REVISION / DATE:
07-16-08 / PAGE:
1 OF 5 / Advisor: Dr. Jacob Jones
Author: Martin E. McBriarty
The University of Florida / Title: Diffractometer Chiller Periodic Maintenance
- Personnel performing this procedure will have training provided by the equipment manufacturer orbytrainedUF personnel.
I.PURPOSE
The purpose of this protocol is to establish a method for the inspection andmaintenance of the Haskris R100 chiller (Figure 1) for the Inel diffractometer.
II.OUTLINE OF METHOD
A checklist has been placed on the diffractometer chillerdelineating a quarterly inspection schedule. This schedule is designed to prevent damage to the chiller, which is integral to the operation of the diffractometer – without a constant circulation of clean, cold water, the diffractometer cannot function. To inspect the chiller, the chiller cover and tank cover must be removed. The tank and intake strainer must be cleaned of any debris, and if algae growth is detected, special treatments must be used. The pH must also be kept around neutral levels. Periodically, the water must be replaced and the motor oiled. These steps are necessary to keep the chiller and its parts fully functional. For more information on the pump used in this chiller, view the Positive Displacement Pump Troubleshooting document on the Haskris website.
Before any inspection or maintenance may be performed on the chiller, the diffractometer must be turned off. Ask Dr. Jones before beginning.
III.RESOURCES
Necessary information or equipment that may be needed for maintenance of the chiller is listed here. Please read through this entire SOP before gathering materials or performing any maintenance. It may not be necessary to use all materials listed. Required PPE is listed and should be closely followed. Other information is given in the manual for the chiller. If potentially hazardous chemicals are used, such as when treating the system for algae, it is recommended that the MSDS for all involved chemicals are on hand when performing this procedure.
- Resources (Prior knowledge and required materials)
- Distilled water (do not use DI water; just purchase a few jugs)
- pH test strips
- Wash cloth
- Wet vac (MAIC may provide this)
- SAE #10 motor oil
- Short-circuit hose (~3 foot long blue flexible tube)
- Hydrogen peroxide
- Flat-head screwdriver
- Replacement strainer
- PPE
- Appropriate gloves
- Close-toed shoes
- Long pants
- Protective eyewear
- Lab coat (optional)
IV.PROCEDURE
The basic procedure, safety information, and emergency protocol are discussed below. When working with hazardous chemicals, never perform this procedure alone – be sure someone else is in the diffractometer room in case of emergency.
A. Inspecting the Chiller
- Turn off the diffractometer. Ask Dr. Jones for help with this.
- Turn off the chiller by flipping the ON/OFF switch on the chiller front panel.
- Lift off the top panel of the chiller and set it aside.
- Visually inspect the inside of the chiller for leaks. Be sure that there is no water pooling below the chiller.
Standing water in the diffractometer room may pose a major hazard to equipment and anyone nearby. If there are any leaks or pools of water in the diffractometer room, contact Dr. Jones immediately.
- Remove the cover of the large white plastic chiller tank. To do this, turn the knobs at the sides of the cover counterclockwise, loosening the screws.
- Check the strainer, the white object shown in Figure 2. If it does not look clean, perform Procedure B – “Cleaning the Strainer”.
- Visually inspect the inside of the chiller tank. If there is debris at the bottom of the tank, perform Procedure C – “Cleaning the Tank and Replacing the Water”. If there is algae growing in the tank, perform Procedure D – “Treating for Algae”.
- Check the pH of the water using a piece of pH strip. If the pH is not neutral, then replace the water as described in Procedure C – “Cleaning the Tank and Replacing the Water”.
- If the water has not been replaced in the past 3 quarters (e.g. if it is October and the water was last replaced in January), then follow the instructions for Procedure C – “Cleaning the Tank and Replacing the Water”.
- The pump motor should be lubricated once per year; to accomplish this, perform Procedure E – “Lubricating the Motor”. For this chiller, the motor is usually lubricated in July.
B. Cleaning the Strainer
- Carefully remove the strainer. Use a flathead screwdriver to loosen the clamp holding the strainer onto the hose.
- Move the strainer to a sink into which dirt and algae may be disposed of.
- Carefully wash the strainer with warm water and a wash cloth. A soft-bristled brush and soap may be used, but the strainer must be thoroughly rinsed of any cleaning agents. Be careful not to damage the nylon mesh.
- If any debris or algae remains inside of the strainer after it has been cleaned, then dispose of it. Put a check mark on the chiller maintenance schedule under “Strainer replaced” and use a new strainer. Otherwise, if the strainer is clean and has not been damaged, put a check mark under “Strainer cleaned”.
- Re-attach the strainer to the hose in the tank and tighten the clamp securely so that air does not enter the pump.
C. Cleaning the Tank and Replacing the Water
- Use a wet vac to suck the water out of the tank and remove as much debris from the tank as possible.
- If visible debris remains, then wipe it up with a washcloth. Do not use any soaps or detergents.
- Refill the tank with distilled water (about 5 gallons should be enough).
- Put check marks on the chiller maintenance schedule under “Tank cleaned” and “Water changed”.
D. Treating for Algae
1. If it has not already been done, perform Procedure C – “Cleaning the Tank”. Fill the tank with enough water so that the strainer is submerged (about 4 gallons should be enough). Do not turn on the chiller if the strainer is not submerged in water.
2. Turn on the chiller and run it for 5 minutes in order to flush out the chiller and diffractometer with fresh water.
3. Turn off the chiller.
4. Close the water valves on the back of the chiller.
5. Carefully disconnect the hoses leading to the diffractometer from the back of the chiller by pushing the black ring in towards the chiller while pulling the hose out.
6. Connect the chiller water input and output with the short circuit hose.
7. Add store-bought 3% hydrogen peroxide solution in a ratio of about 1 fluid ounce per gallon of distilled water.
Hydrogen peroxide will damage components in the diffractometer. Be sure that the diffractometer is disconnected from the chiller before adding any chemicals to the chiller water.
8. Open the water valves on the back of the chiller. Turn on the chiller to allow the water to circulate. Leave the chiller running for 10 minutes in order to remove any algal remnants in the system.
9. After circulating the water, empty the tank with the wet vac and clean it out as necessary. To avoid damage to the system, try to leave as little peroxide-containing water as possible.
10. Reconnect the chiller to the diffractometer. The blue hose coming from the diffractometer should connect to the top nozzle on the chiller, and the black diffractometer hose should connect to the bottom nozzle.
11. Refill the tank with distilled water (about 5 gallons should be enough).
12. Put check marks on the chiller maintenance schedule under “Algae treated” and “Water changed”.
E. Lubricating the Motor
1. Unplug the chiller from the wall.
2. Remove the side panel of the chiller that is farthest from the diffractometer.
3. Remove the plastic plug at the end of the motor and add 3-4 drops of SAE #10 motor oil.
4. Replace the plug in the motor. Plug the chiller back into the wall and put a check mark on the chiller maintenance schedule under “Motor lubricated”.
F. Restarting the Chiller
1. If the chiller tank is empty, then fill it with distilled water (about 5 gallons should be enough) and put a check mark on the chiller maintenance schedule under “Water changed”.
3. Be sure that the strainer is completely immersed. Then, replace the chiller tank cover. Do not turn on the chiller if the strainer is not submerged in water.
4. Turn on the chiller and note the value (in psi) on the pressure gauge. Write this value on the chiller maintenance schedule under “Pressure”.
5. Supervise the chiller for a few minutes to be sure that it is working properly.
6. Write down your name, the date, and any notes (e.g. “pH was very low”, “water was murky”, “tank was full of algae”, etc.) on the chiller maintenance schedule.