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BOC Edwards TCU 40 Plus Instruction Manual

Single channel temperature control unit
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Instruction Manual
TCU 40/80
Single Channel
Temperature Control Unit
BOC EDWARDS
301 Ballardvale Street Wilmington, MA 01887
Telephone: (978) 658-5410
plus
Telex: 710-347-7672 Fax: (978) 658-7969
W95900011
Revision F
June, 2004

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  • Page 1 W95900011 Revision F June, 2004 Instruction Manual plus TCU 40/80 Single Channel Temperature Control Unit BOC EDWARDS 301 Ballardvale Street Wilmington, MA 01887 Telephone: (978) 658-5410 Telex: 710-347-7672 Fax: (978) 658-7969...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION TITLE PAGE PREFACE ………………………………………………………………………………………….. 1 SAFETY CONSIDERATIONS …………………………………………………………………. 1 plus TCU 40/80 …………………………………………………………………………………….. 3 SCOPE OF THE MANUAL …………………………………………………………………….. 3 plus DESCRIPTION FOR THE TCU 40/80 …………………………………………….………. 3 LOCKOUT PROCEDURE ……………………………………………………………………… 3 SAFETY FEATURES ……………………………………………………………………………4 QUICK START PROCEDURE ……………………………………………………………………. 5 POWER UP ………………………………………………………………………………….…..
  • Page 4 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) – “SUVA” HP62 ……………………………………….109...
  • Page 5 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 –...
  • Page 6 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 –...

  • Page 7: Preface

    Preface 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.
  • Page 8 Hot Surfaces symbol denotes a hazard which Hot Surfaces could cause injury or burns. Statement on avoiding the hazard. Hand Hand Protection symbol denotes a hazard which could cause injury or burns Protection Statement on avoiding the hazard. High Pressure symbol denotes a personal hazard High Pressure or equipment failure.

  • Page 9: Tcu 40/80 Plus

    TCU 40/80 plus Scope of the Manual This manual provides information on the installation, start-up and operation of Edwards High Vacuum plus 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.

  • Page 10: Safety Features

    Safety Features plus The safety features listed in Table are designed into the TCU 40/80 Table 1 - Safety Features Component Ref. Des. * Function (PB1) Shuts off power to major system components. EMERGENCY button (EMO) Remote EMERGENCY (J72J2) Remote shut off of power to major system components. Drawer safety switch (LS1) Upon opening the drawer, shuts off power to major system...

  • Page 11: Quick Start Procedure

    Table 2 - Front Panel Indicators Quick Start Procedure Indicator Reset Start Condition Condition This Quick Start procedure is for easy start Power On Green Green up and operation of an installed and fully Reset White White working TCU 40/80 plus. If your TCU 40/80 Facility Power Green plus is not installed, go to Installation,...
  • Page 12 TCU 40/80 Temperature Control Unit...

  • Page 13: Product Description

    4. Product Description 4.1 Refrigeration and Coolant Circuits Figure 1, Figure 2, and Table 3 on page 80 describe the refrigeration and coolant components of the TCU 40/80 plus. Figure 1- Refrigeration and Coolant Components (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...
  • Page 14 Figure 2 - Refrigeration and Coolant Components (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 Temperature Control Unit...
  • Page 15 Table 3 - Refrigeration and Coolant Components Item Component Name Function Reservoir A holding tank for the Fluorinert coolant. Level Switch Monitors the coolant level in the reservoir. Compressor Compresses the refrigerant fluid. Crankcase Regulator Protects the compressor against pressure overload. Suction Service Valve Allows isolation at the compressor.

  • Page 16: Refrigeration

    Bypass valve Fill port Pressure relief Crankcase Flow valve pressure Pressure switch Compressor switch regulator Level switch Vent valve bulb Circulation Coolant pump Service Service return valve valve bulb Water out Bypass Heater valve Subcooler Plate Hot gas Pressure heat solenoid valve relief Condenser...

  • Page 17: Coolant Circuit

    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 plus reservoir by means of the coolant return hose.

  • Page 18: Rear Panel

    Table 4 - Front Panel Controls Control Name Description Lights green when power is being supplied to the TCU 40/80 plus. Power On Reset Resets alarms and makes the TCU 40/80 plus ready to operate. The white light indicates that the TCU 40/80 plus is ready to operate. Removes power from all TCU 40/80 plus circuits except the EMERGENCY Emergency Off OFF circuit.

  • Page 19: Rear Panel

    Rear Panel ** Figure 5 shows the rear panel. Table 7 identifies the controls and indicators on the rear panel. Figure 5 - Electrical Rear Panel (G:\Technical Documents\MANUALS\W95900011- All) Table 7 - Description of Rear Panel Components and Indicators Label Description J72J3 Five-pin connector for remote RTD interface.

  • Page 20: Specifications

    Specifications Parameter Conditions Specification Temperature Ramp Coolant Short Circuit Conditions Elapsed Time: <25 Minutes +25 °C to +80 °C Elapsed Time: <15 Minutes +25 °C to -30 °C Cooling capacity process equipment 750 Watts Process Coolant @ -40 °C 150 watt coolant line losses; coolant water @ 15 °C 2400 Watts Process Coolant @-20 °C to +80...

  • Page 21: Dimensions

    Dimensions 30.0 22.0 [762.0] [558.8] BOC EDWARDS 30.0 [762.0] 35.1 [892.3] plus Figure 6 - TCU 40/80 (TCU 40/80 ) Dimensions G:\Technical Documents\MANUALS\W95900011- All) CENTER OF GRAVITY SINGLE 11.10 16.86 17.02 DUAL STACKED 11.10 16.86 33.83 Figure 7 - plus...
  • Page 22 5.4.3 Water Connections to the water supply and return are made to either ½" brass barb fittings or ½" compression fittings. For bare hose connections (½" nominal ID): 1. Slip the hose over the barb fitting and tighten the hose clamp. 2.

  • Page 23: Installation

    5. Installation 5.1 Receiving and Unpacking Do a complete visual inspection of the TCU 40/80 plus for any damage. Do not use the TCU 40/80 plus if physical damage is evident. If there is any damage, notify your supplier and the carrier in writing within three days;...

  • Page 24: Stacking

    Stacking The TCU 40/80 plus may be stacked two high. Be sure that the mounting surface can safely support the weight of the two units (920 lbs., 420 kg). Be sure that the casters of the top unit are turned inwards, but are not locked, until the top unit is fully seated.

  • Page 25: Figure 9 - System Rear View

    Figure 9 - System Rear View (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 Temperature Control Unit...

  • Page 26: Water

    5.4.3 Water Connections to the water supply and return are made to either ½" brass barb fittings or ½" compression fittings. For bare hose connections (½" nominal ID): Slip the hose over the barb fitting and tighten the hose clamp. Turn on the water supply and check for leaks.

  • Page 27: Operation

    Operation 6.1 Preparation Verify that water and coolant connections are made at both ends that the drain valve is closed and the coolant supply and return valves are open. Connect the remote interfaces if required. 1. To use an external RTD probe, attach it to connector J72J3. Refer to Figure 16 on page 60. Verify that the plug J72J2 is installed.

  • Page 28: Changing The Setpoint Value (Sv1)

    OUT 2 OUT 3 OUT 4 RESET PAGE PAGE Figure 11 - Temperature Controller (G:\Technical Documents\MANUALS\W95900011- All) Temperature Controller PID Settings BOC Edwards default settings are: PID1 - Heating Value PID2 - Cooling Value Parameter 14.0 18.0 Proportional Band Automatic Reset...

  • Page 29: Flow Rate Adjustment

    Flow Rate Adjustment Caution Do not exceed coolant pressure of 100 psi. Exceeding the coolant pressure may result in damage to the pump. The Fluorinert flow rate of the TCU 40/80 plus is factory set to provide approximately 3 gpm at 60 psig/20°C for a unit operating at 208vac/3-ph/60Hz.
  • Page 30 TCU 40/80 plus Temperature Control Unit...

  • Page 31: Maintenance

    Maintenance This section contains information that will allow you to safely keep your TCU 40/80 plus in working order. It contains important Hazard Warnings, and a Preventive Maintenance Schedule on page 28. Maintenance to the electrical Warning system of the TCU40/80 should be performed by qualified personnel only.
  • Page 32 The refrigerant lines are at high High pressure. Pressure Under no circumstances should the refrigerant pressure relief valve be removed or capped off. Leakage or failure of high- pressure circuits may cause injury Protection or irritation of the eyes. Eye protection should be worn when working with fluid systems.

  • Page 33: Hazards

    Hazards Table 9 gives the classifications of electrical hazards. This number indicates the severity of the hazard as defined by SEMI S2-93. Table 9 - Electrical Hazards Classifications Classification Description Comment Type 1 Equipment is fully de-energized. None called out. Type 2 Equipment is energized.

  • Page 34: Draining/Bleeding The Coolant Reservoir

    Note: Uncontaminated Fluorinert may be reused. The Fluorinert should be stored in a compatible and sealed container. 7.5 Temperature Probe Calibration The BOC Edwards Temperature Controller comes equipped with a factory calibrated internal ±10V remote input/output option making calibration unnecessary. Preventive Maintenance Schedule Table 10 shows the maintenance required to keep the TCU 40/80 plus in good working order.

  • Page 35: Semi-Annual Preventative Maintenance

    Semi-Annual Preventative Maintenance Refer to the Troubleshooting section 8 on page43 when results for any of the following checkpoints are not as expected. 7.7.1 Required Equipment · · 12” slotted screwdriver Spare lamps (24 vac / 60 mA) · · 4”...

  • Page 36: Lamp Check/Replacement

    7.7.8 Lamp Check/Replacement Electric Ensure all electrical power has been removed and the main Shock circuit breaker has been turned off due to the presence of high voltage or current. Should a lamp require Caution replacement, notify the appropriate personnel that an EMO condition will occur.

  • Page 37: Annual Preventative Maintenance

    Annual Preventative Maintenance Refer to the Troubleshooting section 8 on page47 when results for any of the following checkpoints are not as expected. 7.8.1 Required Equipment · · 12” slotted screwdriver Miniature diagonal cutters · · 4” slotted screwdriver Halogen leak detector ·...

  • Page 38: Figure 13 - Solenoid Coil Replacement

    14. Strip the ends of all wires on base assembly and solenoid valve coils. 15. Attach wires and secure mating connections per figure 13 below. 16. Tighten the strain relief-retaining nut. 17. Install the original junction box cover and fasten attachment screw. 18.

  • Page 39: System Check

    7.8.4 System Check Component Settings Motor Overload Setting (K3) 3.5 amps Current Sensing Relay Setting (CSR) 25 amps Thermostat Setting (TS1) 210°F (Differential set at 10°F) High Pressure Switch Setting (PS1) 300 psig. (Differential set at 40 psig) Power-Up Conditions ·...
  • Page 40 Temperature Controller All control parameters and selections procedures for the temperature controller are accomplished through simple MENU selections. These MENU selections are organized into PAGES. On each page you will find a specific set of related functions. The PAGES setup structure is as follows: diSP PAGE, Ctrl PAGE, inPt PAGE, ScAL PAGE, Out1 PAGE and Out2 PAGE.
  • Page 41 EMO Circuit Do not perform the EMO circuit check while the TCU is Warning on-line with the process tool. Failure to follow these instructions will lead to the shutdown of the process tool and other associated equipment. Press the EMO button and check that the following occur. ·...
  • Page 42 Current Sensing Relay Set CSR1 to 50 amps. The indicator LED on CSR1 should go from green to red. After a 5 second time delay, verify that the unit shuts down, COMPRESSOR illuminates red and the alarm sounds. Press MUTE. Indicator Condition Relays...
  • Page 43 Water Supply Open TCU right side panel and remove PS1 cover. Using a flat head screwdriver, lift up PS1 tab. The TCU will shut down, alarm will sound, and FACILITY WATER LED should illuminate red. Press MUTE. Indicator Condition Relays CR1, CR2, CR4, CR11, CR12, CR13 On all others, Off Circuit Breakers, Coolant Temperature, Coolant...
  • Page 44 Coolant Flow Shut off coolant supply valve. After 5 second delay, the TCU will shut down, alarm will sound and COOLANT FLOW LED should be red. Press MUTE. Indicator Condition Relays CR1, CR4, CR7, CR11, CR12, CR13 On all others, Off Facility Water, Circuit Breakers, Coolant Temperature, Coolant Normal Level, Green Facility Power, Compressor, Coolant Low...
  • Page 45 Circulation Pump Adjust overload trip on K3 to the minimum setting. Within three minutes the overload will trip. After a five second time delay, the TCU will shut down, the alarm will sound and the COOLANT FLOW LED should illuminate red. Press MUTE.
  • Page 46 Remote Start/Stop Remove jumper from terminal strip (TB1). The TCU will shut down. Press RESET. Press START. Remote Temperature Probe Install connector J72J3 and verify REMOTE RTD illuminates green. Indicator Condition Relays CR1, CR4, CR9, CR10, CR12 On all others, Off Facility Power, Facility Water, Circuit Breakers, Compressor, Coolant Temperature, Coolant Flow, Coolant Normal Level,...
  • Page 47 Heating Change the temperature controller set point to 80°C. Verify contactor K4 pulls in. Verify CR15 goes out. Verify OUT 1 on the temperature controller is on and OUT 2 is off. Verify hot gas bypass solenoid (SV2) is energized. Indicator Condition Relays...

  • Page 48: Preventative Maintenance Checklist

    Preventive Maintenance Checklist Record Date: Serial No: Customer Name: Line / Area: Checked By: Tool Name: System Status Timer Hours: Hours Coolant Pressure: psig Process Temperature: °C Fluorinert Type: ” FC8270 ” FC77 ” Other: Quantity Of Fluorinert Added: ” lbs. ”...

  • Page 49: Troubleshooting

    Troubleshooting Table 11, Table 12, Table 13 and Table 14 identify fault conditions that may encounter with the TCU 40/80 plus. For additional assistance contact the BOC Edwards Service Department. Table 11 - Faults Identified By Front Panel Lamps Indicator...
  • Page 50 Table 11 - Faults Identified By Front Panel Lamps (continued) Indicator Possible Causes Action Hazard POWER ON lamp Local EMERGENCY Verify the front panel EMERGENCY OFF Type 3 is illuminated, but OFF circuit (EMO) is (EMO) is engaged. when RESET is engaged.
  • Page 51 Circulation Pump: 3.5 amps per · Heater: 3 amps per leg If the current draw is in excess of the values noted above, remove power to the unit and contact a BOC Edwards service representative. TCU 40/80 plus Temperature Control Unit...
  • Page 52 If compressor oil is noted or a leak is located remove all power to the unit and contact a BOC Edwards service representative. Hot gas bypass solenoid Verify 24 VAC is present between wire #15 Type 4 valve (SV2) fail.
  • Page 53 1.4 W (± 0.3 W). Verify all three phases are within specification. If the motor winding resistance is out of tolerance contact an BOC Edwards service representative. Incorrect line voltage to Verify that the compressor is receiving all Type 4 the compressor.
  • Page 54 Table 12 - Faults Indicated by the Front Panel LED Indicators (continued) Indicator Possible Causes Action Hazard Flow switch may not be Monitor the voltage between wire #57 (J2-5) Type 4 set properly. and wire #58 (J3-9) located on the relay board.
  • Page 55 Table 13 - Faults Identified By Rear Panel Indicators Indicator Possible Causes Action Hazard Coolant NORMAL Reservoir is over-filled. Drain the reservoir until the LED turns green. LEVEL LED is Refer to “ Draining/Bleeding the Coolant amber. Reservoir” Section 7.4 page 28. Coolant LOW Fluid volume is low;...
  • Page 56 Moisture is in the system. Verify that the moisture indicator in the sight Type 2 glass is green. If it appears yellow in color remove power from the unit and notify a BOC Edwards service representative. TCU 40/80 Temperature Control Unit...
  • Page 57 If compressor oil is noted or a leak is located remove all power to the unit and contact a BOC Edwards service representative. Temperature controller Verify temperature controller PID settings. Type 2 parameters are not set to Refer to the “Temperature Controller PID...

  • Page 58: Figure 14 - Electrical Drawer Analog

    Figure 14 - Electrical Drawer Analog (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 Temperature Control Unit...
  • Page 59 No Text TCU 40/80 plus Temperature Control Unit...

  • Page 60: Figure 15 - Electrical Drawer Schematic

    Figure 15 - Electrical Drawer Schematic (Page 1) (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 Temperature Control Unit...
  • Page 61 Figure 15 - Electrical Drawer Schematic (Page 2) (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...

  • Page 62: Figure 16 - Remote Interface

    Figure 16 – Remote Interface (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 Temperature Control Unit...

  • Page 63: Accessories And Spare Parts

    Accessories And Spare Parts Accessories and spare parts are available from service centers at BOC Edwards companies in Brazil, Canada, Germany, Great Britain, Italy, Japan, USA, and a worldwide network of distributors. The majority of these centers employ service engineers who have undergone comprehensive BOC Edwards training courses.
  • Page 64 TCU 40/80 Temperature Control Unit...

  • Page 65: Options

    Lam, CSD5014 V0.1, 300mm Software Requirements Specification for Generic LonWorks Interface, 21 April 1997 Lam, CSD5139 V0.1, Software Requirements Specification for LonWorks Interface for the BOC Edwards Chiller, 20 June 1997 Echelon Corporation, The SNVT Master List and Programmers Guide, May 1997 10.1.2...

  • Page 66: Requirements

    10.1.3 Requirements 1. Physical The LTCI is configured as two subassemblies: the Interface Module (IM) and the Control Module (CM). The CM utilizes a standard Echelon twisted pair control module programmed to implement the control and status monitoring functions. In addition to the NEURON processor and support functions, the CM provides the LonWorks network interface transceiver, allowing the LTCI to be adapted to different LonWorks physical media by exchanging the CM.
  • Page 67 3. Address and Subnet Switch Settings The LonWorks PCB has two DIP switches SW3 and SW4. Switch SW3, which has four switches, is the Subnet Switch. When the switches are in the CLOSE position, their value is 0. When they are in the OPEN position, their values from right to left are 1, 2, 4 and 8.
  • Page 68 6. Functional Requirements The LTCI supports the following TCU 40/80 plus control and monitoring functions: 1. Temperature Monitoring/Control 2. Start/Stop Control 3. Status Monitoring The functional requirements associated with each of these capabilities are described in detail below. LTCI operation involves communication with the Lam Host Node using LonWorks network variables (NVs) and the following descriptions make a number of references to these NVs.

  • Page 69: Interfaces

    On initial Power-up, prior to receiving a setpoint specification from the host, the LTCI will command a default setpoint of 25° C. 8. TCU 40/80 plus Start/Stop Control The LTCI provides the Lam Host Node with the ability to start and stop chiller operation using the nviControl network variable.
  • Page 70 Interface Protocol The LTCI L interface communicates with the Lam Host node through the ORKS exchange of messages using LonWorks Network Variables (NVs). Each NV contains one or more parameters, is defined using a C syntax to include any valid C data type (i.e., ints, structures, enums, etc.), and is declared as either an input or output.
  • Page 71 2: Lam Specification defines these as unsigned short (8 bits). unit represents an unsigned, which NEURON C represents as 8 bits. 3: This nviHeartbeat definition is taken from the Lam SRS for the BOC Edwards Chiller [2]. c. Network Variables This section describes the network variables provided by the LTCI.
  • Page 72 nvoStatus The nvoStatus NV contains the status information shown in Table 18. It is sent to the Lam Host node in response to receipt of a nviHeartbeat message containing the LTCI address and in response to a NEURON chip watchdog time-out. Table18 - Definition of nvoStatus Network Variable Status Parameter Meaning...
  • Page 73 nviCommReset The LTCI will verify the successful transmission of each message from itself to the Lam Host as specified in [1]. Upon detection of a communication failure the LTCI will enter the COMM FAIL state and remain there until it receives an nviCommReset message having a value of “1”.
  • Page 74 TCU 40/80 plus Interface LTCI Power Interface The LTCI will require ±15VDC and +5VDC at CB1 for use as primary power. Power conditioning circuitry onboard the LTCI will re-regulate this to provide +5VDC and ±12VDC for use by the LTCI circuitry. The LTCI will not separately fuse the input power.

  • Page 75: Figure 19 - Electrical Rear Panel

    Rear Panel Figure 18 shows the rear panel. Table 19 identifies the controls and indicators on the rear panel. Figure 19 - Electrical Rear Panel (G:\Technical Documents\MANUALS\W95900011- All) Table 19 - Description of Rear Panel Components and Indicators Label Description J72J3 Five-pin connector for remote RTD interface.

  • Page 76: Figure 20 - Electrical Drawer Lonworks

    PSU1 PSU2 TB GND CB10 CB10 PHASE MONITOR RELAY CB12 CB12 Figure 20 - Electrical Drawer LonWorks (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...
  • Page 77 No Text TCU 40/80 Temperature Control Unit...

  • Page 78: Figure 21 - Electrical Drawer Schematic

    Figure 21 - Electrical Drawer Schematic (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...
  • Page 79 (continued …..) Figure 21 - Electrical Drawer Schematic (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 Temperature Control Unit...

  • Page 80: Figure 22 - Remote Interface

    Figure 22 - Remote Interface (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...

  • Page 81: Rs232 Tel

    10.2 RS 232 TEL 10.2.1 Block Diagram The signals comprises contact I/O signals and an RS-232C communication function. See Figure 23. 9 WAY [RS 232C] DIGITAL I/O D SU B ANALOG I/O A - D 15 WAY D SU B [H OST CON TROL I/O SIGN ALS] INTERFACE BLOCK DIAGRAM...

  • Page 82: Table 20 – Available Functions

    Table 20 – Available Functions Operation At the TCU At the Host RS-232 Local operation mode Stop Temperature Setting BAND Setting Alarm reacting ----------------- -------------- ----- Reading of set C (with display) temperature Reading of BAND set M (with value display) Reading of process C (with display)

  • Page 83: Description Of External Control And Monitoring Signals

    10.2.3 Description of External Control and Monitoring Signals Two methods of communication are used together, these are: Contact I/O Signals RS 232 Communication A. Contact I/O Signals 1. Host control signals (Signals to and from an external host device to the TCU) a.
  • Page 84 BETWEEN 100 [M SEC] AND 1 [SEC] SIGNAL O FF Fig 25 - Control Signal State (G:\Technical Documents\MANUALS\W95900011- All) c. Input impedance: 3.0 kΩ Host monitoring signals (Signals from the TCU to an external host device) 1. “Operation mode” signal When in remote operation mode, the contact is set to ON.
  • Page 85 Table 21 - Pin Assignments at the TCU Host Connection (15 way D sub) Pin # Function/Use Comment Operation Mode Isolated Solid State Operation Mode Return Contact Closure Contact Closure to Common Stop (Not Used) Contact Closure to common Fault Contact Closure to common Warning Contact Closure to common...
  • Page 86 RS-232C Specifications • Standard---------------------------------------------------------RS-232C (EIA) • Communication Method-------------------------------------Half-Duplex • Synchronous Type---------------------------------------------Start-stop • Baud Rate-------------------------------------------------------9600bps • Character Code-------------------------------------------------ASCII • Parity------------------------------------------------------------Non • Start Bit---------------------------------------------------------1 bit • Data Length-----------------------------------------------------8 bit • Stop Bit----------------------------------------------------------1 bit • Block Check----------------------------------------------------See page 80 4. Description Of Transmission/Reception Of Messages 1.
  • Page 87 5. Block Check (Frame Check Sequence) FCS is calculated in accordance with the following steps: Calculation Procedure By putting 3 to the head of each value, this translates each byte into its ASCII Hex code. Add the target of calculation per byte. This will give a 2-byte answer in Hex, which will be FCS.
  • Page 88 Set Point Temperature Data 2 digits ASCII code with +/- sign (-30°C--+90°C) Example: +10°C: 2B , 31 , 30 0°C: 2B , 30 , 30 -20°C: 2D , 32 , 30 b. Reading of BAND Set Value Command format [Transmission from host (external device) to the unit] Header Response format [Response from the unit to the host (external device) Equal Box...
  • Page 89 d. Reading of Status 1 Command format [Transmission from host (external device) to the unit] Header Response format [Transmission from host (external device ) to the unit] Header 0011 Not used (0 fixed) Not used (0 fixed) Not used (0 fixed) Not used (0 fixed) 0011...
  • Page 90 0011 Facility Water (a: Fault) Compressor (1: Fault) Not used (0 fixed) Not used (0 fixed) 0011 Not used (0 fixed) Circuit Breaker (1: Fault) Low Battery fault (1: Fault) Not used (0 fixed) 0011 Coolant Temperature Hi (1: Fault) Not used (0 fixed) Not used...
  • Page 91 0011 Not used (0 fixed) Not used (0 fixed) Not used (0 fixed) Not used (0 fixed) 0011 Not used (0 fixed) Not used (0 fixed) Not used (0 fixed) Not used (0 fixed) 0011 Not used (0 fixed) Not used (0 fixed) Not used (0 fixed)
  • Page 92 e. Reading of Status 2 Command format [Transmission from host (external device) to the unit] Header Response format [response from the unit to the host (external device)] Header 0011 “RUN”/ “STOP signal (1: RUN 0: STOP) Not used (0 fixed) Not used (0 fixed) Not used...
  • Page 93 7. Description of Write Command The write command is effective only when the unit is in remote operation mode. If the unit is in local operation mode, [ACK] is returned but the command is neglected. A. Writing of Set Temperature Command format [Transmission from the host] (external device to the unit] Header Dummy code...
  • Page 94 Fig 27 – Electrical Rear Panel (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...
  • Page 95 Table 24 - Description of Rear Panel Components and Indicators Label Description J72J3 Five-pin connector for remote RTD interface. See Figure 31 on page 98 for pin outs. CB7 24 VAC 1-pole, 2 Amp circuit breaker. Isolates the 24 VAC transformer. Normally on (in).
  • Page 96 Fig 28 – RS232 Electrical Drawer (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...
  • Page 97 No Text TCU 40/80 Temperature Control Unit...
  • Page 98 Fig 29 - RS 232 Power Distribution Schematic (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...
  • Page 99 (continued …..) Fig 29 - RS 232 Power Distribution Schematic (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 Temperature Control Unit...
  • Page 100 Fig 30 - Assy,Cable,TCU Host Comm (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...
  • Page 101 Fig 31 - Assy,Cable,TCU RS232 Comm (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 Temperature Control Unit...

  • Page 102: Rs485 Serial Communication

    10.3. RS485 Serial Communication The RS485 Interface Box Assembly was designed specifically to install only on the BOC Edwards model TCU 40/80 with RS485, BOC Edwards P.N. NW9501194. The TCU 40/80 with RS485 communications consists of two major components: TCU 40/80 with modified electrical controls drawer, External RS485 Interface Box Assembly 10.3.1 Modified Electrical Controls Drawer...

  • Page 103: Installation And Se-Up Of Rs485 Interface Box Assembly

    TERMINATION JUMPER SETTING: As mentioned above, the Interface Box is manufactured and shipped by BOC Edwards to the customer with the termination jumper installed. This jumper is designated “JP7” on the Microprocessor PCA, as shown in Figure 35 on page 105. Pin designation and functions for JP7 are defined in Figure 36 on page 105.

  • Page 104: Figure 32 - Rs485 Electrical Drawer Component Layout

    “PSU2” CB10 PHASE NITOR RELAY CB12 Figure 32 - RS-485 Electrical Drawer Component Layout (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...
  • Page 105 No Text TCU 40/80 Temperature Control Unit...

  • Page 106: Figure 33 - Rs485 Electrical Drawer Schematic

    Figure 33 - RS-485 Electrical Drawer Schematic (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 plus Temperature Control Unit...
  • Page 107 (continued …) Figure 33 - RS-485 Electrical Drawer Schematic (G:\Technical Documents\MANUALS\W95900011- All) TCU 40/80 Temperature Control Unit...
  • Page 108 Fig 34 - RS485 Interface Box – Physical Dimensions (G:\Technical Documents\MANUALS\W95900011- All) Host RS-485 Connector Chiller Interface Connector TCU 40/80 plus Temperature Control Unit...

  • Page 109: Figure 36 - Microprocessor Pca - Jp7 Pin Description And Function

    Fig 35 - RS485 Interface Box with Top Cover Removed (G:\Technical Documents\MANUALS\W95900011- All) Interface PCA Microprocessor PCA (on Microprocessor PCA) (on Interface PCA) Figure 36 - Microprocessor PCA – JP7 Pin Description and Function (G:\Technical Documents\MANUALS\W95900011- All) Enable pull-up RS-485 termination Enable 100-ohm RS-485 termination Enable pull-down RS-485 termination JP7 shows termination of the RS-485 lines enabled...
  • Page 110 Table 25 - TCU 40/80 “J72J1” Connector Modified for RS-485 (37-Pin D-subminiature Female) Note: Same pin designation applies to mating “P72J1” male connector PIN # ID # DESCRIPTION 5V COM I/F PCB, J2-8 +5 V I/F PCB, J2-9 +5 V Processor PCB, P2-1 +15 V I/F PCB, J2-4...
  • Page 111 Table 26 - Host RS-485 Communication Connector (9-Pin D-Subminiature Female) Note: Connection type is 2-wire half-duplex multi-drop RS-485 Signal Type Function TCU 40/80 Temperature Control Unit...

  • Page 112: Rs485 Modicon Modbus Protocol Specification For Tcu 40/80

    10.3.4 RS485 Modicon Modbus Protocol Specification for TCU 40/80 Purpose: The purpose of this document is to define the RS485 transmission characteristics using the Modicon protocol. References: Modicon Modbus Protocol Reference Guide PI-MBUS-300 Rev J dated June 1996. RS485 Transmission Characteristics: The Modbus protocol implemented is ASCII mode (1 start bit, 7 data bits, 1 even parity bit, 1 stop bit), Longitudinal Redundancy Check (LRC), and operation at 9600 baud.

  • Page 113: Rs485 4X Memory Map For Tcu 40/80 Heat Exchanger

    4X Memory Map: The memory-mapped registers are 16 bits in length and for purposes of discussion the least significant bit is b0 and the most significant bit is b15. The registers written to or read from are organized in a memory map. The memory map starts at location 0100 hex and runs through location 010E hex.

  • Page 114: Rs485 Tcu 40/80 Message Example

    10.3.6 RS485 TCU 40/80 Message Example QUERY MESSAGE & Response Message: Field ASCII Code Start Character ":" = 0x3A Unit Address 0x05 "0" = 0x30 "5" = 0x35 Function 0x16 "1" = 0x31 "6" = 0x36 Reference Address Hi 0x01 "0"...

  • Page 115: Appendix

    Appendix Return of BOC Edwards Equipment - Procedure (Form HS1) Introduction Before you return your equipment you must warn your supplier if the substances you used (and produced) in the equipment can be dangerous. You must do this to comply with health and safety at work laws.

  • Page 116: Return Of Boc Edwards Equipment - Declaration (Form Hs2)

    Telephone number: __________________ Date of equipment delivery:______________________________________ I have made reasonable inquiry and I have supplied accurate information in this Declaration. I have not withheld any information. I have followed the Return of BOC Edwards Equipment Procedure (HS1) on the previous page. Signed: _______________________________________ Date: ____________________________________________...

  • Page 117: Legal Notices, Limitations And Disclaimers

    BOC Edwards, transportation charges prepaid. In the event that BOC Edwards elects to refund the purchase price, the apparatus shall be the property of BOC Edwards and shall be shipped to BOC Edwards at BOC Edwards expense. This Mechanical Warranty shall be void and the apparatus shall be deemed to be purchased AS IS in the event that the entire purchase price has not been paid within thirty (30) days of original shipment of apparatus.

  • Page 118: Msds (Material Safety Data Sheet) - "Suva" Hp62

    MSDS (material safety data sheet) - “SUVA” HP62 Du Pont Chemicals 6002FR Revised 15-JUL- 1993 Printed 16-DEC-1993 “SUVA” HP62” CHEMICAL PRODUCT/COMPANY IDENTIFICATION Material Identification "SUVA” is a registered trademark of DuPont. Corporate MSDS Number DUO05612 Company Identification Manufacturer/Distributor DuPont 1007 Market Street Wilmington, DE 19898 Phone Numbers Product Information...
  • Page 119 (Continued) Human Health Effects: Overexposure to the vapors by inhalation may include temporary nervous system depression with anesthetic effects such as dizziness, headaches, confusion, incoordination, and loss of consciousness. Higher exposures to the vapors may cause temporary alteration of the heart's electrical activity with irregular pulse, palpitations, or inadequate circulation;...
  • Page 120 (Continued) FIRE FIGHTING MEASURES Flammable Properties Flash Point will not burn Method Flammable limits in Air % by Volume Not applicable Not applicable Auto-ignition Not determined Fire and Explosion Hazards: Cylinders may rupture under fire conditions. Decomposition may occur. Potential Combustibility: "SUVA”...
  • Page 121 (Continued) HANDLING AND STORAGE Handling (Personnel) Avoid-breathing vapor. Avoid liquid contact with eyes and skin. Use with sufficient ventilation to keep employees exposure below recommended limits. Contact with chlorine or other strong oxidizing agents should also be avoided. See Fire and Explosion Data section. Storage Clean, dry area.
  • Page 122 (Continued) PHYSICAL AND CHEMICAL PROPERTIES Physical Data Boiling Point -46.7ºC (-52, 1ºF) Average Vapor Pressure 182.1 psig at 25°C (77°F) % Volatiles 100 WT% Evaporation Rate (CL4 = 1) Greater than 1 Solubility in Water Not determined Odor slight ethereal Form Liquefied gas Color...
  • Page 123 (Continued) HFC-134a Inhalation 4-hour LC50: 567,000 ppm in rats A 5 or 10 second spray of vapor produced very slight eye irritation and a 24-hour occlusive application produced slight skin irritation in rabbits. The compound is not a skin sensitizer in animals. No toxic effects were seen in animals from exposures by inhalation to concentrations up to 81,000 ppm.
  • Page 124 TRANSPORTATION INFORMATION Shipping Information D /IMO Proper Shipping Name LIQUEFIED GAS, N.O.S. (CONTAINS PENTAFLUORDETHANE AND TETRAFLUOROETHANE) Hazard Class UN No. 1956 DOT/IMO Label NON-FLAMMABLE GAS Shipping Containers Tank Cars, Cylinders Ton Tanks REGULATORY INFORMATION US Federal Regulations TSCA Inventory Status Reported/Included.
  • Page 125 NOTES:...
  • Page 126 BOC Edwards EUROPE AMERICAS PACIFIC UNITED KINGDOM JAPAN Edwards High Vacuum International Edwards High Vacuum International Nippon Edwards KK Manor Royal One Edwards Park Shuwa Shiba Park Building A-3F Crawley 301 Ballardvale St. 2-4-1 Shibakoen West Sussex RH10 2LW Wilmington, MA 01887...

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