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The 16-020 heat exchangers are used with the older Physical Electronics (PHI) 5100 through 5400 X-ray photo-electron spectrometer (XPS) systems.The 16-020 has a built-in deionizer cartridge (and a particle filter) which keeps the water in the closed loop system clean and it also keeps the resistance of the water high.
The original deionizer cartridges were blue and had a recess in the bottom of the filter that matched up with a plastic guide on the bottom of the Millipore housing.Those blue deionizer cartridges are no longer available. The new replacement deionizer cartridges do not have a recess on the bottom.
When a new deionizer cartridge is used with the original Millipore housing the plastic guide on the bottom of the housing will push up on the bottom of the deionizer.This makes it difficult if not impossible to fully screw on the housing.It also puts pressure on the bottom of the deionizer cartridge which can rupture the bottom of the deionizer and cause the media particles to leak out, potentially causing an issue with the water flow and or damage the pump and lead to a catastrophic anode melt down. There are two ways to solve this fit issue. One is to cut and grind out the top part of the guide on the original Millipore housing. To do that you need to remove the plug on the bottom of the housing and then use a drill or cutting wheel that is mounted on a drill extension. The pictures below show a housing before and after modification.
The other option is to replace the original Millipore housing with new housing that correctly fits the new deionizer cartridge. But if you replace the housing you will also need to replace the manifold as the new manifold will not fit into the original Millipore manifold.
RBD Instruments provides both deionizer cartridges and housings. If you have the original Millipore housing on your 12” deionizer cartridge then I recommend that you inspect it to see whether the guide on the bottom has been cut down or not.If not, you should cut it down or replace the housing.
If the deionizer is ruptured then the entire cooling system (reservoir, pump, water lines and source) needs to be inspected and flushed out.This problem is an issue only with the 12″ deionizer cartridge on the 16-020 heat exchangers.
The 16-050 heat exchanger that is used on the 5600 and up XPS systems has a 10″ deionizer cartridge.
Not sure if you need to replace your deionizer cartridge?Just run up the high voltage on your X-ray source to 15kV but do not set an power to the X-ray source.Observe the emission current reading on the HV supply.If the deionizer is good the reading will be 1-2 mA.Once the leakage current gets up to 3-4 mA at 15kV you should plan on replacing the deionizer cartridge and particle filter soon.If the leakage current at 15kV is 5 mA or higher you should replace the deionizer and particle filter and also flush out the water with new distilled water from a grocery store.Lab distilled water does not always work but grocery store distilled water works every time.
Contact RBD Instruments to order the deionizer and particle filter.
The original flow switch for the 16-050 heat exchanger used 220 VAC for the input power.
About 10 years ago that flow switch was discontinued and was replaced with a similar model that used 120 VAC for the input power. A 220 VAC to 120 VAC step down transformer was also needed.
Very recently, the 120 VAC input power flow switch was discontinued, and it has been replaced by another version that uses 24 VDC as the input power. To provide 24V DC to the replacement flow switch a small 220VAC to 24 V DC power supply is needed.
This blog post will provide step by step instructions on how to install the new 24V DC flow switch and power supply into a 16-050 heat exchanger.
Step one is to drain the water from the heat exchanger. The easiest way to do that is to remove the IN and OUT couplers from the X-ray source and then connect those to the IN and OUT lines. Mark the IN and OUT water lines to make sure that you do not get them mixed up. Hold them over a clean container (such as a plastic waste basket) and then turn on the 32-095 or 32-096 X-ray source control.
The 16-050 will turn on and water will come out of the source IN line. After about 9 seconds the 32-095/96 will shut down the 16-050 heat exchanger due to insufficient flow. Turn the 32-095/96 OFF for a few seconds, then back ON. Repeat several times (it might take 10 to 15 times) until water stops coming out of the source IN line and the pump starts to make noise. This will drain most of the water out of the 16-050. You want to use a clean container for the water so that you can reuse the water. Or you can replace the water after the flow switch has been replaced with distilled water from a grocery store. Lab DI water does not always work.
After the water has been drained, turn the 16-050 heat exchanger front panel power switch to OFF.
Next, trace the power cord that is on the back of the 16-050 into the electronics console and unplug the power cord. Make a note of where that power cord plugs into so that you can plug it into the same receptacle later.
Turn the 16-050 front panel power switch to ON just to make sure that the 16-050 power cord is unplugged. Verify that the 16-050 motor does not turn on and then turn the 16-050 heat exchanger front panel power switch back to OFF. Do not work on the 16-050 if it is still plugged in!
Remove the top cover on the 16-050.
Remove the small cover that is located just behind the 16-050 power switch. There are 4 nuts that need to be removed then the cover comes off.
Remove the wires that go to the flow switch. Those will be TB1 sections 1, 2, 5 and 7.
Remove the old flow switch. Use your phone to take pictures of where the IN and OUT lines connect on the flow switch.
Install the new flow switch making sure that it is connected EXACTLY the way that the old flow switch was.
Route the new flow switch wires up to where the old flow switch wires were.
The wires need to be connected as follows:
RAVCV04-24 power supply:
Blue to TB1 7
Brown to TB1 5
Red to Flow Switch Brown
Black to Flow Switch White
Flow Switch:
White to RACV04-24 Black (use twist nut)
Brown to RACV04-24 Red (use twist nut)
Red to TB1 2
Black to TB1 1
Green – Not used.
This drawing shows the connections –
Verify that the wires are all tight and then replace the little cover using the 4 nuts.
Reconnect the couplers and water lines to the X-ray source. Make sure that you have the IN and Out going to the correct ports on the X-ray source.
Pour most of the water back into the reservoir or use 2-3 gallons of distilled water from a grocery store.
Plug the 16-050 power cord back in and then turn on the 16-050 front panel power switch.
Turn on the 32-095/96 and the 16-050 motor should turn on. It will turn off after 9 seconds. Turn the 32-095/06 off and then back on to reset the pump. Do this a few times until the air bubbles work themselves out and the 16-050 pump motor stays on.
You will need to top off the water reservoir once the water fills up the lines. Do not overfill!
If the 16-050 will not stay on even when the water is full (close to the upper line on the water level indicator on the back of the 16-050) then the flow switch may need to be adjusted.
The flow switch adjustment potentiometer is on the back of the flow switch under a label. It is a small, slotted screw.
Try turning the flow switch a few turns CW and then turn on the 32-095/96. If that does not work, try a few turns CCW plus a few more turns. Once you get it to where the 16-050 pump stays ON then you can slowly turn the potentiometer the opposite direction until the red interlock light on the 32-095/96 turns ON, then adjust the potentiometer 1.5 turns the other direction until the red interlock light just turns off. The idea is that you want to set the potentiometer so that the 16-050 pump is ON when you have water flow, but you want to be somewhat close to the edge so that the 16-050 pump will shut off when the flow drops.
Typical flow rates are 1.1 GPM for XPS systems with a 10-610 mono-chromator source and up to 1.8 GM for systems that have only a single 04-548 dual anode X-ray source.
The RBD Instruments Part number for the kit that includes the 24V flow switch and the power supply is FLOW-SWITCH-24-Kit.
In a previous post we showed you how to remove dust from the radiator in a 16-020 or 16-050 X-ray source heat exchanger
For this post we will replace the flow switch, which is used in a 16-050 heat exchanger, and also replace all of the water lines. The water lines in this particular heat exchanger have become green with contamination from long term corrosion of the fittings and copper X-ray source anode.
We will remove the motor and pump as part of the hose replacement procedure and will also clean and lubricate the pump to motor connection.
This procedure will take about 2 hours. The replacement hose should be clear reinforced braided tubing that is 5/8” OD and 3/8” ID. This type of hose is available from Home Depot, McMaster-Carr, and Grainger. Measure the length of the existing water lines and then add another 10 feet for the16-050 lines. You may be able to get by with 50 feet but a100 foot roll at Home Depot is only about $50.00.
You will also need 3 gallons of distilled water from a grocery store
First of all, drain as much water as possible out of the water lines. Here is the best way to do that –
Turn OFF the 16-050 OFF and also unplug the power cord from the back of the system. Remove the top cover on the 16-050 and also remove the electrical cover that is located in front left hand corner of the 16-050.
Locate the Crydom Power On relay under the switch cover.
Double check that the power cord to the 16-050 is unplugged.
Move the black output wire from pin one to pin two. Both black output wires should be on pin two.
move wire from here
move wire to here
Remove the quick disconnects from the X-ray source and plug them into the ends of the IN and OUT water lines that connect to the 16-050. That way, when you turn on the 16-050 one line will have water coming out and the other one will have air going into it.
Plug the 16-050 power cord back in. Hold the water lines over a water tight pail (a plastic garbage container will work well). When you turn the 16-050 switch back ON, the water will flow out of the end of the water lines.
Turn the switch breaker OFF when the water stops flowing and is mostly spurting air.
(Note, if you have a 16-020 heat exchanger move the Pump power cord to the HV receptacle and the you can control the pump by turning the circuit breaker ON and OFF)
Unplug the 16-050 power cord.
Remove the side covers on the 16-050.
Remove the DI cartridge and water filter. Note the position of the cartridges so that you can replace them in the same locations later.
Remove the pump from the motor (one screw and a clamp) and set it aside. You do not need to disconnect the wires.
Remove the fan (the outer screws in the square metal fan support).
Next, remove the radiator.
Clean the radiator by flushing it with some Alconox or other detergent followed by a thorough rinse out with warm water.
Clean the cooling fins as needed.
Reinstall the radiator
Replace all the water lines one at a time. Remove a line by unscrewing the hose clamps and twisting the hose off the connector. If the connector has barbs on it you will need to cut a slit in the hose with a box cutter or utility knife. Use the old hose section to measure the length of replacement hose then cut the new hose to the same length. Feel free to make the new hoses slightly shorter or longer if that will make it fit better.
Also, to soften the line and make it easier to slide over a barbed connector, dip the line in Acetone for about 20 seconds. This works quite well. You could also heat the line with a heat gun on the low heat setting for a few seconds.
When you get to the flow switch, unscrew the two front panel screws and pull the flow switch away from the fort panel. If you are going to replace the flow switch, now is the time. You may need to pull some blanking plugs off of the old flow switch. Make sure that you put the new flow switch on exactly the same way that the old one comes off as that is very important for the water flow direction. Take a picture with your phone before you remove the lines for reference. Also note the location of the wires in the terminal strip.
Note that the 220VAC version of the flow switch is no longer made and so in a 16-050 you would also need a 220VAC to 120VAC step down transformer. Contact RBD Instruments if you need a replacement flow switch.
Step down transformer mounted in 16-050
terminal strip
16-050 schematic
After all of the water lines have been replaced, remove the quick disconnects from the water lines and plug the water lines together.
Reinstall the DI and water filter cartridges. You should replace both the De-ionizer and filter cartridges if it has been a while (a few years) since the last time you replaced them. If you replaced the x-ray anode in a 10-610 mono source as part of this maintenance then the deionizer cartridge MUST be replaced. Contact RBD Instruments if you need a deionizer cartridge or water filter.
Reinstall the motor.
Inspect the water pump and clean and lubricate (with grease) as necessary. The motor to pump connection can get a lot of debris and some rust accumulation.
Reattach the pump to the motor.
Put one gallon of fresh distilled water (from a grocery store, not lab DI) into the reservoir.
Plug in the 16-050 power cord.
Turn on the 16-050.
Immediately add another gallon of fresh DI water into the resistor as the water will be filling the lines and cartridges.
Check for leaks and tighten hose clamps as needed.
Add more water as needed until the level is correct on the back of the 16-050. It will take 3 to 3.5 gallons. Give it some time for the cartridges to fill up, about 10 to 15 minutes before you do a final top off.
If you have replaced the flow switch you can monitor pins 1 to 5 on the Coolant ON/OFF connector with an ohmmeter. With the 16-050 on and water flowing, adjust the potentiometer on the flow switch until the resistance between pins 1 and 5 drops down to 1 ohm or less.
Reconnect the Coolant ON/OFF cable.
Turn off the power to the 16-050 and unplug the power cord from the back of the system.
Confirm that the power cord is unplugged.
Move the wire on the terminal block form pin two back to pin one.
Replace the electrical cover.
Replace the side covers.
Replace the top cover.
Plug the 16-050 back in and turn on the power switch.
The 16-050 should turn on and off when the 32-095/6 is turned off and on.
Turn off the 32-095/6 and then reconnect the water lines to the X-ray source.