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Thermo ThermoFlex 900 User Manual

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Product Service Information, Applications
Notes, MSDS Forms, e-mail.
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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

Questions and Answers:

Thermo ThermoFlex 900 Specifications

General IconGeneral
Temperature Stability±0.1°C
RefrigerantR134a
Power Requirements230V, 50/60Hz
DisplayDigital
Power Supply230V, 50/60Hz
Cooling Capacity900 W

Summary

Section I Safety

Warnings

Safety warnings posted throughout the manual, identified by an exclamation mark icon.

Section II Theory of Operation

Abbreviations

Lists and defines common abbreviations used in the manual.

RA Process Data Dictionary

Lists components, signal names, and their descriptions.

Flow Diagram, Air-Cooled

Illustrates the refrigerant flow and component layout for air-cooled units.

Flow Diagram, Water-Cooled

Illustrates the refrigerant flow and component layout for water-cooled units.

Components

Detailed descriptions of major components like the compressor, valves, and sensors.

Section III General Information

Specifications

Details the technical specifications for ThermoFlex 900 and 1400 models.

Performance Curves

Graphical representation of cooling and pumping capacities for different models.

Section IV Installation

Site Requirements

Outlines environmental and spatial requirements for unit installation.

Electrical Requirements

Details voltage, frequency, phase, and receptacle ratings for unit power supply.

Plumbing Requirements

Specifies connection types, sizes, and material for process fluid lines.

Fluid Requirements

Lists acceptable fluids and precautions for use in the unit.

Section V Operation

Basic Controller

Explains the functions of the controller interface and its keys.

Prestart

Pre-operational checks and fluid preparation before starting the unit.

Start Up

Procedure for powering on the unit and initiating its self-test sequence.

Controller Loops

Describes navigation through different operational modes like Setpoint, Setup, and Diagnostic.

Setpoint Loop

Details how to view and change the desired process fluid temperature setpoint.

Setup Loop

Explains how to adjust controller software settings, alarms, and features.

Diagnostic Loop

Displays and allows resetting of operating times for various unit components.

Adjusting the Controller PID Values

Procedure for tuning proportional-integral-derivative parameters for temperature control.

Shut Down

Steps for safely powering down the unit and its compressor.

Section VI Troubleshooting

Operational Error Codes

Lists error codes, their causes, and recommended actions for troubleshooting.

Checklist

Provides step-by-step checks for common operational issues like starting, shutting down, and fluid circulation.

Flowcharts

Visual troubleshooting guides for specific problems like "Unit doesn't cool" and "Unit won't power on".

Section VII Service Functions

Entering Service Function

Procedure to access the controller's service mode for advanced operations.

Diagnostic Loop (dia9)

Displays and allows resetting of operating times for various unit components.

Calibration Loop (CAL)

Procedure for calibrating temperature sensors and pressure transducers.

Engineering Loop (En9)

Accesses parameters for viewing unit data like temperatures, pressures, and flow rates.

Tune Loop (tunE)

Allows adjustment of PID controller parameters for optimal temperature control.

Master Reset

Procedure to reset the controller to factory default settings.

Configuration Loop (ConF)

Used to set unit configuration parameters such as unit type, voltage, and pump type.

Section VIII Advanced Service

Removing the Side Panels

Instructions for safely disassembling the unit's outer casing.

Draining

Procedure for emptying the unit's internal fluid lines and reservoir.

Control Board Replacement

Step-by-step guide for replacing the unit's main electronic control board.

Pump

Detailed instructions for removing and replacing the unit's circulation pump.

Top Assembly

Procedures for accessing and removing the upper components of the unit.

Pressure Transducers

Steps for disconnecting and removing pressure sensor components.

Temp Sensor (rtd1)

Visual guide for locating and accessing the temperature sensor.

Testing RTD Temperature Sensors

Method for testing the resistance of RTD sensors using a multimeter.

Temperature Sensor Replacement

Comprehensive guide for replacing internal temperature sensors.

Internal Process Fluid Temperature Sensor (rtd1) Calibration

Procedure for calibrating the process fluid temperature sensor.

Optional Process Fluid Flow Transducer (FLo) Calibration

Steps for calibrating the optional flow transducer.

Section IX Pressure Transducer Check

PD Pump Pressure Transducer (Psia vs VDC)

Chart and procedure for checking PD pump pressure transducer output.

Suction Pressure Transducer Data

Data and testing procedure for the suction pressure transducer.

Section X Refrigeration

R 134a Refrigerant Charging Data

Specifies refrigerant amounts for different models and cooling types.

Section XI C1-C3 Service Testing

Heat Load Capacity

Procedure for testing unit heat load capacity at specified conditions.

Section XII Printed Circuit Board Assembly (PCBA) Calibration

PCBA Calibration

Details PCBA calibration using NIST traceable reference values.

PCBA + Sensor calibration

Describes calibration matching sensors to PCBA after integration.

Section XIII Firmware Download

Procedure

Step-by-step instructions for downloading firmware to the unit's control board.

Appendix A

Country Specific Receptacle Rating Requirements

Lists countries and their required electrical receptacle current ratings.

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