Neslab System I Liquid to Liquid Manual

Instruction and Operation Manual

NESLAB Manual P/N 013564

Rev. 06/05/97

System I Liquid to Liquid

Heat Exchanger

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- 1 -

System I Liquid to Liquid Heat Exchanger

Table of Contents

PREFACE Compliance ............................................................................................ 2

Unpacking.............................................................................................. 2

Warranty ................................................................................................ 2

After-sale Support .................................................................................. 2

SECTION I

Safety Warnings................................................................................................ 3

SECTION II

General Information Description ............................................................................................. 4

Specifications......................................................................................... 4

SECTION III

Installation Site......................................................................................................... 5

Facility Water Requirements .................................................................. 5

Electrical Requirements ......................................................................... 5

Plumbing Requirements......................................................................... 6

Fluids ..................................................................................................... 6

Water Quality Standards and Recommendations .................................. 7

Filling Requirements .............................................................................. 9

Pump Purging ........................................................................................ 9

SECTION IV

Operation Start Up.................................................................................................. 10

Temperature Adjustment ....................................................................... 10

SECTION V

Special Features Low Level Fluid Monitor ......................................................................... 11

High Temperature Monitor ..................................................................... 11

EXTERNAL INTERLOCK Contacts........................................................ 11

SECTION VI

Maintenance and

Service Service Contracts................................................................................... 12

Cleaning................................................................................................. 12

Algae...................................................................................................... 12

Pump Strainer ........................................................................................ 12

Pressure Relief Valve Adjustment.......................................................... 13

Pump Lubrication ................................................................................... 14

SECTION VII

Troubleshooting Checklist ................................................................................................ 15

Service Assistan .................................................................................... 16

Technical Support .................................................................................. 16

SECTION VIII

Diagrams Flow Diagram......................................................................................... 17

SECTION IX

Warranty ............................................................................................................... 18

- 2 -

Preface

Compliance Products tested and found to be in compliance with the requirements defined

in the EMC standards defined by 89/336/EEC as well as Low Voltage Direc-

tive (LVD) 73/23/EEC can be identified by the CE label on the rear of the unit.

The testing has demonstrated compliance with the following directives:

LVD, 73/23/EEC Complies with UL 3101-1:93

EMC, 89/336/EEC EN 55011, Class A Verification

EN50082-1:1992

IEC1000-4-2:1995

IEC1000-4-3:1994

IEC1000-4-4:1995

For any additional information refer to the Letter of Compliance that shipped

with the unit (Declaration of Conformity).

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, or does

not operate properly, contact the transportation company and file a damage

claim. Under ICC regulations, this is your responsibility.

Warranty Units have a one year warranty against defective parts and workmanship

from date of shipment. See back page for more details.

After-sale Support NESLAB is committed to customer service both during and after the sale. If

you have questions concerning the operation of your unit, contact our Sales

Department. If your unit fails to operate properly, or if you have questions

concerning spare parts or Service Contracts, please contact our Service

Department for assistance.

- 3 -

Section I Safety

Warnings Make sure you read and understand all instructions and safety precautions

listed in this manual before installing or operating your unit. If you have any

questions concerning the operation of your unit or the information in this

manual, contact our Sales Department (see After-sale Support).

Observe all warning labels.

Never remove warning labels.

Never operate damaged or leaking equipment.

Never operate the unit without cooling fluid in the reservoir.

Always turn off the unit and disconnect the line cord from the power

source before performing any service or maintenance procedures.

Always empty the reservoir before moving the unit.

Always turn off the unit and disconnect the line cord from the power

source before moving the unit.

Never operate equipment with damaged line cords.

In addition to the safety warnings listed above, warnings are posted through

out the manual. These warnings are designated by an exclamation mark

inside an equilateral triangle with text highlighted in bold. Read and follow

these important instructions. Failure to observe these instructions can result

in permanent damage to the unit, significant property damage, or personal

injury or death.

- 4 -

Section II General Information

Description The System I Liquid to Liquid Heat Exchanger uses building recirculating or

tap water as the secondary cooling medium to remove heat from the cooling

fluid in the closed recirculation loop.

The unit consists of a heat exchanger, recirculation pump, PVC reservoir,

and an analog temperature controller.

Specifications

Temperature Range

Temperature Stability1

Cooling Capacity1,2

+5°C to +35°C

±1.0°C

2 3 4 5 6 7 Flow Rate (gpm)

3.5 7.5 12.5 18.0 25.0 33.0 Pressure (psi)

Reservoir Volume

Gallons

Liters

Unit Dimensions

(H x W x D)

Inches

Centimeters

1.0

3.8

25½ x 14¼ x 20½

64.7 x 36.2 x 52.1

1. Specifications listed are for a standard unit, operating at +20°C fluid temperature, with

tap water as the cooling fluid.

2. Cooling capacity is based on a 10°C difference between the temperature of the cooling

water supply (house water) and the cooling fluid as it leaves the System I (see Section

III, Facility Water Requirements).

- 5 -

Section III Installation

Site The unit should be placed in a location with easy access to a cooling water

source and a drain. Never place the unit in a location where excessive heat,

moisture, or corrosive materials are present.

Facility Water

Requirements

Limit the facility water inlet pressure to approximately 65 psig.

Refer to the Cooling Capacity chart in Section II, Specifications. The flow rate

of the cooling water supply must meet or exceed these requirements for the

unit to operate at its full rated capacity. If the cooling water does not meet

these standards, the cooling capacity will derate. The chart is based on a

10°C difference between the temperature of the cooling water supply (facility

water) and the cooling fluid as it leaves the System I.

As the heat load increases, the required flow rate of the cooling water supply

increases. For example, if the heat load is 8 kilowatts, only 3.25 gallons per

minute at 8.5 psi is required to remove the heat. However, if the heat load

is 14 kilowatts, about 5.5 gallons per minute at 21.5 psi is required.

Electrical

Requirements Refer to the serial number on the rear of the unit for the specific electrical

requirements of your unit.

Ensure the voltage of the power source meets the specified voltage, ±10%.

Make sure an adequate ground connection is provided.

- 6 -

Plumbing

Requirements Before installing the unit to an instrument that previously used tap water as a

cooling fluid, flush the instrument several times to remove any rust or scale

that has built up. The manufacturer of the instrument should be able to

recommend a cleaning fluid for their equipment.

The plumbing connections are located on the rear of the unit and are

labelled COOLING WATER and RECIRCULATING WATER. The top fittings

are inlets and the bottom fittings are outlets. The COOLING WATER

connections are ¾ inch FPT. The RECIRCULATING WATER connections

are ½ inch MPT.

Connect the COOLING WATER connections to the cooling water supply.

Connect the RECIRCULATING WATER connections to the instrument being

cooled.

Flexible tubing, if used, should be of heavy wall or reinforced construction.

All tubing should be rated to withstand 80 psi at +35°C. Make sure all tubing

connections are securely clamped. Avoid running tubing near radiators, hot

water pipes, etc. If substantial lengths of tubing are necessary, insulation

may be required to prevent loss of cooling capacity.

Tubing and insulation are available from NESLAB. Contact our Sales Depart-

ment for more information (see Preface, After-sale Support).

It is important to keep the distance between the unit and the instrument being

cooled as short as possible, and to use the largest diameter tubing practical.

Tubing should be straight and without bends. If diameter reductions must be

made, they should be made at the inlet and outlet of the instrument being

cooled, not at the unit.

If substantial lengths of cooling lines are required, they should be pre-filled

with cooling fluid before connecting them to the unit.

Fluids Refer to the Water Quality and Recommendations section.

The selected fluid must have a viscosity of 50 centistokes or less at the

lowest operating temperature.

Tap water is the recommended fluid for operation.

Never use flammable or corrosive fluids with this unit.

- 7 -

Water Quality Standards

and Recommendations Permissible(PPM) Desirable(PPM)

Microbiologicals

(algae,bacteria,fungi) 0 0

Inorganic Chemicals

Calcium <40 0.6

Chloride 250 <25

Copper 1.3 1.0

Iron 0.3 <0.1

Lead 0.015 0

Magnesium <12 0.1

Manganese 0.05 <0.03

Nitrates\Nitrites 10 as N 0

Potassium <20 0.3

Silicate 25 <1.0

Sodium <20 0.3

Sulfate 250 <50

Hardness 17 <0.05

Total Dissolved Solids 50 10

Other Parameters

pH 6.5-8.5 7-8

Resistivity 0.01* 0.05-0.1*

* Megohm-Cm (Compensated at 25C)

Unfavorably high total ionized solids (TIS) can accelerate the rate of galvanic

corrosion. These contaminants can function as electrolytes which increase

the potential for galvanic cell corrosion and lead to localized corrosion such

as pitting which can be observed at the studs and on the outside surface of

cooling coils. Eventually, the pitting will become so extensive that the coil will

leak refrigerant into the water reservoir.

As an example, raw water in the United States averages 171 ppm (as NaCl).

The recommended level for use in a water system is between 0.5 to 5.0 ppm

(as NaCl).

Recommendation: Initially fill the tank with distilled/deionized water. Do not

use untreated tap water as the total ionized solids level may be too high.

- 8 -

Maintain this water quality at a resistivity of between 1 to 10 megohm-cm

(compensated at 25°C) by using a purification system. Although the initial fill

may be as high as 10 megohm-cm (compensated at 25°C), the desired level

for long time usage is 1 to 3 megohm-cm (compensated at 25°C).

The above two recommendations will reduce the electrolytic potential of the

water and prevent or reduce the galvanic corrosion observed.

Resistivity (megohm-cm @ 25°C)

Not Recommended, Increasingly Corrosive

Operations with Stainless Steel Systems

Operations with

Mixed Metals

Copper/Brass/

Stainless Steel CONSULT MATERIALS ENGINEER

10 20 30 40 50 60 70 80

18.30

15.00

10.00

3.00

1.00

0.10

0.05

Water Quality Considerations

Temperature °C

- 9 -

Filling

Requirements The reservoir access cover is located on top of the unit. Remove the reservoir

access cover and locate the reservoir plug (square nut). Remove the plug

and fill the reservoir to the bottom of the fill hole flange. Keep extra cooling

fluid on hand until the entire system (the System I, the instrument being

cooled and the tubing that connects them) is filled.

Do not replace the reservoir plug until the unit is circulating fluid through the

instrument being cooled (see Section IV, Start Up).

Pump Purging Units with TU-1 pumps may require pump purging. Refer to the identification

label on the rear of the unit to identify the specific pump.

Pump purging is necessary to purge air trapped in the pump head cavity.

When the unit is started, if there is no flow in the RECIRCULATING

SUPPLY tube, or if the flow is restricted (see Section II, Pumps to review the

pump flow and pressure specifications), purging is necessary.

Place a container under the SUPPLY connection. Start the unit. Loosen

the hose clamp on the SUPPLY connection and partially remove the hose

from the connection. Do not completely remove the hose from the

SUPPLY connection. Allow the air to escape. After a few moments,

cooling fluid should flow from the connection.

If fluid does not flow on its own accord, attach a short piece of tubing to the

connection and apply suction to start flow.

Once flow is established, reconnect the tubing on the SUPPLY connection.

The pump is now purged and the unit is ready for operation.

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