpm Setpoint Setpoint value. +5°C to +40°C +20°C (+90° for high temp QUICK START chillers) UNITS TEMPERATURE...
Page 10 Anzeige Inhalt Bereich Standardwert UNITS Einheiten für die Temperatur-, Druck- C oder F (EINHEITEN) und Flussanzeige auf dem Regler. psi, bar oder kPa (Die Flussanzeige ist optional.) gpm oder lpm Setpoint Sollwert. +5 °C bis +40 °C +20 °C (Sollwert) (+90 °C bei Hochtemperaturkühlern) QUICK START (SCHNELLSTART)
Page 11: Preface
Thermo Fisher Scientific has contracted with one or more recycling/ disposal companies in each EU Member State, dispose of or recycle this product through them. Further information on Thermo Fisher Scientific’s compliance with these Directives is available at: www.thermoscientific.com/WEEERoHS ThermoFlex i Thermo Scientific...
Page 12: After-Sale Support
Be sure to include the manual part number and the revision date listed on the front cover. Warranty Thermo Scientific ThermoFlex chillers have a warranty against defective parts and workmanship for 24 months (excluding MD1/MD2 Magnetic Drive and P1/P2 Positive Displacement pumps which are warranted for 12 months) from date of shipment.
Page 13: Safety
If the chiller's power cord is used as the disconnecting device, it must be easily accessible at all times.  Never operate the chiller with damaged cords.  Never place the chiller in a location or atmosphere where excessive heat, moisture, or corrosive materials are present.  ThermoFlex Thermo Scientific...
Page 14 Refer service and repairs to a qualified technician.  Performance of installation, operation, or maintenance procedures other than those described in this manual may result in a hazardous situation and will void the manufacturer's warranty.  1-2 ThermoFlex Thermo Scientific...
Page 15: General Information
General Information Section 2 Description The Thermo Scientific ThermoFlex recirculating chiller is designed to provide a continuous supply of fluid at a constant temperature and flow rate. The chiller consists of an air-cooled or water-cooled refrigeration system, heat exchanger, recirculating pump, reservoir, and a microprocessor controller.
Page 16 • Additional dimensions are at the end of this section, add 1/8" (3 cm) to height for SEMI. • Add 30 pounds (14 kilograms) for global voltage chillers. • Thermo Fisher Scientific reserves the right to change specifications without notice. ThermoFlex Thermo Scientific...
Page 17 • Add 30 pounds (14 kilograms) for global voltage chillers with a P 2 pump. Add 10 pounds (4.5 kilograms) for chillers with a P 3 or P 5 pump. • Thermo Fisher Scientific reserves the right to change specifications without notice. ThermoFlex Thermo Scientific...
Page 18 25°C ambient condition, at nominal operating voltage, on chillers with P 2 pumps with no back pressure. Other fluids, fluid temperatures, ambient temperatures, altitude, operating voltages or pumps will affect performance. See Section 3. • Thermo Fisher Scientific reserves the right to change specifications without notice. ThermoFlex Thermo Scientific...
Page 19 See Section 3. • Chillers require the use of 50/50 EG/water or 50/50 PG/water below 10°C process temperature to prevent freezing/glazing of the plate exchanger. • Thermo Fisher Scientific reserves the right to change specifications without notice. ThermoFlex Thermo Scientific...
Page 20 • 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. See Section 3. • Thermo Fisher Scientific reserves the right to change specifications without notice. ThermoFlex Thermo Scientific...
Page 21 • 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. See Section 3. • Thermo Fisher Scientific reserves the right to change specifications without notice. ThermoFlex Thermo Scientific...
Page 22 • 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. See Section 3. • Thermo Fisher Scientific reserves the right to change specifications without notice. ThermoFlex Thermo Scientific...
Page 23 Section 2 ThermoFlex900/1400 Dimensions (inches/centimeters) "* 69.2 Front View * Add 1/8" (3 mm) for SEMI chillers , see Section 5. " " 31.0 Side View " " 47.0 " 62.8 ThermoFlex Thermo Scientific...
Page 24 20" 50.8 " 43.7 Shipping crate dimensions (approximate): 21” (53 cm) wide " 35” (89 cm) tall Top View 36.0 40” (102 cm) deep • Thermo Fisher Scientific reserves the right to change specifications without notice. 2-10 ThermoFlex Thermo Scientific...
Page 25 Section 2 ThermoFlex2500 Dimensions (inches/centimeters) "* 73.6 Front View * Add 1/8" (3 mm) for SEMI chillers , see Section 5. " 38.4 1" Side View " " 51.0 " 68.0 2-11 ThermoFlex Thermo Scientific...
Page 26 22" 55.9 " 48.8 Top View " Shipping crate dimensions (approximate): 43.6 23” (58 cm) wide 36” (91 cm) tall 40” (102 cm) deep • Thermo Fisher Scientific reserves the right to change specifications without notice. 2-12 ThermoFlex Thermo Scientific...
Page 27 Section 2 ThermoFlex3500/5000 Dimensions (inches/centimeters) Front View "* 98.7 * Add 1/8" (3 mm) for SEMI chillers, see Section 5. 1" " 43.7 Side View " " 62.2 " 78.0 2-13 ThermoFlex Thermo Scientific...
Page 28 (P3, P4 pumps only) Top View " 48.8 ~ Shipping crate dimensions 26" (66 cm) wide 48" (122 cm) tall 47" (119 cm) deep • Thermo Fisher Scientific reserves the right to change specifications without notice. 2-14 ThermoFlex Thermo Scientific...
Page 29 Top View " Water-cooled shipping crate 63.9 dimensions (approximate): 35 3/4” (91 cm) wide 55 1/2” (141 cm) tall 46 3/8” (118 cm) deep • Thermo Fisher Scientific reserves the right to change specifications without notice. 2-15 ThermoFlex Thermo Scientific...
Page 30 "(3) a Riton connector DRAIN Rear View (Water-Cooled) T 5 Flow Control - see above. Facility water connections Cast Bronze " 3/4" FNPT 116.4 "(2) " 27" 74.7 68.5 " 42.5 " 21.6 " " 55.3 2-16 ThermoFlex Thermo Scientific...
Page 31: Installation
IP 20 *Because of the decrease in air density, maximum temperature for the air entering an air-cooled ThermoFlex is 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.
Page 32 Process Setpoint Temperature: Below 30°C (86°F) Ambient: Below 40°C (104°F) Before operating the chiller in conditions outside any of those listed in this manual please contact Thermo Fisher Scientific's Sales, Service and Customer Support to review your installation. Figure 3-1 Minimum Clearance ThermoFlex Thermo Scientific...
Page 33: Electrical Requirements
The chiller is intended for use on a dedicated outlet. The ThermoFlex has an internal circuit protection that is equivalent (approximately) to the branch circuit rating. This is to protect the ThermoFlex, and is not intended as a substitute for branch circuit protection.
Page 34 400 VAC T 5 Pump 50 Hz 3Ø IEC309 MCA = Minimum Current Ampacity MOPD = Maximum Overcurrent Protective Device Continued on next page. Values reflect those on the nameplate located on the rear of the chiller. ThermoFlex Thermo Scientific...
Page 35 For installation information on Variable Voltage and Global Voltage chillers refer to Appendix B. Refer to the nameplate label located on the rear of the chiller for specific electrical requirements. Continued on next page. ThermoFlex Thermo Scientific...
Page 36 200 VAC T 1 Pump 50 Hz 1Ø Hard wire 208-230 VAC T 1 Pump 60 Hz 1Ø Hard wire 230 VAC 50 Hz 1Ø * Refer to Appendix A for country specific ratings. Continued on next page. ThermoFlex Thermo Scientific...
Page 37 400 VAC T 5 Pump 50 Hz 3Ø 16.7 IEC309 MCA = Minimum Current Ampacity MOPD = Maximum Overcurrent Protective Device Values reflect those on the nameplate located on the rear of the chiller. Continued on next page. ThermoFlex Thermo Scientific...
Page 38 ** Chillers selected for 230 VAC operation have a range of -10% to +7%. Refer to Appendix A for country specific ratings. For installation information Global Voltage chillers refer to Appendix B. Refer to the nameplate on the chiller's rear for specific electrical requirements. ThermoFlex Thermo Scientific...
Page 39: Hard Wire Installation
Remove the double knock out ( " and 1 "). • Insert the cable through the hole. • Refer to the label in the electrical box to configure your chiller, see Figure 3-3. • Secure the cable's ground wire to the ground stud. • Reinstall the cover. Figure 3-3 Sample Label ThermoFlex Thermo Scientific...
Page 40: Plumbing Requirements
 Note Ensure your plumbing installation will develop a back pressure to the ThermoFlex greater than 3 PSIG. Lower pressure will shut down the chiller.  The process fluid connections are located on the rear of the chiller and are...
Page 41 If diameter reductions are required, Connections (2 of 2) make them at the inlet and outlet of your application, not at the ThermoFlex. Water-cooled Chillers For water-cooled chillers the facility water plumbing connections are also located on the rear and are labeled...
Page 42: Process Fluid Requirements
Do not use a Deionization (DI) filter cartridge with Inhibited EG CAUTION or Inhibited PG. A DI filter will remove inhibitors from the solution rendering the fluid ineffective against corrosion protection. Also, inhibitors increase fluid conductivity.  3-12 ThermoFlex Thermo Scientific...
Page 43: Compatibility With Approved Fluids
Biocides are corrosive and can cause irreversible eye damage and skin WARNING burns. They are harmful if inhaled, swallowed or absorbed through the skin. Refer to the manufacturer's most current MSDS.  ThermoFlex 3-13 Thermo Scientific...
Page 44 Inhibited Propylene Glycol/Water Inhibited propylene glycol has the same properties as uninhibited propylene glycol and the same concerns as inhibited ethylene glycol. 3-14 ThermoFlex Thermo Scientific...
Page 45: Additional Fluid Information
Section 3 Additional Fluid When using the ThermoFlex chiller to circulate through aluminum, use a compatible corrosion inhibitor to prevent galvanic corrosion. Information Fluid viscosity should be 50 cSt or less at the lowest temperature used. Visible pump weepage may occur when compatible glycols, oils or other additives are used.
Page 46 Potassium <20 <0.3 Silicate <25 <1.0 Sodium <20 <0.3 Sulfate <250 <50 Hardness <17 <0.05 Total Dissolved Solids <50 <10 Note A corrosion inhibitor is recommended if mixed metals are in the facility water loop.  3-16 ThermoFlex Thermo Scientific...
Page 47: Facility Water Requirements (Water-Cooled Chillers)
A - go across to temperature curve B - drop down to determine the mini- mum required facility flow. PSID C - Where B crosses the PSID curve, go across to determine the minimum required PSID. Facility Flow - GPM ThermoFlex 3-17 Thermo Scientific...
Page 48 Start with a known, e.g., facility water temperature. A - go across to temperature curve B - drop down to determine the minimum required facility flow. C - Where B crosses the PSID curve, go across to determine the minimum required PSID. 3-18 ThermoFlex Thermo Scientific...
Page 49: Initial Filling Requirements
CAUTION Before replacing the reservoir cap ensure the reservoir sight tube ball stopper is securely in place, see next page.  Replace the reservoir cap by screwing it clockwise. Cap should be hand tight. ThermoFlex 3-19 Thermo Scientific...
Page 50: Fluid Top Off
 Before replacing the reservoir cap ensure the reservoir sight tube ball CAUTION stopper is securely in place.  Reservoir Ball Stopper Figure 3-8 Reservoir Ball Stopper 3-20 ThermoFlex Thermo Scientific...
Page 51: Operation
This button is used to abort any changes and at the same time return the controller to its previous display. Aborting a change can only be made before the change is saved. Thermo Scientific ThermoFlex 4-1...
Page 52: Setup
In either case the screen will go blank. If enter was pressed, press on the controller to bring up the Daily Start Up displays and start the chiller. See next page. Note After start up, check the plumbing connections for leaks.  4-2 ThermoFlex Thermo Scientific...
Page 53: Daily Start Up
FLUID LEVEL SETPOINT HIGH xx.x°C xx gpm xx psi LOW xx.x°C TEMPERATURE LIMITS FLUID FLOW RATE PRESSURE Optional Display SETPOINT MENU +24.2 C Pressure: xxx.x psi Process Fluid Temperature Display Figure 4-2 Daily Start Up Displays Thermo Scientific ThermoFlex 4-3...
Page 54: Setpoint
Indicates the chiller is heating up to the setpoint. Indicates the chiller is cooling down to the setpoint. The small circle indicates which sensor is controlling the chiller. When displayed, indicates the ThermoFlex is responding to the chiller's internal temperature sensor. When displayed, indicates the ThermoFlex is responding to an external temperature sensor.
Page 55 Once the desired value is displayed press the enter button again to accept the change and to stop the flashing. Return to the Process Fluid Temperature Display by pressing the left arrow or esc button. SETPOINT MENU +24.2 C Pressure: xxx.x psi Thermo Scientific ThermoFlex 4-5...
Page 56: Status Display
A means you can only scroll down to the next display. A means you can only scroll up to the next display. means you can scroll up or down. 4-6 ThermoFlex Thermo Scientific...
Page 57: Menu Display
Section 4 MENU Displays The ThermoFlex controller uses menus to view/change the controller's settings. Note Depressing and holding the enter button for two seconds before starting the chiller allows you to view and to make changes to the settings. ...
Page 58: Main Menu Tree
Sec- tion 6. MONITOR VAL- UES and PASSWORD are used only by qualified technicians. FIRMWARE VERSION is used to display the controller's firmware information. Press the esc button to return to the Main Menu Display. 4-8 ThermoFlex Thermo Scientific...
Page 59 Section 4 Thermo Scientific ThermoFlex 4-9...
Page 60 Line Frequency* 60HZ Auto Restart Audible Alarms RA FAN SPEED MODE* Care Level SERIAL COMM - DCOM* ANALOG COMM - ACOM* RESISTIVITY* RESTORE DEFAULTS mm/dd/yy hh:mm:ss Show Quick Start *Only displays on chillers equipped with the option. 4-10 ThermoFlex Thermo Scientific...
Page 61 Setpoint Range: SETTINGS +5°C to +40°C for standard temperature chillers UNITS +5°C to +90°C for high temperature chillers, Setpoint +5°C to +88°C for P1 and P2 high temp chillers TEMPERATURE Setpoint Default: PRESSURE +20°C for all chillers Thermo Scientific ThermoFlex 4-11...
Page 62 +2°C to +93°C for high temperature chillers High Warning High Fault/Warning Default: Low Warning +42°C for standard temperature chillers +92°C for high temperature chillers Low Fault Low Fault/Warning Range: +2°C to +43°C for all chillers Low Fault/Warning Default: +3°C for all chillers 4-12 ThermoFlex Thermo Scientific...
Page 63 87 PSI 4 PSI P5 50 Hz: 4 to 56 PSI 56 PSI 4 PSI T5 60 Hz: 4 to 105 PSI 105 PSI 4 PSI T5 50 Hz: 4 to 105 PSI 105 PSI 4 PSI Thermo Scientific ThermoFlex 4-13...
Page 64 93 - 100% 5.0 kW: 87 - 100% 4.6 kW: 87 - 100% Time Out Range: 0 - 900 seconds Time Out Default: 45 seconds 80 seconds for ThermoFlex7500/10000 Setting the time to 0 disables the option. 4-14 ThermoFlex Thermo Scientific...
Page 65 50 Hz or 60 Hz. The selected frequency automatically adjusts the firmware’s fixed high pressure default setting. Frequency Range: 50 Hz or 60 Hz Line Frequency 60Hz Auto Restart Frequency Default: 60 Hz Audible Alarms RA FAN SPEED MODE Care Level SERIAL COMM - DCOM Thermo Scientific ThermoFlex 4-15...
Page 66 Audible Alarms is used to turn the audible alarm on/off With Audible Alarms highlighted press enter. The Line Frequency 60Hz box will turn black indicating the feature is enabled. Auto Restart Audible Alarms RA FAN SPEED MODE Care Level SERIAL COMM - DCOM 4-16 ThermoFlex Thermo Scientific...
Page 67 Section 4 RA FAN SPEED MODE (ThermoFlex 2500 air-cooled chillers only) RA FAN SPEED MODE controls the fan speed. Auto allows the fan to run under the conditions listed in Section 3. Selecting On allows the fan to run at high speed all the time.
Page 68 Remote Sensor MESSAGE! Remote Start Remote Sensor Enabled Remote Setpt volts Temp Out volts Press ENTER RELAY 1 RELAY 2 Press enter to extinguish the message. USER RANGE SETTINGS Refer to Appendix D for additional information. 4-18 ThermoFlex Thermo Scientific...
Page 69 RESTORE DEFAULTS restores the controller back to factory default values. A reset is automatically performed whenever new firmware is installed. Use the left arrow or esc key to return to the RESTORE SETTINGS display. DEFAULT SETTINGS? Thermo Scientific ThermoFlex 4-19...
Page 70 DRAINING opens/closes the optional anti drainback valve. The chiller must be off to drain the valve. Press enter to start the draining. The display will change to Close Valve. When the draining is com- plete press enter again to close the valve. DRAINING DRAINING Close Valve Open Valve 4-20 ThermoFlex Thermo Scientific...
Page 71: Shut Down
Always turn the chiller off and disconnect it from its supply CAUTION voltage before moving.  CAUTION The circuit protector located on the rear of the chiller is not intended to act as a disconnecting means.  Thermo Scientific ThermoFlex 4-21...
Page 72 Section 4 4-22 ThermoFlex Thermo Scientific...
Page 73: Auto Refill
The fluid reaches the correct operating level. • The delay timer exceeds user fill time entered in the Quick Start or SETTINGS menu. • The chiller shuts down for any reason. Note Setting the fill time to 0 disables auto refill.  Thermo Scientific ThermoFlex...
Page 74: Internal Di Cartridge
Note The cartridge can be changed with the chiller running, however, since the cartridge runs in a parallel arrangement, disconnecting the cartridge adds 0.5 gpm to the main flow. The additional flow will cause an increase in system pressure which may cause a high fluid pressure fault.  ThermoFlex Thermo Scientific...
Page 75 Note Should the chiller start to vibrate the valve setting may be the cause. Changing the pressure setting ± 5 psi (0.3 bar) will eliminate the vibration.  ThermoFlex Thermo Scientific...
Page 76 CAUTION Do not exceed 100 psi (6.9 bar).  When complete, inspect the area around the " packing nut for fluid. If fluid is present, slightly tighten the nut and reinspect. ThermoFlex Thermo Scientific...
Page 77: Flow Control With Flow Readout
This valve is plumbed into the chiller's auxiliary Drain port, allowing you to also monitor the flow rate Plug to your application using the controller's Status Display. Process Inlet The valve's outlet connection is ½" FNPT. See Figure 5-10. Figure 5-10 Pressure Relief ThermoFlex Thermo Scientific...
Page 78: Anti Drainback
In the analog I/O mode, the chiller starts when the error is cleared. Chiller Circuit Breaker Interrupt Rating The main power circuit breaker located on the rear of the chiller has an Interrupting Capacity (AIC) of 10,000 amps. ThermoFlex Thermo Scientific...
Page 79 7500/10000 " 8.8 cm 4" 10.1 cm " 11.3 cm " 10.8 cm " 7.0 cm " 6.8 cm " 7.1 cm " 6.6 cm " 17.7 cm " 16.7 cm " 24.3 cm " 19.5 cm ThermoFlex Thermo Scientific...
Page 80 24 ½" 62.2 cm 17" 43.1 cm C* 19 " 50.0 cm " 57.8 cm " 62.9 cm " 69.6 " 53.8 cm " 61.5 cm " 66.7 cm " 73.4 * Distance between Ø.53 Seismic mounting holes ThermoFlex Thermo Scientific...
Page 81 45.3 kg Right Front 32.9 lbs 14.9 kg 45.7 lbs 20.7 kg 68.2 lbs 30.9 kg 89.2 lbs 40.5 kg Right Rear 36.2 lbs 16.4 kg 47.1 lbs 21.4 kg 70.0 lbs 31.8 kg 91.1 lbs 41.3 kg ThermoFlex Thermo Scientific...
Page 82: Other Accessories
Please contact Thermo Fisher Scientific's Sales, Service and Customer Support to assist you with questions that you may have regarding accessories for your ThermoFlex, see inside front cover for contact information. 5-10 ThermoFlex...
Page 83: Preventive Maintenance
If you change your filters before the preventive timer trips, you can clear the timer by using the controller's DIAGNOSTICS menu, see next page. Note For air-cooled chillers, both the air and fluid filters in the ThermoFlex can be changed while the chiller is running. For water-cooled chillers, only the fluid filter can be changed while it is running.
Page 84: Diagnostic
. Press enter and the display Reset will flash. Use the arrow buttons to display the desired time, from 0 to 9999 hours. Press enter De-I Period again to stop the flashing and accept the new value. (Optional Display) ThermoFlex Thermo Scientific...
Page 85: Fluid Bag Filter
 Note To prevent particulates from entering the reservoir, ensure the fluid bag filter is in place before removing the diffuser.  CAUTION Do not operate the chiller unless the diffuser is installed.  ThermoFlex Thermo Scientific...
Page 86: Reservoir Cleaning
Wire Mesh Fluid Diffuser Ball Stopper Sight Tube Figure 6-2 Reservoir Cleaning and Diffuser Fluid Maintenance An effective recommended maintenance plan would include changing the fluid every six months to optimize chiller reliability, see Section 3 for additional information. ThermoFlex Thermo Scientific...
Page 87: Condenser Filter
Replacement grill assemblies are available from Thermo Fisher. ThermoFlex3500s - 5000s water-cooled Screw chillers have two screws securing the (Water-cooled chillers) condenser. One screw on the top and one on the bottom. CAUTION - Sharp edges Figure 6-3 ThermoFlex900s - 5000s Condenser Grill Removal ThermoFlex Thermo Scientific...
Page 88: Chiller Surface
Testing the Safety We recommend slowly draining the chiller to ensure the low level warning and fault messages activated. Features For chillers equipped with auto refill switch we recommend slowly draining and ensure the auto refill activates. ThermoFlex Thermo Scientific...
Page 89: Di Filter (Optional)
XXXXX Run Hours Chiller operating hours (appears every 20,000 hours) You can press the enter key to clear any message Note the message because once the Filter or DEI PM message is cleared it will not reappear. ThermoFlex Thermo Scientific...
Page 90 Section 6 ThermoFlex Thermo Scientific...
Page 101: Messages
5. If desired, press enter again to display: 6. If is selected press enter again to display: Delete alarm msg? Delete Single For either message type, if there aren't any messages the display will indicate: empty ThermoFlex 7-11 Thermo Scientific...
Page 102: Checklist
If the chiller is still running press enter to see if the message clears, a limit may have been only temporarily exceeded. If the message does not clear refer to Messages in this Section. 7-12 ThermoFlex Thermo Scientific...
Page 103 If the chiller is over-cooling, recycle the power. Make sure the condenser/air filter is free of dust and debris. Check the fluid concentration, see Section 3. Ensure your chiller's installation complies with the site requirements listed in Section 3. ThermoFlex 7-13 Thermo Scientific...
Page 104 If operating at high altitude note that heat removal capacity decreases 1.2% per 1,000 feet above sea level. Also, reduce the maximum temperature for the air entering the ThermoFlex by 1°C per 1,000 feet above sea level. Verify/adjust controller PID values, see next page. Ensure the chiller was shut down properly, see Section 4.
Page 105: Tuning
P proportional value, % of span (100°C) Range: 0.0 to 99.9 0.10 Factory Preset: ThermoFlex900-10000 5.0 0.00 I integral value, repeats/minute Range: 0.00 to 9.99 Factory Preset: ThermoFlex900-10000 0.10 D derivative value, minutes Range: 0.0 to 9.9 Factory Preset: ThermoFlex900-10000 0.0 ThermoFlex 7-15 Thermo Scientific...
Page 106 Section 7 7-16 ThermoFlex Thermo Scientific...
Page 107: Additional Information
Reinstall ¼” Male NPT pipe plug using a sealant suitable for the wetted materials or close the Riton filling prior to refilling the chiller. CAUTION Do not overtighten the fitting.  For ThermoFlex7500-10000, close the drain valve. Riton connector Brass plug (typical) Figure 8-1 Drains ThermoFlex Thermo Scientific...
Page 108 Slide the panel back approximately one inch, then lift slightly from the rear to disengage the panel's two tabs from their slots. The drain for ThermoFlex 3500 and 5000 chillers is located behind the condenser filter.
Page 109: Calibration
Section 8 CALIBRATION The ThermoFlex has been designed to minimize the need for calibration. However, if calibration is desired or recommended by our Sales, Service and Customer Support, please use the following procedure. flow1 CALIBRATION calibrates the chiller's temperature (...
Page 110: Wetted Materials
Filter bag Buna N Polypropylene Ceramic Mono-filament nylon Tank Cap and Funnel Polyethylene (standard temp chiller) Acetal Copolymer Polyvinyldiene Diflouride (high temp) Brass EPDM Pyrex ® Riton (optional drain fitting) ® Viton (optional drain fitting o-ring) ® ThermoFlex Thermo Scientific...
Page 111: Decommissioning/Disposal
Store the chiller in the temperature range of -25°C to 60°C (with packaging), and <80% relative humidity.  If the chiller is stored for more than 90 days it must be flushed with CAUTION clean fluid before operating.  ThermoFlex Thermo Scientific...
Page 112 Section 8 ThermoFlex Thermo Scientific...
Page 113 Gambia, Ghana, Gibraltar, Grenada, Hong Kong, India, Ireland, Kenya, Kiribati, Kuwait, Lesotho, Malawi, Malaysia, Maldives, Malta, Mauritius, Myanmar, Nigeria, Oman, Pakistan, Qatar, Saint Lucia, Seychelles, Sierra Leone, Singapore, Sri Lanka, Sudan, Swaziland, Tanzania, Uganda, United Arab Emirates, United Kingdom Yemen, Zambia, Zimbabwe. ThermoFlex A-1 Thermo Scientific...
Page 114: Appendix B Voltage Configuration Instructions
Voltage Configuration Instructions Appendix B ThermoFlex 900 and 1400 chillers equipped with the 115V 60Hz, 100v 50/60Hz Variable Voltage option and ThermoFlex 900 to 5000 chillers equipped with 200-230V 50/60Hz Global Voltage option have a voltage configuration panel located on the rear of the chiller behind an access panel, see Figure B-1.
Page 115 TX = Transmitted data from controller RX = Received data to controller. 5 4 3 2 1 Hardware Mating Connector AMP Part# 745492-2 or equivalent 9 8 7 6 Communication cables are available from Thermo Fisher. Contact us for additional information. ThermoFlex C-1 Thermo Scientific...
Page 116 When a command has no value associated with it, (e.g., REQ ACK), “n d-bytes” will be set to 0. Values such as temperature and flow are sent as either 2 or 4 byte signed integers, depending on how they are stored in the controller RAM. When the controller sends a value, a qualifier byte is sent first, followed by a 2 or 4 byte integer (the least significant byte is sent last). The qualifier indicates the precision and units of the value. The host does not send the qualifier byte; it must send the value using the correct precision, units and number of bytes. The host first inquires about a value it wants to change, then uses the number of data bytes and the qualifier byte it receives to generate the proper integer to send. ThermoFlex Thermo Scientific...
Page 117 Error Response F0 - The "Bad Data" and "Bad Checksum" error responses will not be used. Reject out of range values and return old settings. Do not reply to message frames with bad checksums. This behavior is compatible with existing implementations of the protocol. ThermoFlex C-3 Thermo Scientific Thermo Scientific...
Page 118 S: lc a1 a2 23 03 d1 d2 d3 cs REQ TEMP7 M: lc a1 a2 26 00 cs ThermoFlex 2500 Air-cooled Fan Speed S: lc a1 a2 26 03 d1 d2 d3 cs REQ ANALOG1 M: lc a1 a2 28 00 cs...
Page 119 Auto Refill On Setting S: lc a1 a2 45 03 d1 d2 d3 cs REQ LO RES1 M: lc a1 a2 4C 00 cs Process Warning S: lc a1 a2 4C 03 d1 d2 d3 cs ThermoFlex C-5 Thermo Scientific Thermo Scientific...
Page 120 M: lc a1 a2 72 00 cs S: lc a1 a2 72 03 d1 d2 d3 cs REQ HEAT D M: lc a1 a2 73 00 cs S: lc a1 a2 73 03 d1 d2 d3 cs ThermoFlex Thermo Scientific...
Page 121 S: lc a1 a2 D2 03 d1 d2 d3 cs M: lc a1 a2 E0 02 d1 d2 cs SET HI TEMP1 Process Warning S: lc a1 a2 E0 03 d1 d2 d3 cs ThermoFlex C-7 Thermo Scientific Thermo Scientific...
Page 122 Heat I Term S: lc a1 a2 F2 03 d1 d2 d3 cs SET HEAT D M: lc a1 a2 F3 02 d1 d2 cs Heat D Term S: lc a1 a2 F3 03 d1 d2 d3 cs ThermoFlex Thermo Scientific...
Page 123 Low Flow Error (user set able) Anti Drainback Valve Open High Level Error Clogged Fluid Filter Fault Low Level Error Temp Fault Startup Bypass Drip Pan fault System Low Flow Auto Refill fault Not used ThermoFlex C-9 Thermo Scientific Thermo Scientific...
Page 124 2 effectively turns this command into a request status command. Chiller On/Off Set Keystroke This command is used to affect a keystroke remotely as if someone pressed the key on the controller. Value Null Enter Up/Yes Down/No On/Off Left Right C-10 ThermoFlex Thermo Scientific...
Page 125 Appendix C Set Special Command Used for product specific commands, in the ThermoFlex this command configures the analog options (DAC out, Analog in and turns on and off DAC output) CA 00 01 8D nn d1…dn cs Set Special Command...
Page 126 24V AC/DC, 2A, <= 0.08 Ohm maximum each or 5A total for all relays combined, 1mA minimum, switching capacity: 48VA/48W (Resistive load only). Note 2: Default = 0-10VDC. These ranges are set by the user. Note 3: Connect to digital ground (pin 1) using a low resistance connection (gold contact relay). ThermoFlex D-1 Thermo Scientific...
Page 127 WARNING Never apply line voltage to any of the connections.  RS232 RS485 When making your connection to the ThermoFlex Analog I/0 connector, in order to comply with the EMC directive: A I/O REMOTE • Use a shielded I/0 cable SENSOR •...
Page 128 High Pressure High Pressure Low Pressure Low Pressure Unit Fault Warning Pump/Unit Shut Off PM Timer Refrig. Shut Off Comm Error Limit Fault Sensor Fault Sensor Fault RELAY 2 ThermoFlex Thermo Scientific Thermo Scientific Low Level Tank Overflow Drip Pan Full...
Page 129 Voltage Millivolts Current The ThermoFlex supports three standard analog interface types and defaults to the following scaling: Voltage 0v – 10v = the operating range of the chiller (5° – 40° in standard chillers, 5° – 90° in high temp chillers) MilliVolts 10mv/°C...
Page 130 VoltageOutputGain = (10 – 0) / (90 – 5) = 0.117647 VottageOutputOffset = 10 – (90 * 0.117647) = -0.58823 Now 90° will output 10v. (90 * gain) + offset (90° * 0.117647) + (-0.58823) = 10.0v ThermoFlex Thermo Scientific Thermo Scientific...
Page 131 MilliVoltOutputGain = (1000 – 0mv) / (100 – 0) = 10 MilliVoltOutputOffse = 1000 – (100 * 10) = 0 Now 10° will output 100mv ((10 * gain) + offset) (10° * 10) + 0 = 100mv = 10mv/°C ThermoFlex Thermo Scientific...
Page 132 Note: Ensure that there is sufficient range in the voltage or current to provide enough resolution of temperature. For example a voltage range of 0v – 1v to represent a temperature range of 0° - 150° would not have enough resolution to provide stable readings. ThermoFlex Thermo Scientific Thermo Scientific...
Page 133 CAUTION to lowering the setpoint does not result in operation below 10°C process temperature. Operation below 10°C requires the use of 50/50 EG/water or 50/50 PG/water.  Figure D-2 Remote Sensor Connector ThermoFlex Thermo Scientific...
Page 134 Laboratory Equipment Div. 25 Nimble Hill Road Newington, NH 03801 DECLARATION OF CONFORMITY Manufacturer: Thermo Fisher Scientific Address: 25 Nimble Hill Road Newington, NH 03801 USA Products: Refrigerated chillers and heat exchangers. Year of inception 2008 We declare that the following products conform to the Directives and Standards listed below: Unit has a 15 digit part number consisting of UU C VV PP c XXXXXXX defined as follows: UU = Unit type can be: 10 = TF 900...
Page 135 Thermo Fisher Scientific certifies that ThermoFlex Bill of Material numbers above meet the requirements of DIRECTIVE 2002/95/EC, Restriction of Hazardous Substances Directive ( RoHS ). Thermo Fisher Scientific certifies that ThermoFlex Bill of Material numbers above contain less than the following amounts of the six RoHS banned substances with the...
Page 136 Thermo Fisher Scientific warrants for 24 months (excluding MD 1/MD 2 Magnetic Drive and P 1/P 2 Positive Displacement pumps which are warranted for 12 months) from date of shipment the Thermo Scientific ThermoFlex chiller according to the following terms.
Page 138 Thermo Fisher Scientific 81 Wyman Street P.O. Box 9046 Waltham, Massachusetts 02454-9046 United States www.thermofisher.com...

Thermo Scientific thermoflex Installation, Operation And Maintanance

Quick Start

Preface

Safety

General Information

Installation

Operation

Preventive Maintenance

Additional Information

Appendix A CountrySpecific230Vac,50Hz,1ØRequirements

Appendix B Voltage Configuration Instructions

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