5.2 Troubleshooting and frequently asked questions 156
5.2.1 Hardware operation issues 156
5.2.2 Cell culture operation issues 158
5.2.3 Sparging issues 159
5.2.4 Probe and connector issues 160
5.2.5 BPC issues 161
Page 3
Contents
Chapter 6 General ordering information 162
6.1 Ordering instructions 163
6.2 Ordering/support contact information 163
6.3 Technical support 164
Page 4
Warnings, safety, and warranty information
Warnings, safety, and warranty
information
Congratulations! You have purchased high-quality Thermo Scientific™
equipment. We have included safety information in this guide, based
on our knowledge and experience. It is important, however, for you
to work with your Safety Management personnel to ensure that this
equipment is integrated into your safety practices. Please take some
time to perform your own job safety analysis in order to identify and
control each potential hazard.
WARNING: Read and understand this user’s guide before
using this equipment.
The Thermo Scientific™ DHX Heat Exchanger is designed to be
operated under traditional pharmaceutical conditions. A general
understanding of bioprocessing systems and their operation is
important prior to using the system for the first time. Read and
understand the user’s guide before operating; failure to do so could
result in injury and potential loss of product.
WARNING: Do not exceed maximum operating pressure.
• The maximum jacket operating pressure should not exceed 5.2
bar (75 psi).
• The maximum BioProcess Container (BPC) operating pressure
should not exceed 2.75 bar (40 psi). The recommended standard
operating pressure is 2.06 bar (30 psi).
WARNING: Moving and tipping hazard.
Due to the weight of the Thermo Scientific
operators are required to move the unit. Use caution when moving
the equipment. Ensure that the pathway is clear and free of obstacles.
Avoid moving up or down slopes unless properly supervised by an
equipment-moving professional.
WARNING: Ensure that the temperature of the BPC never
reaches above 50ºC (122ºF).
Any warranties, if applicable, covering this equipment exclude:
(a) normal wear and tear; (b) accident, disaster or event of force
majeure; (c) your misuse, fault or negligence; (d) use of the equipment
in a manner for which it was not designed; (e) causes external to
the equipment such as, but not limited to, external puncturing,
power failure or electrical power surges; (f) improper storage and
handling of the equipment; (g) use of the equipment in combination
with equipment or software that we did not supply; (h) equipment
sold to you as ‘used’ products; (i) contact with improperly used or
unapproved chemicals or samples; (j) installation, removal, use,
maintenance, storage, or handling in an improper, inadequate, or
unapproved manner, such as, but not limited to, failure to follow
the documentation or instructions in the deliverables or related to
the equipment, operation outside of stated environmental or other
operational specifications, or operation with unapproved software,
materials or other products; (k) manufacture in accordance with
requirements you gave us; (l) installation of software or interfacing or
use of the equipment in combination with software or products we
have not approved; (m) use of the deliverables or any documentation
to support regulatory approvals; (n) the performance, efficacy or
compatibility of specified components; and (o) the performance
of custom equipment or products or specified components or
achievement of any results from the equipment, specified components
or services within ranges desired by you even if those ranges are
communicated to us and are described in specifications, a quote,
or a statement of work. ADDITIONALLY, ANY INSTALLATION,
MAINTENANCE, REPAIR, SERVICE, RELOCATION OR
ALTERATION TO OR OF, OR OTHER TAMPERING WITH, THE
EQUIPMENT PERFORMED BY ANY PERSON OR ENTITY OTHER
THAN US WITHOUT OUR PRIOR WRITTEN APPROVAL, OR ANY
USE OF REPLACEMENT PARTS WE HAVE NOT SUPPLIED, WILL
IMMEDIATELY VOID AND CANCEL ALL WARRANTIES WITH
RESPECT TO THE AFFECTED EQUIPMENT. IF THE EQUIPMENT
IS TO BE USED IN THE UNITED STATES, WE MAY VOID YOUR
WARRANTY IF YOU SHIP THE EQUIPMENT OUTSIDE OF THE
UNITED STATES.
Use restrictions
You must use this equipment in accordance with our documentation
and if applicable, with our other associated instructions, including
without limitation, a “research use only” product label or “limited use”
label license. This equipment is intended for research use or further
manufacturing in bioprocessing applications and not for diagnostic
use or direct administration into humans or animals, we do not submit
the equipment for regulatory review by any governmental body or
other organization, and we do not validate the equipment for clinical or
diagnostic use, for safety and effectiveness, or for any other specific
use or application.
Seismic guidance
The buyer of the equipment is responsible for ensuring that countryspecific codes and seismic values are assessed for suitability of
equipment installation and safety at the designated site. In addition,
it is the buyer’s responsibility to assess the building structure for
the designated equipment to ensure correct seismic anchoring and
tethering designs for both the equipment and facility. It is highly
recommended that the buyer consult with a local, licensed third party
architecture and engineering firm to provide the buyer with correct
engineering analysis and stamped documentation prior to equipment
installation at the facility. In addition, the buyer will be responsible for
rigging and anchoring of the equipment to a specified, fixed location.
Upon request, Thermo Fisher Scientific can assist with establishing
compliant seismic anchoring and tethering designs for purchased
equipment based on building and country codes, at an agreed
upon fee.
It is also noted that movable equipment (i.e. non-fixed or caster
mount) is exempt from seismic design requirements according to
ASCE 7-16, Chapter 13, section 1.4. Although these units are exempt
from the seismic design requirements of ASCE 7, it should be noted
that such equipment is susceptible to overturning during a seismic
event. Therefore, it is the responsibility of the buyer to address seismic
safety for movable equipment at the designated facility.
This user's guide contains information about the standard Thermo
Scientific™ DHX™ Heat Exchanger, including hardware, components,
product design verification methods, installation, operation and
specifications. It is intended for use by people who may or may
not have experience with Thermo Scientific systems, but who have
some knowledge of bioproduction processes and large-scale mixing
systems.
Rev.DateSectionChange madeAuthor
--09/2016--Initial release
A05 /2019--ReformattedE. Hale
Questions about this publication
If you have any questions or concerns about the content of this
publication, please contact technicaldocumentation@thermofisher.
The Thermo Scientific™ DHXHeat Exchanger is a modular system
that employs a plate-and-frame concept, using a single-use bag
assembly, or BioProcess Container (BPC), as the sterile fluid path.
Each bag fits tightly between a dimpled, stainless steel plate assembly
(5 total) to transfer heat in a counter-current flow path. In a completely
isolated flow path, the process fluid flows through the bags countercurrently to the heating/cooling fluid within the plates. Once the bags
are loaded into place, no further operator interaction is required. The
system provides efficient, sterile heat transfer that easily integrates into
any new or existing process.
1.2 Main components
Figure 1.1 illustrates the components of the Thermo ScientificDHX
Heat Exchanger.
Use the following steps to inspect the DHX Heat Exchanger:
1. Carefully uncrate the DHX.
2. Thoroughly review the product for damage.
3. Check the product and components against the parts list (see
Chapter 5).
4. If the product is damaged, or if the shipment is not complete,
please contact your service representative immediately.
2.2 Installing the system
Use the following steps to initially install the DHX Heat Exchanger:
1. Unlock all four (4) casters and transport the DHX to the desired
location.
Thermo Scientific
2. Ensure the DHX is on a level surface and lock the casters in place.
3. Refer to Figure 2.1 for the recommended installation setup for the
DHX system.
DHX Heat Exchanger User's Guide | 7
Page 11
Chapter 2 | Installing the DHX
Figure 2.1. DHX system
recommended setup.
*High pressure interlock recommended
to shut down pumps or flow source.
**Temperature control loop
recommended for heating and high
temperature applications. May not be
required for cooling applications.
Process inlet
TE
HTF outlet
**
TIC
TIT
TE
I
*
PI
PI
PSV
PI
STR
FE
Process outlet
HTF supply
(pump or TCU)
Figure 2.2. DHX fluid inlet
and outlet connections.
4. The DHX inlet and outlet connections are 1/2 inch compression
fittings, as standard. It is highly recommeded that a strainer be
used upstream for the DHX plate system if the heat transfer fluid
may contain debris. Any debris that collects within the DHX will
restrict the flow and affect performance.
5. Connect the heat transfer fluid inlet and outlet connections, as
shown in Figure 2.2.
HTF inlet
Thermo Scientific
HTF outlet
DHX Heat Exchanger User's Guide | 8
Page 12
Chapter 2 | Installing the DHX
6. The DHX plate system operates independently of the single-use
bag assembly, or BioProcess Container (BPC). The installation of a
BPC is not required during the initial priming of the plate system.
7. Ensure that all hoses are securely connected to each plate and
that the high point vent valves are closed.
8. Ensure that the plate system is closed, using the locking and
fanning levers.
9. Ensure that the six (6) DHX plate system hinges are secure. Ensure
that the bolts sit in the recessed section of the plate tab, and that
the six (6) wing nuts are firmly hand-tightened.
10. Open the heat transfer circuit to the DHX. Note: It is normal to
hear some "knocking" as the plate system initially pushes the air
through the plates.
11. Bleed off the air in each plate using the high point bleed valves
and a small container to collect any released heat transfer fluid.
The bleeding steps should be repeated until all the air is expelled
from the DHX plate system.
12. Once the DHX plate system is bled, it is ready for operation.
2.3 DHX plate system optional configurations
The DHX system is a modular and changeable system in which one to
three single-use bags can be used. All five (5) plates are not required
to be used at one time. If one to three bags are used, there are two
options in setting up the DHX plate system.
Option 1: Insulation foam between the unused plates
The heat transfer fluid may run through all five plates when using
an assembly consisting of one to three single-use bags. Flexible
insulation foam spacers are provided by Thermo Scientific. These
spacers must be inserted between every unused plate—after the
bags have been installed—to prevent damage or warping (Figure 2.3).
Thermo Scientific
DHX Heat Exchanger User's Guide | 9
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Chapter 2 | Installing the DHX
Figure 2.3. DHX system
Configuation Option 1.
Insulation foam
spacers
Figure 2.4. DHX system
Configuration Option 2.
Option 2: Bypassing the unused plates
The DHX system's unused plates may be disconnected per Figure
2.4. Insulation foam spacers must be inserted between every unused
plate to prevent damage or warping. If option 2 is chosen, the
installation and bleeding instructions described in sections 2.1 and 2.2
must be followed accordingly for the plates in use. Note: Any unused
plates should be capped or sealed appropriately.
Insulation foam
spacers
Thermo Scientific
Disconnected
DHX plates
DHX Heat Exchanger User's Guide | 10
Page 14
Chapter 3 | Operating information
3
Operating information
3.1 Loading the BPC
Figure 3.1. Six (6) DHX
plate system hinges.
Note: Ensure all four (4) casters are in the locked position (down)
before loading the BPC assembly into the DHX.
1. Isolate the heat transfer fluid circuit to stop the heat transfer circuit
from flowing through the DHX plate system. It is acceptable to
have the plates pressurized with heat transfer fluid during the BPC
loading process.
2. Remove the wing nuts and bolts from the six (6) DHX plate system
hinges in the order shown in Figure 3.1. Note: It is recommended
to keep a free hand under the wing nut during its removal to
prevent it from dropping to the floor.
2
1
3
4
6
Thermo Scientific
5
DHX Heat Exchanger User's Guide | 11
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Chapter 3 | Operating information
Figure 3.2. Pulling the
locking lever.
1. Once the bolts are removed, the DHX will open slightly and relax
against the locking mechanism. Use the safety levers to fan out
the plates. This can be done by pulling the locking lever (located
towards the bottom of the unit, closest to the heat transfer fluid
ports) slightly to release the locking mechanism (Figure 3.2).
Locking
lever
Figure 3.3. Moving
fanning lever towards
the locking lever to
open position.
2. Using the upper fanning lever, move it towards the locking lever
with control to fan out the DHX plates (Figure 3.3). Remove the
insulation foam spacers, if applicable. The DHX is now in the open
position and the single-use BPC assembly can be placed.
Fanning
lever
Thermo Scientific
Fanning
lever
Locking
lever
DHX Heat Exchanger User's Guide | 12
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Chapter 3 | Operating information
Figure 3.4. Securing
the single-use BPCs.
3. There are tabs to secure each BPC to the corresponding plate on
the top and bottom of the single-use BPC (Figure 3.4). For ease
of installation, all tabs should be separated prior to placing the
BPCs between the plates. Insert each BPC used in the 1–4 singleuse BPC assembly within each corresponding plate. Ensure the
tubing cascades from one BPC to the next. [See section 2 to view
the two different configuration options if using less than all five (5)
plates.] Attach the bottom tabs of each BPC first.
4. The process flow must always be set up so the process fluid
fills from the bottom of the BPC to the top to displace any air
throughout the single-use BPC assembly.
5. For the DHX BPC assemblies with drain ports, ensure that the
drain port is connected to the proper drain connection in the
process. Close the pinch clamps on each drain line before starting
the process fluid flow.
6. The process must be set up for counter-current flow where the
process fluid enters from the opposite side of the heat transfer
fluid in order to provide the most efficient heat transfer method.
The process fluid should cascade through each BPC in the series
in the opposite direction of the heat transfer fluid path (Figure 3.5).
Thermo Scientific
DHX Heat Exchanger User's Guide | 13
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Chapter 3 | Operating information
Figure 3.5. DHX fluid
flow.
Process
fluid
Heating/cooling
fluid
7. Connect the inlet and outlet of the single-use BPC assembly to
the upstream and downstream process connections with the
DACs, tube welds, or connections specified for the user's custom
BPC assembly.
Figure 3.6. Flow path
tubing.
8. If the optional single-use BPC assembly with low-point drains are
used, the low-point drain connections are manifolded together.
9. The single-use flow path tubing left in its natural state could be
trapped between the braided heat transfer hoses when the DHX
unit is being closed. To prevent this, rest the single-use flow path
tubing across the top of the heat transfer hose assemblies (Figure
3.6).
Thermo Scientific
Incorrect
Correct
DHX Heat Exchanger User's Guide | 14
Page 18
Chapter 3 | Operating information
10. Reinstall the hinge bolts one at a time in the order shown in Figure
3.7. Position all bolts before fully tightening them, and ensure that
each bolt is recessed in the plate tab appropriately. It is a good
practice to check the tightness of the side bolts after tightening
the top bolts and vice versa.
Figure 3.7. Hinge bolt
installation (left) and
hinge detail (right).
21
4
3
6
5
3.2 Operating the DHX
1. Once the fluid connections are made, start the processing by
resuming the heat transfer fluid circuit. The flow of the heat
transfer fluid can be initiated up to 15 lpm. The bleed valves at the
top of each plate can be used to vent any trapped air (Figure 3.8).
A piece of tubing should be used to direct any fluid that may exit
the valves to a waste receptacle.
Figure 3.8. Bleed valve
locations.
Thermo Scientific
DHX Heat Exchanger User's Guide | 15
Page 19
Chapter 3 | Operating information
2. Begin the process flow slowly, starting at 3 lpm (or less). The
BPCs fill from the bottom to top, displacing the air as the process
fluid cascades through the assembly.
3. Carefully monitor the BPC assembly during the priming step to
ensure that there are no leaks, the tubing is not pinched, and all
air is being displaced accordingly.
4. Once the single-use BPC assembly is primed, the desired flow
rate may be set and the process can run continuously. Any
time the flow is stopped while in operation, it is recommended
to slowly ramp-up the pump when the flow is resumed. This
recommendation is especially the case for high flow rate
applications in order to prevent pressure surges in the single-use
BPC assembly.
3.3 Removing the BPC
1. Once the process operation is complete, the single-use BPC
assembly should be depressurized and drained to the extent
possible prior to removal form the DHX plate system.
2. After the BPCs have been partially drained, and they are no longer
pressurized, remove the wing nuts and bolts from each of the six
(6) DHX plate system hinges.
3. Open the DHX plate system using the safety levers (see section
3.1, steps 1 through 3).
4. Release the bottom and top tabs on all the BPCs and remove the
single-use BPC assembly.
5. If gross recovery of the process fluid is desired, start with the BPC
at the process inlet, remove the BPC tabs from the corresponding
connection points on the plate, and gently lift and tilt the BPC
toward the drain lines. Once the first BPC is nearly drained, repeat
the process with the consecutive BPCs until the last BPC in the
assembly has been drained.
Thermo Scientific
6. If the single-use BPC assembly with low-point drains was used,
any remaining process fluid may be recovered through the
process inlet by reversing the pump, or through the low-point
drain manifold outlet. To use the process inlet, the process outlet
and low-point drain manifold outlet tubing should be closed using
a clamp. Open the pinch clamps on each individual drain line
DHX Heat Exchanger User's Guide | 16
Page 20
Chapter 3 | Operating information
before starting the process fluid flow. The process fluid can be
recovered by reversing the pump and routing the process fluid
to an appropriate collection ocntainer. Alternately, to use the low
point drain manifold outlet, the process inlet and outlet tubing of
the BPC assembly should be closed using a clamp and the low
point drain manifold outlet tubing can be routed to a pump so
the process fluid may be recovered. Open the clamps on each
individual drain line before starting the process fluid flow.
7. Discard the assembly in the appropriate waste stream as dictated
by the end user's requirements.
Thermo Scientific
DHX Heat Exchanger User's Guide | 17
Page 21
Chapter 4 | Maintenance and troubleshooting
Maintenance and
troubleshooting
4.1 Routine maintenance
4
• Routinely inspect the plate system for rouge, pitting, or signs
of corrosion. De-rouge and/or passivate the plate system
accordingly.
• If applicable, inspect and clean the strainer upstream of the plate
system rountinely to ensure that the target heat transfer fluid rate
is maintained.
4.2 Preventive maintenance
• Remove the hoses and inspect the plate inlet/outlet connections
for signs of debris. If signs of debris are evident, or if it is
suspected that debris has settled in the bottom of the plates,
clean and flush the DHX plate system accordingly.
• Inspect the DHX plate system hoses for any signs of kinking or
excessive wear. Replace hoses as necessary.
• Inspect the bleed valves to ensure proper performance. Replace
bleed valves as necessary.
Thermo Scientific
Note: The preventive maintenance procedures listed above should
be completed on an annual basis for systems in regular use. Hoses
are recommended to be replaced at least every two years. Preventive
maintenance intervals may be revised at the discretion of the end user
based on system use and service.
DHX Heat Exchanger User's Guide | 18
Page 22
Chapter 4 | Maintenance and troubleshooting
4.3 Troubleshooting
Table 4.1 lists possible situations that may occur during operation of
the DHX and corrective courses of action.
Table 4.1. Troubleshooting causes and solutions.
ProblemProbable causeSolution
DHX system is not set up
correctly.
1. Ensure the system is set up per Figures 1.1 and 2.1.
2. Ensure the heat transfer inlet connection is at the top
of each plate. The hose at the heat transfer outlet
connection at the bottom of each plate should be
connected with a hose to the inlet connection at the top
of the next plate in series.
3. Ensure the single-use BPC assembly is set up to flow
in the opposite direction (counter-currently) to the DHX
plate system. The process fluid should enter the system
from the opposite side as the heat transfer fluid. The
BPCs should flow from bottom to top, where the singleuse tubing at the top of the BPC should connect to the
bottom of the next BPC in series.
Process fluid is not
reaching the desired
temperature at the
DHX outlet.
Lack of positive pressure on
BPC assembly.
Heat transfer fluid flow rate
is too low.
Process fluid flow rate is not
at setpoint.
Single-use BPC assembly is
improperly set up.
1. Ensure there is sufficient pressure so the single-use
BPCs fit tightly within each plate.
2. Ensure there is a source to apply positive pressure
upstream of the DHX system. See Figure 2.1.
1. Verify heat transfer fluid flow rate.
2. Ensure the hoses, plate system connections, and plate
system are not clogged with debris. If applicable, ensure
the strainer is clean.
3. Ensure the DHX plate system hoses are not kinked.
1. Verify the process fluid flow rate.
2. Ensure the single-use BPC assembly hoses are not
kinked or pinched in between the DHX plate system
hoses.
1. Inspect the single-use BPCs to ensure the bottom and
top tabs are secure.
2. Inspect the fit of each single-use BPC to ensure that the
serpentine pattern matches the corresponding DHX.
Thermo Scientific
DHX Heat Exchanger User's Guide | 19
Page 23
Chapter 4 | Maintenance and troubleshooting
Table 4.1. Troubleshooting causes and solutions (continued).
ProblemProbable causeSolution
DHX plate system contains
pockets of air.
Lack of sufficient insulation.
1. Ensure the DHX system is on a relatively flat
surface and bleed valves are at the high point.
2. Bleed any residual air from the DHX plate system
using the high point bleed valves.
If not all plates are in use, reference section 2.3 and
ensure that the flexible insulation is installed on the
outer side of the last plate in series.
DHX plate system and/
or plate system hinges
are becoming warped as
single-use assemblies
are filled or during normal
operation.
Single-use flow paths are
trapped between the heat
transfer hoses.
DHX plate system has
exceeded the heat transfer
capacity.
DHX plate system supports are
installed incorrectly.
Single-use BPC assembly has
exceeded its pressure rating.
DHX plate system has
exceeded its pressure rating.
The flow paths were not placed
on top of the heat transfer
hoses before closing the DHX.
Verify that the process and heat transfer fluid flow
rates align with the DHX sizing calculations. Contact
Thermo Fisher Scientific for support, as necessary.
Ensure all six (6) DHX bolts are sitting securely in the
recessed grooves.
1. Ensure the pressure on the single-use BPC
assembly does not exceed 20 psig at 50ºC
(12 2 º F ). Note: High pressure interlocks are
highly recommended per Figure 2.1.
2. Ensure there are no pressure surges during
initiation of process flow.
Ensure the heat transfer fluid pressure does not
exceed the pressure rating of the DHX plate system.
Note: A pressure safety valve is highly recommended
per Figure 2.1.
Before fluid is introduced, remove the bolts
as instructed and reopen the DHX. Follow the
instructions provided in this guideto properly align
the flow path tubing.
Thermo Scientific
DHX Heat Exchanger User's Guide | 20
Page 24
Chapter 5 | Specifications and parts information
Specifications and
parts information
5
5.1 DHX specifications
Tables 5.1 and 5.2 provide the specifications for the DHX Heat
Exchanger system hardware and BPCs.
Full weight (with 4 BPC assemblies)190 kg (419 lb)
Number of plates5
Effective heat transfer area
Material of construction316L Stainless steel
Up to 2.5 m2 (27 ft2)
Thermo Scientific
Pressure/temperature rating
Code stamp
FV/965 kPa (140 psig) at 60°C (150°F),
standard
ASME U-1 (standard—each plate individually
wrapped)
DHX Heat Exchanger User's Guide | 21
Page 25
Chapter 5 | Specifications and parts information
Table 5.2. DHX Heat Exchanger BPC specifications.
Number of BPCsUp to 4
BPC material of constructionLow-density polyethylene (LDPE)
BPC pressure/temperature rating138 kPa (20 psig) at 50°C (122°F)
5.2 DHX parts information
To ensure the minimum machine downtime, Thermo Fisher Scientific
recommends that the following items be maintained at the minimum
quantity in the manufacturing facility's spare parts inventory. Contact
Thermo Fisher Scientific for spare parts. Other parts may be replaced,
if needed. Figure 5.1 and Table 5.3 detail each of the recommended
spare parts.
ItemSpecification
Figure 5.1. DHX Heat
Exchanger parts.
Note: See Table
5.3 for descriptions
and recommended
number of spares.
E
D
K
I
F
J
B
L
C
G
M
A
H
Thermo Scientific
DHX Heat Exchanger User's Guide | 22
Page 26
Chapter 5 | Specifications and parts information
Table 5.3. Recommended DHX Heat Exchanger spare parts (refer to Figure 5.1).
Chapter 6 | General ordering and contact information
General ordering and
contact information
6
Hardware components and BPCs for the DHX Heat Exchanger can
be ordered directly from Thermo Fisher Scientific. Contact your sales
representative for ordering instructions.
For customer service help, contact one of the following:
In the Americas and Asia
1726 Hyclone Drive
Logan, Utah 84321
United States
Tel: +1 435 792 8500
Email: customerservice.bioprocessing@thermofisher.com
In Europe
Unit 9 Atley Way
Cramlington, NE 23 1WA
Great Britain
Tel: +44 (1) 670 734 093
Fax: +44 (1) 670 732 537
Email: customerservice.bioprocessing@thermofisher.com
Thermo Scientific
DHX Heat Exchanger User's Guide | 24
Page 28
Find out more at thermofisher.com
For Research or Fur ther Manufacturing. Not for diagnostic us e or direct administration into humans or animals.