BOC Edwards TCU 40 Plus User manual

W95900011
Revision F
June, 2004
Instruction Manual
BOC EDWARDS
301 Ballardvale Street Wilmin ton, MA 01887
Telephone: [phone] Telex: 710-347-7672 Fax: [phone]
TCU 40/80
plus
Single Channel
Temperature Control Unit

TCU 40/80 plus Temperature Control Unit i
TABLE OF CONTENTS
SECTION TITLE PAGE
1 PREFACE ………………………………………………………………………………………….. 1
1.1 SAFETY CONSIDERATIONS …………………………………………………………………. 1
2 TCU 40/80
plus
…………………………………………………………………………………….. 3
2.1 SCOPE OF THE MANUAL …………………………………………………………………….. 3
2.2 DESCRIPTION FOR THE TCU 40/80
plus
…………………………………………….………. 3
2.3 LOCKOUT PROCEDURE ……………………………………………………………………… 3
2.4 SAFETY FEATURES ……………………………………………………………………………4
3 QUICK START PROCEDURE ……………………………………………………………………. 5
3.1 POWER UP ………………………………………………………………………………….….. 5
3.2 SETPOINT ERIFICATION …………………………………………………………………… 5
4 PRODUCT DESCRIPTION ……………………………………………………………….………. 6
4.1 REFRIGERATION AND COOLANT CIRCUITS …………………………………………….. 6
4.2 REFRIGERATION ……………………………………………………………………………… 9
4.2.1 IF COOLING IS REQUIRED ………………………………………………………………. 9
4.2.2 IF COOLING IS NOT REQUIRED ………………………………………………………….9
4.3 COOLANT CIRCUIT …………………………………………………………………………… 10
4.4 TEMPERATURE MONITORING ……………………………………………………………… 10
4.5 FRONT PANEL …………………………………………………………………………………. 10
4.6 REAR PANEL ……………………………………………………………………………………12
4.7 SPECIFICATIONS ……………………………………………………………………………… 13
4.8 DIMENSIONS …………………………………………………………………………………... 14
5 INSTALLATION ……………………………………………………………………………………15
5.1 RECEI ING AND UNPACKING ……………………………………………………………… 15
5.2 LOCATION ………………………………………………………………………………………15
5.2.1 SECURING THE UNIT ……………………………………………………………………….15
5.2.2 INSTALLING THE SECONDARY CONTAINMENT RECEPTACLE ……………………. 15
5.2.3 FLOOR LE ELERS …………………………………………………………………………. 15
5.3 STACKING ……………………………………………………………………………………… 16
5.3.1 TIE-BOLTS …………………………………………………………………………………...16
5.4 FACILITIES ……………………………………………………………………………………...16
5.4.1 50 Hz Installations………………………………………………………………………………16
5.4.2 WATER AND COOLANT CONNECTIONS ………………………………………………...16
5.4.3 WATER ………………………………………………………………………………………..18
5.4.4 COOLANT …………………………………………………………………………………….18
5.4.5 REMOTE CONNECTIONS ………………………………………………………………….. 18
6 OPERATION ……………………………………………………………………………………….. 19
6.1 PREPARATION ………………………………………………………………………..………...19
6.2 POWERING UP THE TCU 40/80 plus …………………………………………………………. 19
6.3 CHANGING THE SETPOINT ALUE (S 1) ………………………………………………….20
6.4 TEMPERATURE CONTROLLER PID SETTINGS …………………………………..……….. 20
6.5 REMOTE SET POINT ………………………………………………………………………….. 20
6.6 FLOW RATE ADJUSTMENT ………………………………………………………………….. 21

ii TCU 40/80 plus Temperature Control Unit
7 MAINTENANCE ……………………………………………………………………………………22
7.1 HAZARD WARNINGS ………………………………………………………………………….22
7.2 HAZARDS ………………………………………………………………………………………. 24
7.3 FILLING THE RESER OIR …………………………………………………………..……….. 24
7.4 DRAINING/BLEEDING THE COOLANT RESER OIR ……………………………………... 25
7.5 TEMPERATURE PROBE CALIBRATION ……………………………………………………. 25
7.6 PRE ENTI E MAINTENANCE SCHEDULE ……………………………………………….. 25
7.7 SEMI-ANNUAL PRE ENTATI E MAINTENANCE ………………………………………... 26
7.7.1 REQUIRED EQUIPMENT …………………………………………………………………... 26
7.7.2 PREPARATION ……………………………………………………………………………... 26
7.7.3 ERIFY SYSTEM STATUS ………………………………………………………………… 26
7.7.4 REFRIGERATION LEAK CHECK …………………………………………………………. 26
7.7.5 FLUORINATE LEAK CHECK ……………………………………………………………… 26
7.7.6 WATER LEAK CHECK …………………………………………………………………….. 26
7.7.7 INSULATION REPAIR ……………………………………………………………………... 27
7.7.8 LAMP CHECK/REPLACEMENT …………………………………………………………... 27
7.8 ANNUAL PRE ENTATI E MAINTENANCE ………………………………………………..28
7.8.1 REQUIRED EQUIPMENT …………………………………………………………………... 28
7.8.2 REQUIRED SUPPLIES ……………………………………………………………………… 28
7.8.3 SOLENOID AL E COIL REPLACEMENT ……………………………………………… 28
7.8.4 SYSTEM CHECK ……………………………………………………………………………. 30
7.9 PRE ENTATI E MAINTENANCE CHECKLIST …………………………………………….39
8 TROUBLESHOOTING …………………………………………………………………………….. 40
9 ACCESSORIES AND SPARE PARTS ……………………………………………………………..54
10 OPTIONS …………………………………………………………………………………………… 55
10.1 LON WORKS …………………………………………………………………………………… 55
10.1.1 REFERENCE ………………………………………………………………………………… 55
10.1.2 O ERALL DESCRIPTION …………………………………………………………………. 55
10.1.3 REQUIREMENTS …………………………………………………………………………… 56
10.1.4 INTERFACES ………………………………………………………………………………... 59
10.2 RS232 TEL ………………………………………………………………………………………. 71
10.2.1 BLOCK DIAGRAM …………………………………………………………………………. 71
10.2.2 OPERATION MODE AND CONTENTS OF FUNCTION …………………………………. 71
10.2.3 DESCRIPTION OF EXTERNAL CONTROL AND MONITORING SIGNALS …………... 73
10.3 RS485 SERIAL COMMUNICATION ………………………………………………………….. 92
10.3.1 MODIFIED ELECTRICAL CONTROLS DRAWER …………………………………………...92
10.3.2 RS485 MODICON MODBUS PROTOCOL ………………………………………………… 92
10.3.3 INSTALLATION AND SE-UP OF RS485 INTERFACE BOX ASSEMBLY ……………... 93
10.3.4 RS485 MODICON MODBUS PROTOCOL SPECIFICATION FOR TCU 40/80 ………….. 102
10.3.5 RS485 4X MEMORY MAP FOR TCU 40/80 HEAT EXCHANGER ………………………. 103
10.3.6 RS485 TCU 40/80 MESSAGE EXAMPLE ………………………………………………….. 104
APPENDIX ……………………………………………………………………………………………………105
RETURN OF BOC EDWARDS EQUIPMENT – PROCEDURE (FORM HS1) ………….…………….. 106
RETURN OF BOC EDWARDS EQUIPMENT – DECLARATION (FORM HS2) ……………………...107
LEGAL NOTICES, LIMITATIONS AND DISCLAIMERS …………………………………………….. 108
MSDS (MATERIAL SAFETY DATA SHEET) – “SU A” HP62 ……………………………………….109

TCU 40/80 plus Temperature Control Unit iii
ILLUSTRATIONS
FIGURE TITLE PAGE
FIGURE 1 – REFRIGERATION AND COOLANT COMPONENTS …………………………………… 6
FIGURE 2 – REFRIGERATION AND COOLANT COMPONENTS …………………………………… 7
FIGURE 3 – REFRIGERATION AND COOLANT CIRCUITS …………………………………………. 9
FIGURE 4 – FRONT PANEL ……………………………………………………………………………… 10
FIGURE 5 – ELECTRICAL REAR PANEL ……………………………………………………………… 12
FIGURE 6 – TCU DIMENSIONS …………………………………………………………………………. 14
FIGURE 7 – TCU DIMENSIONS …………………………………………………………………………. 14
FIGURE 8 – STACKED TCU 40/80
plus
SYSTEMS ……………………………………………………… 16
FIGURE 9 – SYSTEM REAR IEW ……………………………………………………………………… 17
FIGURE 10 – WATER CONNECTIONS …………………………………………………………………. 18
FIGURE 11 – TEMPERATURE CONTROLLER ………………………………………………………… 20
FIGURE 12 – LAMP REPLACEMENT …………………………………………………………………… 27
FIGURE 13 – SOLENOID COIL REPLACEMENT ……………………………………………………… 29
FIGURE 14 – ELECTRICAL DRAWER ANALOG………………………………………………………. 49
FIGURE 15 – ELECTRICAL DRAWER SCHEMATIC …………………………………………………. 51
FIGURE 16 – REMOTE INTERFACE ……………………………………………………………………. 53
FIGURE 17 – O ERALL LTCI ARCHITECTURE ……………………………………………………… 55
FIGURE 18 – LTCI PHYSICAL LAYOUT ………………………………………………………………. 56
FIGURE 19 – ELECTRICAL REAR PANEL …………………………………………………………….. 65
FIGURE 20 – ELECTRICAL DRAWER LONWORKS……………………………………………………. 66
FIGURE 21 – ELECTRICAL DRAWER SCHEMATIC …………………………………………………….68
FIGURE 22 – REMOTE INTERFACE ……………………………………………………………………… 70
FIGURE 23 – BLOCK DIAGRAM ………………………………………………………………………….. 71
FIGURE 24 – “RUN”/”STOP” SIGNAL ……………………………………………………………………..73
FIGURE 25 – CONTROL SIGNAL STATE …………………………………………………………………74
FIGURE 26 – PIN ASSIGNMENT FOR TCU-TEL CABLE ……………………………………………….. 75
FIGURE 27 – ELECTRICAL REAR PANEL ………………………………………………………………..84
FIGURE 28 – RS232 ELECTRICAL DRAWER ……………………………………………………………. 86
FIGURE 29 – RS232 POWER DISTRIBUTION SCHEMATIC …………………………………………….88
FIGURE 30 – ASSEMBLY CABLE TCU HOST COMMUNICATION …………………………………… 90
FIGURE 31 – ASSEMBLY CABLE TCU RS232 COMMUNICATION ……………………………………91
FIGURE 32 – RS485 ELECTRICAL DRAWER COMPONENT LAYOUT ………………………………..94
FIGURE 33 – RS485 ELECTRICAL DRAWER SCHEMATIC ……………………………………………. 96
FIGURE 34 – RS485 INTERFACE BOX – PHYSICAL DIMENSIONS …………………………………... 98
FIGURE 35 – RS485 INTERFACE BOX WITH TOP CO ER REMO ED ………………………………. 99
FIGURE 36 – MICROPROCESSOR PCA – JP7 PIN DESCRIPTION AND FUNCTION …………………99

iv TCU 40/80 plus Temperature Control Unit
ILLUSTRATIONS (continued) ….
FIGURE TITLE PAGE
TABLE 1 – SAFETY FEATURES ………………………………………………………………………….. 4
TABLE 2 – FRONT PANEL INDICATORS ……………………………………………………………… 5
TABLE 3 – REFRIGERATION AND COOLANT COMPONENTS ………………………………………..8
TABLE 4 – FRONT PANEL CONTROLS ………………………………………………………………….. 11
TABLE 5 – FRONT PANEL LED INDICATORS ………………………………………………………….. 11
TABLE 6 – TEMPERATURE CONTROLLER …………………………………………………………… 11
TABLE 7 – DESCRIPTION OF REAR PANEL COMPONENTS AND INDICATORS ………………… 12
TABLE 8 – FRONT PANEL POWER UP INDICATOR CONDITIONS ………………………………… 19
TABLE 9 – ELECTRICAL HAZARDS CLASSIFICATIONS …………………………………………… 24
TABLE 10 – PRE ENTI E MAINTENANCE SCHEDULE ……………………………………………….25
TABLE 11 – FAULTS IDENTIFIED BY FRONT PANEL LAMPS ……………………………………….. 40
TABLE 12 – FAULTS INDICATED BY THE FRONT PANEL LED INDICATORS …………………….. 42
TABLE 13 – FAULTS IDENTIFIED BY REAR PANEL INDICATORS …………………………………..46
TABLE 14 – MISCELLANEOUS FAULT CONDITIONS ………………………………………………….47
TABLE 15 – ACCESSORIES ………………………………………………………………………………...54
TABLE 16 – ANALOG TEMPERTURE SIGNAL CHARACTERISTICS ………………………………... 58
TABLE 17 – LTCI NETWORK ARIABLES ……………………………………………………………… 61
TABLE 18 – DEFINITIONS OF N OSTATUS NETWORK ARIABLE ……………………….……….. 62
TABLE 19 – DESCRIPTION OF REAR PANEL COMPONENTS AND INDICATORS ………………….65
TABLE 20 – A AILABLE FUNCTIONS …………………………………………………………………... 72
TABLE 21 – PIN ASSIGNMENTS AT THE TCU HOST CONNECTION ……………………….……….. 75
TABLE 22 – CONTROL CODE ……………………………………………………………………………...76
TABLE 23 – HEADER CODE ………………………………………………………………………………. 76
TABLE 24 – DESCRIPTION OF REAR PANEL COMPONENTS AND INDICATORS ………………….85
TABLE 25 – TCU 40/80 “J72J1” CONNECTOR MODIFIED FOR RS485 ……………………….………..100
TABLE 26 – HOST RS485 COMMUNICATION CONNECTOR …………………………………………..101

TCU 40/80 Temperature Control Unit 1
1. Preface
1.1 Safety Considerations
Many safety features have been designed into the TCU 40/80 plus to protect the operator and the
equipment. The following symbols are used in this manual to indicate the various safety
conditions.
General Alert
General Alert symbol denotes the potential of
personal hazards or equipment failure.
Warnings are given when failure to observe the
instruction could result in injury or death to
persons.
Cautions are given where failure to observe the
instruction could result in damage to the
equipment, associated equipment and process.
Statement on avoiding the hazard.
Electric Shock
Electric Shock symbol denotes the presence of
high voltage or current. It calls attention to the
procedure, practice, or the like, which if not done
correctly or adhered to could result in injury or
death.
Statement on avoiding the hazard.
Eye Protection
Eye Protection symbol denotes a hazard which
could cause injury or irritation to the eyes.
Statement on avoiding the hazard.
Toxic Gases
Toxic Gases symbol denotes a personal hazard.
It calls attention to the procedure, practice, or the
like, which if not done correctly or adhered to
could result in injury or death.
Statement on avoiding the hazard.

2 TCU 40/80 plus Temperature Control Unit
Hot Surfaces
Hot Surfaces symbol denotes a hazard which
could cause injury or burns.
Statement on avoiding the hazard.
Hand
Protection
Hand Protection symbol denotes a hazard which
could cause injury or burns
Statement on avoiding the hazard.
High Pressure
High Pressure symbol denotes a personal hazard
or equipment failure. It calls attention to the
procedure, practice, or the like, which if not done
correctly or adhered to could result in equipment
damage, injury or death.
Statement on avoiding the hazard.
Extreme
Temperatur
e
Extreme Temperature symbol denotes a hazard
which could cause injury or burns.
Statement on avoiding the hazard.

TCU 40/80 Temperature Control Unit 3
2. TCU 40/80 plus
2.1 Scope of the Manual
This manual provides information on the installation, start-up and operation of Edwards High Vacuum
Model 40/80 Temperature Control Unit (TCU 40/80 plus).
The Quick Start Procedure on page 5 is a step by step guide for the start up and use of an installed,
working system.
Installation, starting on page 17, provides instructions and information for installing the system. The
installer must have sufficient technical understanding of electrical and mechanical systems to properly use
this information.
Operation, starting on page 21, provides more complete instructions on the preparation and use of the
system.
2.2 Description of the TCU 40/80 plus
The TCU 40/80 plus is a single-channel temperature control unit engineered for temperature control of
remote heat loads.
From distances up to 50 feet, the TCU 40/80 plus can cool the heat load generated by the process
equipment. The coolant circulates through the TCU 40/80 plus, where it is cooled or heated as required,
then is transferred to the process equipment, and returns in a closed loop. The TCU 40/80 plus maintains
supply coolant at a temperature between -40 °C and +80 °C, selectable in 0.1 °C increments, with a
tolerance of ±1.0 °C.
2.3 Lockout Procedure
To prevent accidental or unauthorized starting of the TCU 40/80 plus during maintenance, disconnect the
power cord from the receptacle and install an appropriate lock-out device (Hubbell Small PlugoutÔor
equivalent) on the end of the power cord.

4 TCU 40/80 plus Temperature Control Unit
2.4 Safety Features
The safety features listed in Table are designed into the TCU 40/80 plus.
Table 1 - Safety Features
Component Ref. Des. * Function
EMERGENCY OFF
button (EMO)
(PB1) Shuts off power to major system components.
Remote EMERGENCY
OFF
(J72J2) Remote shut off of power to major system components.
Drawer safety switch (LS1) Upon opening the drawer, shuts off power to major system
components.
Pressure switch (PS1) Protects the refrigeration system against high discharge
pressure. Interrupts operation at 300 psig.
Condenser pressure relief
valve
(W2) Vents refrigerant to the atmosphere above 350 psig. Fail
safe for PS1, works even if there is no power applied to the
system.
Reservoir pressure relief
valve
(W1) Protects the reservoir from over-pressure.
Temperature switch (TS1) Protects the process fluid from exceeding 99 °C
Coolant flow switch (FS1) Protects the process equipment from inadequate coolant
flow rates.
Coolant float switch (LLS1) Protects against low level in the coolant reservoir by
stopping the equipment.
Coolant float switch (LLS3) Protects against overfill of the coolant reservoir. Indication
on front and rear panels.
Thermal overload (K3) Protects the pump motor from excess current.
Surge suppression VR1-4 Protects the TCU 40/80 plus against voltage surges and
power line transients.
Line phase monitor PMR1 Protects the equipment against incorrect wiring of the
supply phases and low voltage burn-out.
Current sensor CSR1 Protects the compressor against abnormal conditions.
Secondary containment Captures fluids (internal to the TCU) in the event of a leak.
* See Figure 3 on page 10