NESLAB CFT Series
Recirculating Chiller
Thermo Manual P/N U00362
Instruction and Operation Manual
No part of this publication may be reproduced or reprinted except for personal use
without the prior permission of Thermo
Electron.
Rev. 08/18/99
NESLAB CFT Series Recirculating Chiller
PREFACE
SECTION I
Safety
SECTION II
General Information
SECTION III
Installation
SECTION IV
Operation
SECTION V
Maintenance & Service
SECTION VI
Troubleshooting
WARRANTY
Compliance ............................................................................................ 3
Unpacking .............................................................................................. 3
Warranty ................................................................................................. 3
NES-care ................................................................................................ 3
After-sale Support ................................................................................... 3
Warnings ................................................................................................ 4
Additional Warnings ............................................................................... 5
Description ............................................................................................. 6
Specifications ......................................................................................... 6
Cooling Capacity .................................................................................... 8
Pump Capacity....................................................................................... 8
Site ......................................................................................................... 9
Electrical Requirements ......................................................................... 10
Plumbing Requirements ......................................................................... 10
Fluids ..................................................................................................... 11
Water Quality Standards and Recommendations................................... 12
Filling Requirements ............................................................................... 13
Start Up .................................................................................................. 15
Temperature Controller .......................................................................... 16
Temperature Limits ................................................................................ 17
Pressure Relief Valve............................................................................. 17
High/Low Pressure Cutouts .................................................................... 17
High Temperature Cutout (Optional) ...................................................... 18
Heater Package (Optional) ..................................................................... 18
External Pressure Reducer (Optional) .................................................... 19
Service Contracts ................................................................................... 20
Draining the Reservoir ........................................................................... 20
Cleaning ................................................................................................. 20
Algae ...................................................................................................... 21
Pump Strainer ........................................................................................ 21
Pump Lubrication ................................................................................... 22
Hoses..................................................................................................... 22
Suction Discharge Pressure/Speed Check ............................................ 22
Error Codes ............................................................................................ 23
Displaying Software Version ................................................................... 23
CFT-300 Fuses ....................................................................................... 24
Pump Flow Diagram............................................................................... 24
Checklist ................................................................................................ 25
Service Assistance ................................................................................. 25
- 1 -
CFT Series Quick Reference Operating Procedures
Installation
The unit has an air-cooled refrigeration system. Air
is drawn in the front of the unit and discharged
through rear and side. Position the unit so the
intake and discharge are not impeded. Inadequate
ventilation will cause a reduction in cooling capacity and, in extreme cases, compressor failure.
Excessively dusty areas should be avoided and a
periodic cleaning schedule should be instituted.
For proper operation, the unit needs to pull substantial amounts of air through a condenser. A
build up of dust or debris on the fins of the condenser will lead to a loss of cooling capacity.
The unit will retain its full rated capacity in ambient
temperatures up to approximately +24°C.
Make sure the voltage of the power source meets
the specified voltage, ±10%.
The plumbing connections are located on the rear
of the unit and are labelled either SUPPLY and
RETURN or OUTLET and INLET. These connections are ½ inch FPT, ¾ inch FPT for CFT-150s
with CP-55 pumps and CFT-300s. Remove the
plastic protective plugs from both plumbing connections. Connect the OUTLET/SUPPLY fitting to
the inlet of the instrument being cooled. Connect
the INLET/RETURN fitting to the outlet of the
instrument being cooled.
To fill the reservoir, remove the reservoir access
panel by unscrewing the thumbscrews. Locate the
reservoir plug (square nut). Remove the plug and
fill the reservoir with clean cooling fluid.
We recommend using distilled/deionized water with
a 0.05 to 0.1 megohm-cm reading.
If you do not have access to distilled/deionized
water we recommend using filtered tap water.
Operation
Before starting the unit, double-check all electrical
and plumbing connections. Make sure the circulating system has been filled with cooling fluid.
To start the unit, place the Power Switch to the on
position. The Power Switch illuminates (except for
the CFT-150) to indicate the system is operating.
To turn the unit off, place the Power Switch to the
off position.
When the unit is shut off, wait approximately five
minutes before restarting. This allows time for the
refrigeration pressures to equalize. If the pressures
are not allowed to equalize, the compressor will
short-cycle and no cooling will occur.
Temperature Adjustment
To display the temperature setpoint, press the
NEXT ENTER button on the controller. To adjust
the temperature setpoint, press the YES or NO key
until the desired temperature setpoint is indicated.
Once the setpoint is adjusted, press NEXT ENTER. The display will now indicate the temperature
of the fluid in the reservoir.
Periodic Maintenance
Periodically inspect the reservoir fluid. If cleaning is
necessary, flush the reservoir with a cleaning fluid
compatible with the circulating system and the
cooling fluid.
The cooling fluid should be replaced periodically.
When operating at low temperatures, the concentration of water in the cooling fluid will increase
over time, leading to a loss of cooling capacity.
Before changing the cooling fluid, raise the unit's
operating temperature to de-ice the cooling coils.
Periodic vacuuming of the condenser fins is
necessary. The frequency of cleaning depends on
the operating environment. We recommend a
visual inspection of the condenser be made
monthly after initial installation. After several
months, the cleaning frequency will be established.
Units with PD pumps have a strainer. If debris is in
the system, the strainer will prevent the material
from being drawn into the pump and damaging the
pump vanes.
After initial installation, the strainer may become
clogged. Clean the strainer after the first week of
installation. After this first cleaning, we recommend
a monthly visual inspection. After several months,
the cleaning frequency will be established. Before
cleaning, disconnect the power cord from the
power source and drain the reservoir.
The Cool LED indicates the status of the refrigeration system. It illuminates to indicate the refrigeration system is removing heat from the cooling fluid.
As the operating temperature approaches the
setpoint, the LED will flash.
- 2 -
Compliance
Unpacking
Preface
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 Directive (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
EN 50082-1:1992
IEC 1000-4-2:1995
IEC 1000-4-3:1994
IEC 1000-4-4:1995
For any additional information refer to the Letter of Compliance that shipped with
the unit (Declaration of Conformity).
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.
When unpacking the unit, we recommends using a hoist. Units are not equipped
with handles. Roll the unit on its casters to move it.
Warranty
NES-care Extended
Warranty Contract
After-sale Support
If this product has been modified to operate at 0°C or lower, it has been tested with
a non-freezing fluid. Although the system has been drained, some residual fluid
may remain. This will not hinder your unit's performance.
Units have a warranty against defective parts and workmanship for one full year
from date of shipment. See back page for more details.
Extend parts and labor coverage for an additional year.
Worry-free operation.
Control service costs.
Eliminate the need to generate repair orders.
No unexpected repair costs.
Other contract options are available. Please contact us for more information.
Thermo Electron Corporation is committed to customer service both during and
after the sale. If you have questions concerning the unit operation, contact our
Sales Department. If your unit fails to operate properly, or if you have questions
concerning spare parts or Service Contracts, contact our Service Department.
Before calling, please refer to the labels on the rear of the unit to obtain the following information:
- unit BOM number_________________________________
- unit serial number ________________________________
- software version (see page 23)_______________________
- 3 -
Warnings
Section I Safety
Warnings are posted throughout the manual. These warnings are designated by an exclamation mark inside an equilateral triangle and 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.
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 (see After-sale Support).
Never place the unit in a location where excessive heat, moisture, or
corrosive materials are present.
The unit construction provides protection against the risk of electrical
shock by grounding appropriate metal parts. The protection may not
function unless the power cord is connected to a properly grounded
outlet. It is the user's responsibility to assure a proper ground connection is provided.
Never connect the OUTLET/SUPPLY or INLET/RETURN fitting to your
building water supply or any water pressure source.
Never use flammable or corrosive fluids with this unit. Distilled and
deionized water may be aggressive and cause material corrosion.
Please contact us before subjecting this unit to prolonged exposure to
distilled or deionized water.
Do not use automobile anti-freeze. Commercial anti-freeze contains
silicates that can damage the pump seals. Use of automobile antifreeze will void the manufacturers warranty.
Do not replace reservoir plug with a non-vented type or damage to the
tank may occur.
- 4 -
Additional Warnings
In addition to the specific warnings listed on the previous page the following
general warnings apply to you unit:
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.
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 power cord from the power
source before performing any service or maintenance procedures, or
before moving the unit.
Always empty the reservoir before moving the unit.
Never operate equipment with damaged power cords.
Refer service and repairs to a qualified technician.
- 5 -
Description
Specifications
Cooling Capacity
1,2
Section II General Information
The NESLAB CFT Recirculating Chiller is designed to provide a continuous
supply of cooling fluid at a constant temperature and volume.The unit consists
of an air-cooled refrigeration system, a sealable reservoir, recirculating pump,
and a temperature controller.
Throughout the manual, you will be asked to consult the units serial number
label or the pump identification label for specific information. Both labels are
located on the rear of the unit.
12
A
Temperature Range
Temperature Stability
8
4
5
4
3
HEAT REMOVAL (KILOWATTS)
2
1
0 5 10 15 20 25 30
TEMPERATURE (°C)
B
A=CFT-300, 60HZ
B=CFT-300, 50HZ
C
D
E
F
H
G
C=CFT-150, 60HZ
D=CFT-150, 50HZ
E=CFT-75, 60HZ
F=CFT-75, 50HZ
G=CFT-33, 60HZ
H=CFT-33, 50HZ
I=CFT-25, 60HZ
J=CFT-25, 50HZ
I
J
CFT-25 CFT-33 CFT-75 CFT-150 CFT-300
3
4
+5°C to +30°C
±0.5°
+5°C to +35°C
±1.0°C
Reservoir Volume
5
Gallons
Liters
Refrigerant
Pollution Degree
1. 60 Hertz CFT-75s with a "Turbulator" tank have a 2500 watt cooling capacity.
2. Circulating water at 20°C, at 20°C ambient. Cooling capacity will vary depending on fluid
temperature, ambient temperature, and cooling fluid. A PD-1 pump was used in the CFT-25, a
PD-2 in the other units.
3. Modified temperature ranges from -15°C to +85°C are available.
4. CFT-300 stability determined with 86% heat load.
5. 1.25 gallons (4.73 liters) for 50 Hertz CFT-75 units.
0.4
1.4
1.1
4.2
- 6 -
1.8
6.8
II, IAW IEC 664
5.6
21.3
R22R134a
I
H
Unit Dimensions
Dimension A
Dimension B
Dimension C
Dimension D
Dimension E
Dimension F
Dimension G
Dimension H
A
F
E
D
C
B
CFT25 CFT33 CFT75 CFT150 CFT300
22 24½ 26½ 36¾ 43
12½ 14¾ 14 7/8 213/8 25½
21 22 24½ 27¾ 27¾
2¾ 2½ 2½ 3½ 2¾
NA NA NA 23½ 29
171/16 18½ 22 32¼ 38¼
201/16 21½ 25 35¼ 41¼
1½ 1 11/8 11/8 1
G
Dimension I
Crate Dimensions
(H x W x D)
Shipping Weight
Air Intake
NA NA NA 6 1
31x23x28 31x23x32 32x23x40 33x29x42 35x33x56
132 160 215 311 450
280 375 800 1050 2500
Electrical Requirements
Volts
Hertz
Phase
Plug
1. Dimension A is the height of the unit. The unit width and depth (dimensions B and C) are the case dimensions, add
approximately 2 inches to include the plumbing connections. The depth case dimension for CFT-75s with "Turbulator"
tanks is 25¾".
2. Dimension D is the distance from the floor to the bottom of the unit case (height of the castors).
3. Dimension E is the distance from the floor to the center of the DRAIN connection (CFT-150/300 only).
4. Dimension F is the distance from the floor of the center of the OUTLET connection.
5. Dimension G is the distance from the floor of the center of the INLET connection.
6. Dimension H is the distance from the unit's left side to the center of the INLET and OUTLET connections.
7. Dimension I is the distance from the unit's left side to the center of the DRAIN connection (CFT-150/300 only).
8. Weights are given in pounds
9. Air intake is given in cubic feet per minute.
115V 115V 208/230V 208/230V 208/230V
60Hz 60Hz 60Hz 60Hz 60Hz
11113
NEMA5-15P NEMA5-20P NEMAL6-15P NEMAL6-20P NA
Rev 04/12/99
- 7 -
Pump Capacity
Bar PSI
0.7
10
0.5
0.4
Pressure
0.3
A=MD-30 60Hz
8
A
6
4
B
B=MD-30 50Hz
0.1
Bar PSI
4.0
3.4
2.7
2.0
Pressure
1.3
0.7
60
50
40
30
20
10
2
1 2 3 4 5 GPM
3.8 7.5 11.3 15.1 19.0 LPM
A
B
1 2 3 4 GPM
3.8 7.5 11.3 15.1 LPM
Flow
Flow
A=PD-1 60Hz
B=PD-1 50Hz
C
D
C=PD-2 60Hz
D=PD-2 50Hz
Bar PSI
Pressure
3.4
2.7
2.0
1.3
0.7
50
40
30
20
10
A=CP-55 60Hz
A
B
5 10 15 20 25 30 GPM
18.9 37.9 56.8 75.5 94.6 113.6 LPM
Flow
B=CP-55 50Hz
- 8 -
Site
Section III Installation
The unit should be located in a laboratory or clean industrial environment
where ambient temperatures are inside the range of +13°C to +35°C, and
maximum humidity is below 80%.
Never place the unit in a location where excessive heat, moisture, or
corrosive materials are present.
The unit has an air-cooled refrigeration system. Air is drawn through the
front of the unit and discharged through rear and side panels. The unit must
be positioned so the intake and discharge are not impeded. A minimum
clearance of 18 inches (45 centimeters) on all vented sides is necessary for
adequate ventilation. Inadequate ventilation will cause a reduction in cooling
capacity and, in extreme cases, compressor failure.
Excessively dusty areas should be avoided and a periodic cleaning schedule
should be instituted (see Section V, Cleaning).
The unit will retain its full rated capacity at ambient temperatures up to approximately +24°C. Above +24°C, reduce the cooling capacity 1% for every 0.5°C
above +24°C, up to a maximum ambient temperature of +35°C.
Direction of Air Flow
- 9 -
Electrical
Requirements
The unit construction provides protection against the risk of electrical
shock by grounding appropriate metal parts. The protection may not
function unless the power cord is connected to a properly grounded
outlet. It is the user's responsibility to assure a proper ground connection is provided.
Refer to Section II, Specifications, and to the serial number label 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%. Transient overvoltages must comply with OVERVOLTAGE CATEGORY II. For mains supply,
the minimum and normal category is II.
The CFT-300 is supplied with a junction box located behind the controller
panel. Wire the power connections in accordance to local, state and federal
electrical codes. Double check all wiring to make sure it is properly connected
and protected from the elements.
The CFT-300 is also 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. This allows time for the oil to be heated and
separate from the refrigerant.
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 OUTLET/
SUPPLY and INLET/RETURN. CFT-25 to CFT150 connections are ½ inch FPT,
CFT-150s with CP-55 pumps are ¾ inch and
CFT-300 connections are ¾ inch FPT.
Remove the plastic protective plugs from both plumbing connections.
Connect the OUTLET/SUPPLY fitting to the inlet of the instrument being
cooled. Connect the INLET/RETURN fitting to the outlet of the instrument
being cooled.
Never connect the fittings to your building water supply or any water
pressure source.
Two sets of plumbing adapters are included with CFT-25 to CFT-150 units. One
set of adapters will accept 3/8 inch ID tubing. The other set will accept
- 10 -
½ inch ID tubing. If the unit is being plumbed using flexible tubing, install one
set of adapters in the plumbing ports. To prevent leaking, be sure to wrap the
threads of the adapters with Teflon® sealing tape before installing them in the
plumbing ports.
Flexible tubing, if used, should be of heavy wall or reinforced construction. All
tubing should be rated to withstand 80 psig at the highest operating temperatures. 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. Contact our Sales Department 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 CFT.
If substantial lengths of cooling lines are required, they should be pre-filled
with cooling fluid before connecting them to the unit.
Fluids
Never use flammable or corrosive fluids with this unit. Do not use
automotive anti-freeze. Commercial anti-freeze contains silicates that
can damage the pump seals. Use of automotive anti-freeze will void the
manufacturers warranty.
We recommends using distilled/deionized water with a 0.05 to 0.1 megohm-cm
reading.
Highly distilled/deionized water, above the 3 megohm-cm region, may
become aggressive and is not recommended for use with units with
wetted parts other than stainless steel. Distilled/deionized water in the
15 megohm-cm region is definitely aggressive and should not be used.
Units operating in these regions should be closely monitored. See
Water Quality Standards and Recommendations in this section.
If you do not have access to distilled/deionized water we recommend using
filtered tap water. We cannot recommend any custom fluids; these fluids are
too dependent on your particular application.
Below +8°C, a non-freezing solution is required. The selected cooling fluid
must have a viscosity of 50 centistokes or less. A 50/50 mixture, by volume,
of distilled/deionized water and laboratory grade ethylene glycol is suggested.
For units with extended temperature ranges above +35°C, we recommend
distilled/deionized water up to +80°C. Above +80°C, you are responsible for the
fluid(s) used.
- 11 -
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*
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 (of NaCl). The recommended
level for use in a water system is between 0.5 to 5.0
ppm (of 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.
Maintain this water quality at a resistivity of between
1 to 10 megohm-cm (compensated to 25°C) by
using a purification system. Although the initial fill
may be as high as 10 megohm-cm (compensated to
25°C), the desired level for long time usage is 1 to 3
megohm-cm (compensated to 25°C).
The above two recommendations will reduce the
electrolytic potential of the water and prevent or
reduce the galvanic corrosion observed.
* Megohm-Cm (Compensated to 25°C)
15.00
10.00
3.00
1.00
Resistivity (megohm-cm @ 25°C)
0.10
0.05
Operations with
Mixed Metals
Copper/Brass/
Stainless Steel
10 20 30 40 50 60 70 80
Not Recommended, Increasingly Corrosive
Operations with Stainless Steel Systems
CONSULT MATERIALS ENGINEER
°C
Water Quality Considerations
- 12 -
Filling Requirements
Remove the reservoir access panel by unscrewing the thumbscrews. Locate
the reservoir plug (square nut). Remove the plug and fill the reservoir with
clean cooling fluid, following the special considerations outlined in the
following paragraphs.
Thumbscrew
Reservoir Access Panel
Reservoir Plug
Reservoir filling locations (Typical)
Circulating to a closed system (closed to the atmosphere)
|Fill the reservoir to the bottom of the fill hole threads. Since the reservoir
capacity is small compared to many instruments being cooled, have extra
cooling fluid on hand to keep the system topped off when external circulation
is started.
NOTE: The tank in your unit has a vent that relieves pressure built up from
thermal expansion of water. The vent is located on the reservoir plug. It
activates when tank pressure reaches 3 - 5 psi.
Do not replace reservoir plug with a non-vented type or damage to the
tank may occur.
Circulating to an open system (open to the atmosphere)
Fill the reservoir so ¾ of the fill hole threads are covered. Wrap the tank
plug with Teflon® sealing tape. Replace the tank plug and tighten securely to
prevent air entry.
When circulating cooling fluid to an open vessel or tank, connect the OUTLET/
SUPPLY and INLET/RETURN lines to the open tank. Secure the INLET/
RETURN (suction) line below the fluid surface. The INLET/RETURN line should
be submerged deep enough to avoid sucking air. Make sure the INLET/
RETURN line is free of particles and debris that can block the flow of fluid. A
baffle or screen may be required.
- 13 -
Blank page.
- 14 -
Start Up
YES
Section IV Operation
Before starting the unit, double check all electrical and plumbing connections
and make sure the circulating system (the CFT, the instrument being cooled,
and the tubing that connects them) has been properly filled with cooling fluid.
On units with a circuit breaker located on the rear of the unit, ensure it is the
on position. To start the unit, place the POWER Switch to the on ( I ) position.
The refrigeration system and the recirculation pump will start. The POWER
Switch illuminates (except for the CFT-150) to indicate the system is operating. Units with PD pumps display the pump operating pressure on the RECIRCULATING PRESSURE gauge.
To turn the unit off, place the POWER Switch to the off ( 0 ) position.
COOL indicates the status of the refrigeration system. It illuminates to indicate the refrigeration system is removing heat from the cooling fluid. As the
operating temperature approaches the temperature setpoint, the LED will
flash. IDLE indicates the unit is in a hot-gas-bypass mode of operation. As the
operating temperature approaches the temperature setpoint, the LED extinguishes.
When the unit is shut off, wait approximately five minutes before restarting.
This allows time for the refrigeration pressures to equalize. If the pressures
are not allowed to equalize, the compressor will short-cycle (clicking sound)
and no cooling will occur.
COOL
IDLE
°C
NEXT
ENTER
Digital Temperature Controller
NO
- 15 -
Digital Controller
YES
COOL
IDLE
°C
NEXT
ENTER
Digital Temperature Controller
NO
The digital controller controls temperature using a PID (Proportional-IntegralDerivative) algorithm. It is designed with self-diagnostic features and easy to
use operator interface.
NEXT ENTER
Use this key to accept and save changes.
YES,
This key is used to increase numerical values.
NO,
This key is used to decrease numerical values.
When the controller is powered it displays the reservoir fluid temperature.
Press the NEXT ENTER key to view the setpoint. The display flashes between SP and the actual setpoint number. If desired, use the YES and NO
keys to change the setpoint. The display flashes as soon as either key is
depressed. Once the desired setpoint is displayed, press NEXT ENTER.
NOTE: The controller does not use the new value until the NEXT ENTER key
is depressed and the display stops flashing. The controller will not allow you
to enter a value above the maximum or below the minimum value, or any
illegal value. If you try to enter an illegal value the display will revert to its
original value when the last digit was entered.
If the NEXT ENTER key is not depressed within one minute, the controller will
time out and the new value will not be accepted. The controller will revert to
the previous value.
NOTE: Error codes are addressed in Section V, Maintenance and Service.
- 16 -
Temperature Limits
Pressure Relief Valve
The controller is used to set the high and low temperature limits. If a limit is
exceeded the controller will display an error code, see Section V.
With the controller displaying the reservoir fluid temperature, press and hold
the NO key and then press the NEXT ENTER key. The controller will display
TUNE. Press the YES key to display COOL. Press the NO key to display
either HEAT or HIT, for high temperature limit. (HEAT is only displayed on
units with an optional heater, press NO to display HIT.)
To change the HIT value press YES. The display will flash HIT and the actual
value. Use the YES and NO keys to change the value. Once the desired
value is displayed press the NEXT ENTER key twice. The display will indicate
LOT for low temperature limit. Use the same procedure to change the low
temperature limit. The display will indicate STOR. Press YES to accept the
changes, press NO to restore the previous values. The controller will again
display the reservoir fluid temperature.
PD pumps have a pressure relief valve that establishes the maximum operating pressure of the unit. If the pressure of the fluid leaving the pump exceeds
the valve setting, the relief valve bypasses the fluid within the unit to relieve
the pressure. The relief valve does not determine the actual operating pressure; the system back pressure determines operating pressure.
High/Low
Pressure Cutouts
If an adjustment is necessary, contact our Customer Service Department.
All CFT-300 units are equipped with refrigeration
High Pressure Cutouts (HPC) and Low Pressure
Cutouts (LPC). Some CFT-150 units are equipped
with an HPC. Should either cutout activate the unit
will shut down.
The HPC activates if there is a blockage in the
refrigeration lines or if the refrigerant temperature
becomes too hot. The HPC is factory preset at 400
psi.
The LPC activates if there is a leak in the refrigeration lines. THE LPC is factory preset at 4 psi.
The cutouts are located inside the case behind the rear panel. Once the cause
of the shut down has been determined and corrected, manually depress the
white button on the applicable cutout. If a "click" is not heard when depressing
the button, the cutout was not activated and the unit shut down for another
reason.
Reset
HPC/LPC (Typical)
- 17 -
High Temperature
Cutout (Optional)
Heater Package
(Optional)
The High Temperature Cutout (HTC) is designed to shut down the unit in the
event the temperature of the fluid in the reservoir exceeds the HTC setting.
The HTC is normally located on the rear of the unit.
NOTE: The HTC temperature scale is in °F.
A switch on the temperature controller powers the heater. The heater itself is
accessible through the small service panel on the rear of the unit.
The controller will indicate a low-level display if the fluid level in the reservoir
drops below proper operating level.
Illustration A shows the desired fluid level for normal operation.
Should the reservoir be filled as shown in illustration B, units designed to
operate at high-end temperatures (near boiling) may cause air in the reservoir
to become trapped. The air can be vented by slightly tilting the unit forward on
its front castors.
Do not used silicon-based fluids with units designed to operate at high
temperatures. These type fluids will damage the hoses and pump seal.
Fluid Level
Illustration A
Fluid Level
Illustration B
- 18 -
External Pressure
Reducer (Optional)
For applications requiring a maximum pressure less than 55 PSI (380 kPa), an
External Pressure Reducer (EPR) is available. An EPR allows an adjustable
operating pressure of 10 to 50 PSI (70 to 345 kPa). If the pressure of the fluid
leaving the chiller exceeds the relief valve setting, the relief valve will bypass
excess fluid back into the chiller to relieve the overpressure.
The back pressure of the connected
equipment and the flow rate of the
recirculating fluid to your application
determined the system pressure. Connect the EPR as described.
NOTE: Install the fittings in the exact
sequence shown.
NOTE: Use Teflon
®
tape on all threaded
fittings.
Connect the Inlet Tee Assembly (1) to
the chiller. Connect the Outlet Tee
Assembly (2) to the chiller. Attach the
relief valve (3) to the Outlet Tee Assembly (2). Attach the Hose Nipple (4) to
the Relief Valve (3). Attach the Hose (5) between the Inlet Tee Assembly (1)
and the Hose Nipple (4).
The EPR is now installed. Connect the inlet (to your application) to the remaining fitting of the Outlet Tee Assembly (2). Connect the outlet (from your
application) to the remaining fitting of the Inlet Tee Assembly (1).
Tighten the hose clamps tight enough to prevent leakage. Do not overtighten or
the clamps will bite into the flexible tubing and cause excessive wear. If a
torque wrench is available, torque hose clamps to 50 in/lbs (280 cm/kg).
Nylon-reinforced hose tends to cold-flow, so the clamps will need to be retorqued later. (The hose clamps do not actually loosen, but rather the hose
outside diameter decreases.)
The "T" adjustment handle is equipped with a locknut. To adjust the relief
pressure setting loosen the locknut and turn the "T" handle to the minimum
pressure setting (direction of arrow).
To simulate blockage, close (or pinch off) the hose between the EPR outlet tee
assembly and your application. Monitor the operating pressure of the unit. Turn
the "T" handle until the desired relief pressure is set. (The EPR valve cannot be
set lower than the total back pressure of the instrument being cooled or the
instrument will not receive any flow.)
Tighten the locknut to secure the position of the "T" handle. Open the hose
between the EPR outlet tee assembly and your application.
- 19 -
Service Contracts
Draining the
Reservoir
Section V Maintenance and Service
For personal safety and equipment reliability, only a qualified technician should perform the following procedures. Contact our Service
Department for assistance (see Preface, After-sale Support).
Thermo offers on-site Service Contracts designed to provide extended life and
minimal down-time for your unit. For more information, contact our Service
Department (see Preface, After-sale Support).
CFT-150s and CFT-300s are equipped with a ½ inch FPT DRAIN fitting located
on the rear of the unit.
To drain the other CFT reservoirs we recommend the use of a wet/dry vacuum.
Remove the reservoir plug and carefully insert the wet/dry vacuum so as not to
damage the cooling coils. NOTE: Tilting the unit more than 45° may allow
compressor oil to seep into the suction line.
Cleaning
Do not blow high-pressure air into the system. Doing so may rupture the
reservoir.
Reservoir
Periodically inspect the fluid inside the reservoir. If cleaning is necessary,
flush the reservoir with a cleaning fluid compatible with the circulating system
and the cooling fluid.
The cooling fluid should be replaced periodically. When operating at low
temperatures, the concentration of water in the cooling fluid will increase
over time, leading to a loss of cooling capacity.
Before changing the cooling fluid, raise the operating temperature of the unit
to de-ice the cooling coils. Refer to Section III, Filling Requirements for
instructions on replacing the cooling fluid.
Condenser
For proper operation, the unit needs to pull substantial amounts of air
through a condenser. A build up of dust or debris on the fins of the condenser
will lead to a loss of cooling capacity.
The lower front of the unit has a one-piece grille assembly. Gently pry the
assembly off with a flathead screwdriver. Use care not to scratch the paint.
Periodic vacuuming of the condenser fins is necessary. The frequency of
cleaning depends on the operating environment. After initial installation, we
recommend doing a monthly visual inspection of the condenser. After several
months, the cleaning frequency will be established.
- 20 -
Algae
Pump Strainer
To restrict the growth of algae in the reservoir, it is recommended that the
reservoir cover be kept in place and that all circulation lines be opaque. This
will eliminate the entrance of light that is required for the growth of most
common algae.
We recommend the use of Chloramine-T, 1 gram per 3.5 liters. Other algicides
can be harmful to the unit's internal components. Contact us for additional
information.
Units with PD pumps have a strainer. Refer to the pump label on the rear of the
unit to identify the type of pump in your unit.
If debris is in the system, the strainer will prevent the material from being drawn
into the pump and damaging the pump vanes.
After initial installation, the strainer may become clogged with debris and
scale. Therefore, the strainer must be cleaned after the first week of installation. After this first cleaning, we recommend a monthly visual inspection. After
several months, the cleaning frequency will be established.
Before cleaning the strainer, disconnect the power cord from the power
source and drain the reservoir.
PD-1 pumps have a wire mesh strainer located in the pump head. PD-2
pumps have the strainer located in the pump suction line.
Remove the wrapper from the unit. Unscrew the plastic cap, or the larger of
the two acorn nuts on the pump head, and remove the screen.
Clean the screen by rinsing it with water.
When the screen is clean, replace it in the strainer, tighten the cap or acorn
nut and replace the wrapper. Refer to Section III, Filling Requirements for
instructions on replacing the cooling fluid.
PD-2 Strainer
PD-1 Strainer
- 21 -
Pump Motor Lubrication
Some PD pump motors require periodic lubrication. Refer to the pump label on
the rear of the unit to identify the type of pump in your unit.
PD pumps use sleeve type bearings with large reservoirs. Oiling instructions
are generally posted on each motor. In the absence of instructions, add
approximately 30 to 35 drops of SAE 20 non-detergent oil to each bearing on
the following schedule (SAE 20 = 142 CS viscosity):
Duty Cycle Oiling Frequency
Continuous Once every year
Intermittent Once every 2 years
Occasional Once every 5 years
Fill Holes (Typical)
Hoses
The unit's internal and external hoses and clamps should be inspected and
tightened on at least a semiannual basis.
Suction Discharge Pressure
Speed Check
Unit Pump Refrigerant Suction PSIG Discharge PSIG Speed °C/Min
CFT-25 PD-1 R134a 36 -38 160 - 170 4.8
CFT-25 MD-30 R134a 25 - 28 145 -160 4.0
CFT-33 PD1/2 R134a 42 - 45 180 - 200 3.0
CFT-75 PD1/2 R134a 37 - 41 170 -185 4.6
CFT-150 PD2 R22 70 270 2.8
CFT-300 PD2 R22 88 - 94 265 - 280 6.8
CFT-300 CP-55 R22 85 - 90 268 - 280 6.8
Standard temperature 60 Hertz units, derate 17% for 50 Hertz Units. +20°C fluid temperature,
unit in the COOL mode, +20°C ambient. 100% water in the reservoir. Wrapper removed.
- 22 -
Error Codes
The controller also has the capability to display error codes. The codes are:
Display Indication
16 Bad calibration data, redo calibration
19 Temperature below low temperature setpoint
21 Temperature above high temperature setpoint
22 Excessive high temperature, unit requires immediate
attention
23 Shorted RTD2
24 Open RTD2
25 Shorted RTD1
26 Open RTD1
ADD Reservoir fluid below normal operating level, add fluid
The unit will continue to run with any of the above codes. If any other
code appears contact customer service, see Preface.
NOTE: Depressing the NEXT ENTER key may clear error codes 01 through 04.
Doing so restores the controller to factory-set default values.
Displaying Software
Version
This procedure will display the software version number on the units display. In
the event the unit is not operational, the software version (and the checksum)
can also be read from the label which is on the microprocessor chip itself.
The following chart uses an example of software version 000507.49b
begin at the reservoir temperature display 20.3°C
Press and hold NO for at least 10 seconds. 0507
displays software version digits to left of decimal. Note the two leading zeros
do not display.
Press NEXT 49
displays software version digits to right of decimal.
Press NEXT 2
displays software version revision letter (as its equivalent number - display
cannot show letters. A=1, B=2, etc.)
Press NEXT 0000
displays checksum - this can be disregarded
Press NEXT 20.3°C
returns to reservoir temperature display
- 23 -
CFT-300 Fuses
Pump Flow Diagram
Three Class J fuses are used to protect the motor, in addition to a thermal
overload device. These fuses are located inside the main control panel. In the
event of an open fuse, investigate and correct the source of the overload before
replacing the fuse(s).
Always turn off the unit and disconnect the line cord from the power
source before attempting to do any service.
To replace the fuses, remove the two screws from the main control panel and
then open the panel door. For units equipped with a 380V, 3-Phase, CP-55
pump, our part number 008596, replace the fuses with Class J, 600V, 3A,
TDLY fuses only. Do not replace the fuses with an alternate amperage.
Pressure Gauge
(PD Pumps Only)
Relief Valve
(PD Pumps Only)
Pump
Reservoir
Strainer (PD Pumps Only)
Supply Return
Checklist
Section VI Troubleshooting
Unit will not start
Check the position of the optional circuit breaker on the rear of the unit.
Check the line cord; make sure it is plugged in.
Check that the Power Switch/Circuit Breaker has not tripped.
Check the setting on the optional High Temperature Cutout.
Check the voltage of the power source. Make sure it is within the rated
voltage of the unit, ±10%.
CFT-300s and some CFT-150s units are equipped with high and low pressure switches. If either switch activates the unit will shut down. Once the
cause has been determined you have to manually reset the switch. The
switches are located behind the rear panel, see Section IV, Operation.
Unit will not circulate fluid
Check the reservoir level. Fill, if necessary.
Make sure the pump has been purged.
Check the pressure gauge (units with PD pumps). If the reading is 60
psig, check the instrument being cooled for restrictions in the cooling line.
Service Assistance
Check the pump strainer (units with PD pumps). A clogged strainer can
starve the pump.
Inadequate temperature control
If the temperature continues to rise, make sure the heat load of the
instrument being cooled does not exceed the rated specification, see
Section II, Specifications.
Make sure the air intake and discharge are not impeded and the ambient
temperature does not exceed +35°C.
Make sure the condenser is free of dust and debris, see Section V,
Cleaning.
If the compressor short-cycles (a clicking sound), check the line voltage.
It should be within the 10% of the specified voltage. Wait 5 minutes
before restarting the unit.
If, after following these troubleshooting steps, your unit fails to operate
properly, contact our Service Department for assistance (see Preface, Aftersale Support). Before calling, please refer to the serial number label on the
rear of the unit to obtain the following information:
- unit BOM number
- unit serial number
- voltage of unit
- voltage of power source
- software version
WARRANTY
Thermo Electron Corporation warrants for 12 months from date of shipment any Thermo unit according to the
following terms.
Any part of the unit manufactured or supplied by Thermo and found in the reasonable judgment of Thermo to be
defective in material or workmanship will be repaired at an authorized Thermo Repair Depot without charge for
parts or labor. The unit, including any defective part must be returned to an authorized Thermo Repair Depot
within the warranty period. The expense of returning the unit to the authorized Thermo Repair Depot for warranty
service will be paid for by the buyer. Thermo's 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. With respect to units that qualify for field service repairs, Thermos
responsibility is limited to the component parts necessary for the repair and the labor that is required on site to
perform the repair. Any travel labor or mileage charges are the financial responsibility of the buyer.
The buyer shall be responsible for any evaluation or warranty service call (including labor charges) if no defects
are found with the Thermo product.
This warranty does not cover any unit that has been subject to misuse, neglect, or accident. This warranty does
not apply to any damage to the unit that is the result of improper installation or maintenance, or to any unit that
has been operated or maintained in any way contrary to the operating or maintenance instructions specified in
Thermos Instruction and Operation Manual. This warranty does not cover any unit that has been altered or
modified so as to change its intended use.
In addition, this warranty does not extend to repairs made by the use of parts, accessories, or fluids which are
either incompatible with the unit or adversely affect its operation, performance, or durability.
Thermo reserves the right to change or improve the design of any unit without assuming any obligation to modify
any unit previously manufactured.
THE FOREGOING EXPRESS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR
IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE.
Thermo's OBLIGATION UNDER THIS WARRANTY IS STRICTLY AND EXCLUSIVELY LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE COMPONENT PARTS AND Thermo DOES NOT ASSUME OR
AUTHORIZE ANYONE TO ASSUME FOR IT ANY OTHER OBLIGATION.
Thermo ASSUMES NO RESPONSIBILITY FOR INCIDENTAL, CONSEQUENTIAL, OR OTHER DAMAGES
INCLUDING, BUT NOT LIMITED TO LOSS OR DAMAGE TO PROPERTY, LOSS OF PROFITS OR REVENUE,
LOSS OF THE UNIT, LOSS OF TIME, OR INCONVENIENCE.
This warranty applies to units sold in the United States. Any units sold elsewhere are warranted by the affiliated
marketing company of Thermo. This warranty and all matters arising pursuant to it shall be governed by the law of
the State of New Hampshire, United States. All legal actions brought in relation hereto shall be filed in the appropriate state or federal courts in New Hampshire, unless waived by Thermo.
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