Edwards TCU 40/80 User manual

W959-000-01
Revision F
October, 96
Instruction Manual
TCU 40/80
Single Channel
Temperature Control Unit
EDWARDS
Edwards High Vacuum International
One Edwards Park 301 Ballardvale Street Wilmington, MA 01887
Telephone: [phone] Telex: 710-347-7672 Fax: [phone]

Declaration of Conformity
We, Edwards High Vacuum International,
One Edwards Park
301 Ballardvale St.
Wilmington, MA 01887
declare under our sole responsibility that the product(s)
TCU 40/80 Temperature Control Unit
W95000000
to which this declaration relates is in confonnity with the following standard(s)
or other normative document(s)
BSIEC1010-1
BS EN50O81-1
BSEN50082-1
following the provisions of
89/392/EEC
89/336/EEC
73/023/EEC
Safety Requirements for Electrical Equipment for Measurement,
Control and Laboratory Use.
Electromagnetic Compatibility, General Emission Standard.
Generic Standard Class: Domestic, Commercial & Light Industry.
Electromagnetic Compatibility, General Immunity Standard.
Generic Standard Class: Domestic, Commercial & Light Industry
Machinery Safety Directive
Electromagnetic Compatibility Directive
Low Voltage Directive
0
Dr. A. P. Troup, Director of Technology
Date and Place
This product has been manufactured under a quality system registered to ISO900I
EDWARDS

CONTENTS
Section Title Page
1 PREFACE 1
1.1 Safety considerations 1
2 TCU 40/80 3
2.1 Scope of the manual 3
2.2 Description of the TCU 40/80 3
2.3 Lockout procedure 3
2.4 Safety features 4
3 QUICK START PROCEDURE 5
3.1 Power up 5
3.2 Sctpoint verification 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: 10
4.3 Coolant circuit 10
4.4 Temperature monitoring 10
4.5 Front panel 1 ]
4.6 Rear panel 13
4.7 Specifications 14
4.8 Dimensions 15
5 INSTALLATION ]6
5.1 Receiving and unpacking 16
5.2 Location 16
5.2.1 Securing the unit 16
5.2.2 Installing the secondary containment receptacle 16
5.2.3 Floor levclers 16
5.3 Stacking 17
5.3.1 Tie-bolts 17
5.4 Facilities 17
5.4.1 Water and coolant connections 18
5.4.2 Water 19
5.4.3 Coolant 19
5.4.4 Remote connections 19
6 OPERATION 20
6.1 Preparation 20
6.2 Powering up the TCU 40/80 20
6.3 Changing the setpoint value (SV1) 21
6.4 Temperature controller Pid settings 21
6.5 Remote set-point 22
6.6 Flow rate adjustment 22
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TCU 40/80 Temperature Control Unit

7 MAINTENANCE 23
7.1 Hazard warnings 23
7.2 Hazards 25
7.3 Filling the reservoir 26
7.4 Draining/bleeding the coolant reservoir 26
7.5 Temperature probe calibration 27
7.6 Preventive maintenance schedule 27
7.7 Semi-annual preventative maintenance 28
7.7.1 Required equipment 28
7.7.2 Preparation 28
7.7.3 Verify system status 28
7.7.4 Refrigeration leak check 28
7.7.5 Fluorinert leak check 28
7.7.6 Water leak check 28
7.7.7 Insulation repair 28
7.7.8 Lamp check/replacement 29
7.8 Annual preventative maintenance 30
7.8.1 Required equipment 30
7.8.2 Required supplies 30
7.8.3 Solenoid valve coil replacement 30
7.8.4 System check 32
7.9 Preventive maintenance checklist 41
8 TROUBLESHOOTING 42
9 ACCESSORIES AND SPARE PARTS 52
APPENDIX 54
Return of Edwards Equipment - Procedure (Form HS1) 58
Return of Edwards Equipment- Declaration (FormHS2) 59
Legal notices, limitations and disclaimers 60
MSDS (material safety data sheet)- "SUVA" HP62 61
'-""5\
TCU 40/80 Temperature Control Unit

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 11
Figure 5 - Electrical rear panel 13
Figure 6 - TCU dimensions 15
Figure 7- Stacked TCU 40/80 systems 17
Figure 8-System rear view 18
Figure 9 Water connections J9
Figure 10 - Temperature controller 21
Figure 11 - Lamp replacement 29
Figure 12 - Solenoid coil replacement 31
Figure 13 -Electrical drawer 51
Figure 14-Electrical drawer schematic 54
Figure 15 - Remote interface 56
Table Title Page
Table 1 - Safety features 4
Table2 -Frontpanel Indicators 5
Table 3 - Refrigeration and coolant components 8
Table 4 - Front panel controls 11
Table 5 - Front panel LED indicators 12
Table 6 - Temperature controller 12
Table 7 - Description of rear panel components and indicators 13
Table 8 - Front panel power up indicator conditions 20
Table 9 - Electrical hazards classifications 25
Table 10 - Preventive maintenance schedule 27
Table 11- Faults identified by front panel lamps 42
Table 12 - Faults indicated by the front panel LED indicators 44
Table 13 -Faults identified by rear panel indicators 48
Table 14 - Miscellaneous fault conditions 49
Table 15 -Accessories 52
Table 16 Spare parts 53
TCU 40/80 Temperature Control Unit Hi

TRANSLATIONS
The TCU 40/80 Instruction Manual is available in the following translations:
Language
English
French
German
Italian
Japanese
Edwards part number
W95900001
W95900004
W95900005
W95900006
W95900007
For each TCU 40/80 purchased, you are entitled to one translated manual free of charge. This is
in addition to the English version provided. Fax this completed form to the nearest Edwards
location to receive your complimentary translation.
Name:
Title:
Company:
Address:
TCU serial number:
Language: (circle one)
French
German
Italian
Japanese
TCU 40/80 Temperature Control Unit

1 PREFACE
1.1 Safety considerations
Many safety features have been designed into the TCU 40/80 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.
TCU 40/80 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 Temperature
Extreme Temperature symbol denotes a hazard which could
cause injury or burns.
Statement on avoiding the hazard.
^
TCU 40/80 Temperature Control Unit

2 TCU 40/80
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).
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 16, 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 20, provides more complete instructions on the preparation and use of the
system.
2.2 Description of the TCU 40/80
The TCU 40/80 is a single-channel temperature control unit engineered for temperature control of remote
heat loads.
From distances up to SO feet, the TCU 40/80 can cool the heat load generated by the process equipment.
The coolant circulates through the TCU 40/80, 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 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 during maintenance, disconnect the
power cord from the receptacle and install an appropriate lock-out device (Hubbell Small Plugout™ or
equivalent) on the end of the power cord.
0
TCU 40/80 Temperature Control Unit

2.4 Safety features
The safety features listed in Table 1 are designed into the TCU 40/80.
Table I - Safety features
Component
EMERGENCY OFF
button (EMO)
Remote EMERGENCY
OFF
Drawer safety switch
Pressure switch
Condenser pressure relief
valve
Reservoir pressure relief
valve
Temperature switch
Coolant flow switch
Coolant float switch
Coolant float switch
Thermal overload
Surge suppression
Line phase monitor
Current sensor
Secondary containment
Ref. des.*
(PB1)
(J72J2)
(LSD
(PS1)
(W2)
(Wl)
(TS1)
(FS1)
(LLS1)
(LLS3)
(K3)
VR1-4
PMR1
CSR1
Function
Shuts off power to major system components.
Remote shut off of power to major system components.
Upon opening the drawer, shuts off power to major system
components.
Protects the refrigeration system against high discharge
pressure. Interrupts operation at 300 psig.
Vents refrigerant to the atmosphere above 350 psig. Fail
safe for PS1, works even if there is no power applied to the
system.
Protects the reservoir from over-pressure.
Protects the process fluid from exceeding 99 °C
Protects the process equipment from inadequate coolant
flow rates.
Protects against low level in the coolant reservoir by
stopping the equipment.
Protects against overfill of the coolant reservoir. Indication
on front and rear panels.
Protects the pump motor from excess current.
Protects the TCU 40/80 against voltage surges and power
line transients.
Protects the equipment against incorrect wiring of the
supply phases and low voltage burn-out.
Protects the compressor against abnormal conditions.
Captures fluids (internal to the TCU) in the event of a leak.
• See Figure 3 on page 9.
TCU 40/80 Temperature Control Unit

3 QUICK START
PROCEDURE
This Quick Start procedure is for easy start
up and operation of an installed and fully
working TCU 40/80. If your TCU 40/80 is
not installed, go to Installation on page 16.
Detailed operating instructions are in
Operation on page 20.
If at any time an alarm occurs, press STOP
and correct the fault indicated by the display
as directed in the Troubleshooting Guide
on page 42. Press RESET and START to
continue operation.
3.1 Power up
Before applying power, verify that all water
and coolant lines are connected to the
system. The handles on both coolant line
valves should be in the open position. For
the location of these connections, refer to
Figure 8 on page 18.
To power up the TCU 40/80:
1. READY light should be on. If the
ready light is not on see Powering Up
the TCU 40/80 on page 20.
2. Press RESET. Verify that front panel
indicators are as shown in the Reset
column of Table 2 on this page.
3. Press START. Verify that front panel
indicators are as shown in the Start
Condition column of Table 2 on this
page.
If in steps two or three any front panel
indicators do not match Table 2, refer to the
Troubleshooting Guide on page 42 for
corrective action.
4. Verify that the coolant pressure gauge
(located on the front access panel)
reads less than 100 psig.
Table 2 - Front panel Indicators
Indicator
POWER ON
RESET
FACILITY POWER
FACILITY WATER
CIRCUIT
BREAKERS
COMPRESSOR
TEMPERATURE
FLOW
NORMAL LEVEL
LOW LEVEL
REMOTE RTD
(optional)
Reset
Condition
Green
White
Green
Green
Green
Off
Green
Off
Green
OfT
Green
(if used)
Start
Condition
Green
White
Green
Green
Green
Green
Green
Green
Green
Off
Green
(if used)
3.2 Setpoint verification
Verify that the manual mode setpoint value
(SV1) displayed on the temperature control
is the value desired. To change the Setpoint
value see Changing the Setpoint Value
(SVl)onpage21.
Do not to exceed the normal operating
parameters. The system is designed to
operate from -40 °C to +80 °C.
TCU 40/80 Temperature Control Unit

4 PRODUCT DESCRIPTION
4.1 Refrigeration and coolant circuits
Figure 1, Figure 2, and Table 3 on page 8 describe the refrigeration and coolant components of the TCU
40/80.
Figure 1- Refrigeration and coolant components
TCU40/80 Temperature Control Unit

Figure 2 - Refrigeration and coolant components
TCU 40/80 Temperature Control Unit

/^\
Table 3 - Refrigeration and coolant components
Item
I
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Component name
Reservoir
Level switch
Compressor
Crankcase regulator
Suction service valve
Discharge service valve
Temperature switch
Pressure switch
Condenser
Filter dryer
Safety cooling valve
Motor
Pump
Bypass valve
Hot gas bypass valve
Subcooler
Solenoid valve SV2
Solenoid valve SV1
Sight glass
TEV (Thermostatic
expansion valve)
Heater
Flow switch
Heat exchanger
Pressure relief valve
Function
A holding tank for the Fluorinert coolant.
Monitors the coolant level in the reservoir.
Compresses the refrigerant fluid.
Protects the compressor against pressure overload.
Allows isolation at the compressor.
Allows isolation at the compressor.
High limit switch for reservoir heater.
Limits maximum allowable discharge pressure.
Transfers heat from the compressed refrigerant to the facility water.
Removes contaminants and moisture from the refrigerant.
Limits the discharge temperature.
Drives the coolant pump.
Circulates the Fluorinert coolant.
Regulates coolant flow.
Regulates cooling capacity.
Further cools the refrigerant that is returning to the compressor.
Allows refrigerant to pass through the hot gas bypass valve, then to
the compressor suction line when energized.
Allows refrigerant to pass to the TEV when energized.
Allows visual inspection of the refrigerant charge and presence of
moisture in the system.
Allows the refrigerant to expand from a liquid to a gas.
Raises the temperature of the coolant when the process requires
heating.
Monitors the flow rate.
Extracts heat from the coolant and transfers it to the refrigerant.
Discharges refrigerant from the system to the atmosphere in the
event of severe over-pressure condition.
TCU 40/80 Temperature Control Unit

/
Bypass vaSn
Oran valve
I RID
temperature
probe
Profisure
Gwlttfc
Figure 3- Refrigeration and coolant circuits
4.2 Refrigeration
(see figure 3 above)
1. Refrigerant gas enters the compressor at low temperature and pressure. It leaves the compressor at
high pressure and temperature.
2. The gas passes into the condenser, where heat is removed by the external water supply, causing the
gas to condense into a liquid.
3. The cool liquid refrigerant exits the condenser and passes through a filter dryer that removes any
residual moisture or contaminants.
4.2.1 If cooling is required:
1. Solenoid valve SV1 opens (coil energized), allowing the refrigerant to flow into the Thermostatic
Expansion Valve (TEV). The pressure drop across the TEV causes the refrigerant to change from a
liquid to a mixture of liquid and gas.
2. The liquid and gas mixture enters the heat exchanger where it becomes entirely a gas. The process of
expansion from a liquid to a gas reduces the temperature by absorbing energy.
3. The refrigerant leaving the heat exchanger returns to the compressor through the subcooler and a
crankcase pressure regulator. The subcoolcr further cools the refrigerant entering the TEV.
TCU 40/80 Temperature Control Unit

4.2.2 If cooling is not required:
1. Solenoid valve SVl closes (coil de-energized).
2. Hot refrigerant from the compressor is passed through SV2 (coil energized) and a hot gas bypass
valve before returning to the compressor suction line. This bypassing allows the compressor to run
continuously.
3. Cooling, required to prevent the compressor from overheating, is provided by allowing some of the
liquid from the condenser to pass through the safety cooling automatic expansion valve into the
suction line, thus maintaining the discharge gas temperature below 99 °C.
4.3 Coolant circuit
Coolant is pulled from the reservoir by the circulation pump and transferred to the heat exchanger where
it is cooled by the refrigeration system as required. It then flows to the process equipment by means of the
coolant supply hose.
The coolant returns to the TCU 40/80 reservoir by means of the coolant return hose.
The coolant system requires 8 liters of coolant for the reservoir, plus the volume of the circulation lines
and any other spaces filled with coolant that are attached to the TCU 40/80.
To increase the coolant temperature, the reservoir uses an electrical resistance heater that is controlled by
the temperature controller. The heater must be fully submerged at all times, and if the coolant in the
reservoir falls below 3.S liters, a level switch causes the status alarm signal to automatically shut down the
TCU 40/80.
A three-float level switch, a thermostat, and a flow sensor provide coolant status signals to the TCU 40/80
control system.
4.4 Temperature monitoring
A Resistance Temperature Device (RTD) monitors the temperature of the coolant leaving the TCU 40/80
and transmits this information to the temperature controller. The TCU 40/80 compares the output of the
RTD to the selected process temperature (SVl) and determines if the coolant needs to be cooled or heated.
The temperature controller then operates the main cooling solenoid valve or heater.
The coolant temperature at the supply port on the rear panel is measured by a local, internally connected
RTD. If sensing of process equipment temperature is needed, connect an RTD to J72J3 at the rear panel
(see Figure 5 on page 13). For remote connection schematic details, see Figure IS on page 56.
^WIITV
10 TCU 40/80 Temperature Control Unit

4.5 Front panel
Figure 4 shows the Front Panel. Table 4, Table 5 and Table 6 identify its controls and indicators.
|M O <
? 5
> mat mu
0 aw-"
Figure 4 - Front panel
Table 4 - Front panel controls
Control name
POWER ON
RESET
EMERGENCY OFF
START/STOP
ALARM
MUTE
Description
Lights green when power is being supplied to the TCU 40/80.
Resets alarms and makes the TCU 40/80 ready to operate. The white light
indicates that the TCU 40/80 is ready to operate.
Removes power from all TCU 40/80 circuits except the EMERGENCY
OFF circuit. To shut off power, push EMERGENCY OFF (EMO). To reset,
rotate the EMERGENCY OFF button clockwise as shown on the switch.
Starts and stops the operation of the TCU 40/80.
Emits a high pitched sound when there is a fault condition which has caused
the TCU 40/80 to stop operation.
Silences the audible alarm.
TCU 40/80 Temperature Control Unit
II

Table 5 - Front panel LED indicators
LED name
FACILITY POWER
FACILITY WATER
CIRCUIT BREAKERS
COMPRESSOR
COOLANT
TEMPERATURE
COOLANT FLOW
COOLANT NORMAL
LEVEL
COOLANT LOW LEVEL
REMOTE RTD
Condition
Green
Red
Green
Red
Green
Red
Green
Red
Green
Red
Green
Red
Green
Amber
Off
Amber
Red
Off
Green
Description
Power phases are normal.
Power phases are reversed or low line voltage.
Water pressure and flow are normal.
Water pressure or flow are not adequate. (See
Specifications on page 14.
Rear panel circuit breakers 2, 3, and 4 are on.
One or more of these breakers is tripped or off.
Compressor is operating normally.
Compressor has stopped operating.
Coolant reservoir temperature is normal.
Coolant temperature is above the operating range.
Coolant flow is normal.
Coolant flow is not adequate.
Coolant level is normal.
Coolant level is over filled.
Coolant level is normal
Coolant level is low.
Coolant level is very low.
Remote RTD not connected.
Remote RTD temperature probe is in use.
Table 6 - Temperature controller
Controls and indicators
Process Value (PV)
Setpoint Value (SP)
Pushbuttons
Remote Mode LED (Aux)
Description
The present temperature of the coolant, as indicated by the internal RTD
or the remote RTD.
The TCU 40/80 regulates to this temperature, as set by the operator.
Used to program the controller.
Indicates mode of operation:
Off indicates local operation.
On indicates remote operation.
12 TCU 40/80 Temperature Control Unit

4.6 Rear panel
Figure 5 shows the rear panel. Table 7 identifies the controls and indicators on the rear panel.
D G
t
Fj
cocuurr iml
p
n
n
pi
n
p!
=
H
t90/t0* VAC » *M
•0/W Hi *0A
Figure 5 - Electrical rear panel
Table 7 ■
Label
J72J3
CB7 24 VAC
CB8 24 VDC
J72J2
CB4 reservoir heater
CB3 circulation pump
CB2 compressor
CB1 main power
normal/overfill
low/fault
200/208 VAC 3 PH
50/60 Hz 30A
CB5-XFMR
CB6-PSU
J72J1
■ Description of rear panel components and indicators
Description
Five pin connector for remote RTD interface. See Figure 15 on page 56 for
pinouts.
1 -pole, 2 Amp circuit breaker. Isolates the 24 VAC transformer. Normally on
(in).
l-pole, 2 Amp circuit breaker. Isolates the 24 VDC power supply output.
Normally on (in).
Nine pin connector for remote EMERGENCY OFF, start-stop operation, and
remote setpoint operation enable. See Figure 15 on page 56 for pinouts.
3-pole, 10 Amp circuit breaker. Normally on (up).
3-pole, 6 Amp circuit breaker. Normally on (up).
3-pole, 16 Amp circuit breaker. Normally on (up).
3-pole, 25 Amp circuit breaker. Normally on (up).
Normal, LED Green
Overfilled, LED Amber
Low, LED Amber
Fault, LED Red
Mains input power connector.
2-pole, 0.5 Amp circuit breaker. Isolates the equipment transformer.
2-poIe, 0.3 Amp circuit breaker. Isolates the power supply.
37 pin D-subminiature connector, for setpoint value signal, process value
signal, and remote fail and warning signals.
See Figure 15 on page 56 for pinouts.
TCU 40/80 Temperature Control Unit
13

4.7 Specifications
Parameter
Temperature ramp
Cooling capacity @
process equipment
ISO watt coolant line
losses; coolant water @
15 °C
Heating element
System flow
Process temperature
range
Setpoint resolution
Temperature regulation
Facility water
requirements
Power requirements
Ambient operating
temperature
Weight
Dimensions
Altitude
Max. relative humidity
Transient overvoltage
Pollution Degree
Sound pressure level
Conditions
Coolant short circuit conditions
+25°Cto+80°C
+25°Cto-30°C
Process coolant @ -40 °C
Process coolant @-20 °C to +80 "C,
@20 °C, 60 psig
+10oC(-0°+2°)to
+26 "C (+0° -2°)
3-phase delta (balanced load), 4 wire
(3 phases & earth gnd), 200 to 208
VAC, 50/60 Hz
Up to 31 "C
Above31°C
IEC 664, Installation Category II
IEC 664
At a distance of 1 meter.
Specification
Elapsed time: <25 minutes
Elapsed
time: <20 minutes
350 watts
2000 watts
2800 watts
3 gpm (11.36 lpm)
-40°Cto+80°C
±0.1 °C
± 1.0 °C typical
3 to 6 gpm
(11.36 to 22.71 lpm)
30 amp outlet
+ 10°Cto+50°C
450 pounds (204 kg)
22" wide x 30" deep x 35" high
(56 cm x 76 cm x 89 cm)
Up to 2000 meters
(6562 ft.)
80%
Derate linearly to 50% @ 50 °C,
2.5 kV
211
65dB(A)
14
TCU 40/80 Temperature Control Unit