Summary of Contents for inTest TEMPTRONIC ThermoStream TP04300 Series
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4 Commerical Street, Sharon, MA 02067-1653 U.S.A. Tel: (781) 688-2300 Fax: (781) 688-2301 Part Number: LM02290 http://www.temptronic.com TP04300 Series ThermoStream ® Service Manual Revision A. April 2005...
Preface ........Copyright 2005 by Temptronic Corporation Notice Patents have been granted and/or patent applications are pending or are in process of preparation on all our developments.
P R E F A C E Temptronic Support Temptronic Support Introduction Temptronic is committed to assisting end users and technicians to maintain operational systems which are highly reliable. Temptronic offers the following support services. Customer Training Formal technical training courses are available. The training courses cover the theory of operation and the maintenance procedures for the System.
P R E F A C E Before You Call Before You Call Introduction You can help us support your machine in timely fashion by having on hand specific information when calling in: • Software Version • System Model Number System Model A modular system design allows the customer to select options or features as desired for a Number...
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P R E F A C E Before You Call TP04300B Name Plate TP04300 Series Service Manual...
S A F E T Y Warnings Section A: Safety Precautions, Warnings, Cautions ........Warnings WARNING WARNING: Refer to Accompanying Documentation...
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S A F E T Y Warnings WARNING 7: Per SEMI S2-93A, energized electrical work (“Hot Work”) is specified by Type as follows: TYPE DESCRIPTION (per SEMI S2-93A) EXPOSURE THRESHOLD Fully de-energized (electrically “cold.”) n.a. Live circuits, covered or insulated. Work performed n.a.
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S A F E T Y Warnings WARNING 14: To prevent high-pressure ejection of condensate (which may or may not contain injurious substances) when draining moisture from the air filter elements, first turn off the System's air pressure supply, second bleed all air from the System by turning on ac power to the System just long enough to exhaust air in the System, third disconnect the supply line from the air supply port fitting located on the rear panel.
S A F E T Y Cautions Cautions CAUTION CAUTION: Refer to Accompanying Documentation Electrical Hazard CAUTION: High Voltage, Electrical Shock Hazard Hot Surface CAUTION: Hot Surface Cold Surface CAUTION: Cold Surface CAUTION 1: Observe the precautions given on the equipment and within this manual to prevent damage to the equipment.
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S A F E T Y Cautions CAUTION 9: When making the system air connection to the System, hold the AIR INPUT fitting with a second wrench while tightening the barb fitting to prevent the AIR INPUT fitting from rotating in the panel. CAUTION 10: Use suitable Clean Dry Air (CDA) compressed air supply for the System: a) to prevent premature fouling of the filters/regulator assemblies provided with the System, b) to prevent ice forming from within the cooling module and possibly reducing or obstructing...
S A F E T Y AVERTISSEMENT Section B: CONSIGNES DE SÉCURITÉ POUR LE PERSONNEL EXPLOITANT ........AVERTISSEMENT WARNING AVERTISSEMENT: Attention...
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S A F E T Y AVERTISSEMENT AVERTISSEMENT 5: Les pièces à l’intérieur de la tête thermique fonctionnant à des températures très élevées ou très basses, tout contact avec ces pièces est dangereux. N’effectuer aucune maintenance à l’intérieur de la tête thermique tant que le système n’est pas arrêté.
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S A F E T Y AVERTISSEMENT AVERTISSEMENT 11: En aucun cas (essai d’étanchéité ou toute autre situation) on ne doit charger le module du refroidisseur d’air avec un gaz à une pression supérieure à 10,34 bars. AVERTISSEMENT 12: Le module de refroidissement d’air sert de contrepoids à la tête thermique.
S A F E T Y ATTENTION ATTENTION CAUTION ATTENTION: Attention Electrical Hazard AVERTISSEMENT: Haute tension Hot Surface AVERTISSEMENT: Surface chaude Cold Surface AVERTISSEMENT: Surface froide Se conformer aux mesures de sécurité figurant sur le matériel et dans ATTENTION 1: ce manuel pour ne pas endommager le matériel.
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S A F E T Y ATTENTION Lors de la dépose de la carte de régulation du débit, éviter ATTENTION 8: soigneusement de plier la carte lors du débranchement des tuyaux d’arrivée et de sortie d’air. Une légère flexion de la carte suffit pour endommager ses composants délicats et/ou son câblage.
S A F E T Y WARNUNG Section C: RHEITSHINWEISE FÜR BEDIENUNGSPERSONAL ........WARNUNG WARNING WARNUNG: Attention...
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S A F E T Y WARNUNG WARNUNG 5: m Thermalkopf befindliche Teile werden während des Betriebs extrem heiß und kalt; es besteht daher Berührungsgefahr. Wartungsarbeiten im Thermalkopf dürfen nur durchgeführt werden, wenn das System ausgeschaltet ist. Warten Sie, bis die Teile im Thermalkopf eine sichere und beständige Temperatur, nahe der Raumtemperatur erreicht haben.
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S A F E T Y WARNUNG WARNUNG 11: Auf keinen Fall darf das Luftkühlungsmodul (zu Dichtheitsprüfungen oder anderen Zwecken) mit einem Gas geladen werden, das unter einem Druck von mehr als 10,34 Bar steht. WARNUNG 12: Das Luftkühlungsmodul dient als Gegengewicht für den Thermalkopfaufbau.
S A F E T Y VORSICHT VORSICHT VORSICHT 1: Die am Gerät und in diesem Handbuch gegebenen Vorsichtsmaßregeln beachten, um Geräteschäden zu vermeiden. Das Gerät darf nur für die vom Hersteller angegebenen Verwendungszwecke benutzt werden. VORSICHT 2: Schutz- und Kühlabdeckungen sowie Abdeckungen, die mit einem Werkzeug abgenommen werden müssen, dürfen nur von dazu befugtem Personal vom Gerät entfernt werden.
S A F E T Y ADVERTENCIA Section D: PRECAUCIONES DE SEGURIDAD PARA EL PERSONAL DE OPERACIONES ........ADVERTENCIA WARNING ADVERTENCIA: Precaución...
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S A F E T Y ADVERTENCIA ADVERTENCIA 5: Las piezas dentro de la cabeza térmica funcionan a temperaturas extremadamente calientes y frías y son peligrosas al tocarlas. No efectúe ningún mantenimiento dentro de la cabeza térmica hasta que el sistema no haya sido apagado. Espere hasta que las piezas de la cabeza hayan alcanzado una temperatura segura y estable, cerca a la temperatura ambiente.
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S A F E T Y ADVERTENCIA ADVERTENCIA 10: Si se necesita hacer alguna reparación del Módulo del Enfriador de Aire, solamente un técnico de refrigeración con licencia (y/o certificado por EPA) y autorizado por Temptronic Corporation estará calificado para efectuar cualquier carga o manipulación de los refrigerantes en el Sistema.
S A F E T Y PRECAUCION PRECAUCION PRECAUCION 1: Observe las precauciones indicadas en el equipo y en este manual, para evitar causar daños al equipo. Use el equipo únicamente para los fines especificados por el fabricante. PRECAUCION 2: Personal no autorizado no deberá quitar del equipo los paneles de enfriamiento y/o protección, o aquellos que necesitan una herramienta para quitarlos.
S A F E T Y Varningar Section E: Säkerhets Föreskrifter och Varningar, Varsamhet ........Varningar WARNING Varningar...
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S A F E T Y Varningar VARNING 5: Delar i det termiska huvudet arbetar i extrema varma och kalla temperaturer och är mycket farligt att vidröra. Utför inget underhåll på eller i det termiska huvudet innan utrustningen helt har stängts av. Vänta tills huvudets delar erhållit en säker temperatur i närhet av rumstemperaturen.
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S A F E T Y Varningar Två personer behövs för borttagning (eller installation) av det termiska VARNING 13: huvudet på den horisontala armen. En person måste lyfta huvudet med båda händer medan den andra personen lossar (eller drar åt) dess fästskruvar. VARNING 14: För att undvika högtrycks utblås eller smällar (vilka kan eller inte oftast täckas av försäkringar) när utrustningens filter skall rengöras, stäng alltid först av lufttillförseln till utrustningen, sedan låt lufttrycket läcka ut genom att sätta på...
S A F E T Y Försiktighet och Varsamhet Försiktighet och Varsamhet VARSHAMET 1:Observera den varsamhet och försiktighet som angives på utrustningen och dess manual för att undvika skador på utrustningen. Använd enbart utrustningen såsom leverantören angivit och specificerat. VARSHAMET 2: Personal som ej är aktualiserad för ändamålet skall inte avlägsna skydd eller paneler på...
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S A F E T Y Försiktighet och Varsamhet 1-24 TP04300 Series Service Manual...
System Overview ........Chapter Overview Introduction The Model TP04300 ThermoStream System is a programmable temperature controlling air- flow system to support the testing and characterizing of electronic devices.
S Y S T E M O V E R V I E W Section B: User/Owner Documentation ........Introduction The following section details the owner’s warranty and related forms for the TP04300.
S Y S T E M O V E R V I E W Section C: Physical Requirements ........Introduction The TP04300 System uses a modular design for its main functional parts.
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S Y S T E M O V E R V I E W Environmental and Service Features Over-Temperature +250 C (factory-set) (Also uses user-settable high and low Protection air temperature limit) Mobility 4 swivel caster wheels with locks 10.16cm (4 in.) diameter Refrigerants 50 Hz systems: HCFC-free and CFC-free, non-toxic, non- flammable...
S Y S T E M O V E R V I E W Section D: Theory of Operation ........System Block The following diagram is a functional block diagram of the TP04300 System at a modular Diagram...
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S Y S T E M O V E R V I E W Description Program instructions entered by the local user or from the remote host (prober/tester) are stored in the OCM microcontroller. From these instructions, via a serial interface, the Main Controller board directs the Flow board to set the air flow through the thermal head at the programmed flow rate.
S Y S T E M O V E R V I E W Section Overview Section E: Pictorial Overview ........Section Overview Introduction This Section is divided into the following topics:...
S Y S T E M O V E R V I E W TP04300, Front Full View TP04300, Front Full View Flow/Linear Actuator Board Power On/Off Switch (SW1) Ports EMO Switch Diskette Drive (SW2) Pneumatics Assembly Auto- Transformer Linear Actuator Assembly Condenser...
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S Y S T E M O V E R V I E W TP04300, Front Full View Part Description Operator Control Module, an approximately 10.4 inch (diagonal size) color touch screen for operator inputs. This graphical user interface allows non-technical individuals, production operators, and test engineers optimum ease of use with minimum training time.
S Y S T E M O V E R V I E W TP04300, Left Full View TP04300, Left Full View Sound Blanket FRONT Air Chiller Module LM01990_203.JPG Description Part Description Sound Blanket Secured to the frame with velcro, the blanket muffles noise from and protects the Air Chiller Assembly.
S Y S T E M O V E R V I E W TP04300, Right Full View TP04300, Right Full View Air Dryer Input Air Pressure Gauge Watlow PC Assembly Low Voltage Terminal Blocks Power Supply (PS2) Power Supply (PS1) Air Supply (inlet)
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S Y S T E M O V E R V I E W TP04300, Right Full View Part Description Watlow PC The Main Controller Board(s); an assembly of 3 PCBs, primarily Assembly responsible for temperature control. For greater detail on the Watlow PC Assembly, see Chapter 4, Machine Interface.
S Y S T E M O V E R V I E W TP04300, Rear Full View TP04300, Rear Full View Air Pressure Gauge Rear I/O Ports Purge Flow Valve (PFV) Purge Out Air Supply (inlet) Main Power Cord Rear Ventilation LM01990_205.JPG Descriptions...
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S Y S T E M O V E R V I E W TP04300, Rear Full View Part Description Purge Out The Purge Out (PO) port supplies dry, ambient, purged air to protect the tester platform (test board, test cables, socket lead wires and related interconnections) from moisture related problems.
S Y S T E M O V E R V I E W TP04300A, Thermal Head TP04300A, Thermal Head Membrane Switch Stand Up Head Up/Down Stand Down Thermal Head Cover Heater Assembly (not visible with Cover attached) Main Air Output Nozzle LM01990_601.JPG Descriptions...
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S Y S T E M O V E R V I E W TP04300A, Thermal Head Part Description Head Up/Down Generally, the manipulator (with the thermal Head in the down position) is lowered until the Head’s thermal cap covers the DUT site. The Head must be down to initiate air flow to the DUT.
S Y S T E M O V E R V I E W Section Overview Section F: System Initialization ........Section Overview Introduction This Section describes Initial System checkout procedures.
S Y S T E M O V E R V I E W Initializing Cold Flow Initializing Cold Flow Procedure To initialize cold air flow: 1. Toggle the front panel switch to start the TP04300 System. 2. Wait for software to boot: the System Startup Screen displays, then a functional screen dis- plays.
S Y S T E M O V E R V I E W Initializing Hot Flow Initializing Hot Flow Procedure To initialize hot air flow: 1. Toggle the front panel switch to start the TP04300 System. 2. Wait for software to boot: the System Startup Screen displays, then a functional screen dis- plays.
S Y S T E M O V E R V I E W Head and Arm Test (TP04300A) Head and Arm Test (TP04300A) Procedure To test the head and arm: 1. Check the Head up and down movement, • Press and release the "Head" membrane switch (button) on the thermal head assem- bly for alternate up and down travel of the head over a 6-inch (15-cm) distance.
S Y S T E M O V E R V I E W Temperature Cycle Test Temperature Cycle Test Procedure To perform a temperature cycle test: 1. Press "Utility" tab to access Utility Screen, and set Flow to "Safe" and Head to "Unlocked."...
S Y S T E M O V E R V I E W Remote Interface Test Remote Interface Test Procedure To test the remote interface: 1. Connect the remote host (prober/computer) to the TP04300 at the appropriate IEEE-488 or RS232 connector in the system I/O panel, (see TP04300 Interface & Applications Man- ual, LM01980).
S Y S T E M O V E R V I E W Section G: Calibrate System ........Introduction Calibration of the TP04300 System sensors should be verified every year, or more often if in question or required by user certification schedules, to determine the temperature control...
U S E R I N T E R F A C E Section Overview Section A: Parts Pictorial ........Section Overview In this Section The following topics are covered in this Section:...
U S E R I N T E R F A C E User Interface Overview User Interface Overview User Interface Operator Control Module Operator Control Module Operator Control Module (OCM) (OCM) Assembly (OCM) Touch Screen Power On/Off Switch (SW1) Printer Diskette Mouse...
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U S E R I N T E R F A C E User Interface Overview PART DESCRIPTION Power On/Off The system’s on/off switch (which contains an "On" indicator LED Switch (SW1) light). P/N SS01840 EMO Switch (SW2) Press the EMO to trip the back panel Circuit Breaker (CB1) and interrupt power input to the TP04300 (shutting down the entire unit).
U S E R I N T E R F A C E Operator Control Module Assembly Operator Control Module Assembly OCM Assembly, Front View OCM Touch Screen Touch Screen Power Cable LCD Display Cable Floppy Drive IDE Cable Main Floppy Drive Power Power Cable...
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U S E R I N T E R F A C E Operator Control Module Assembly PART DESCRIPTION Touch Screen routes from the OCM Motherboard (JP3) to the 12vdc power input Power Cable port of the Touch Screen. LCD Display routes from the OCM Motherboard (VGA) to the display input port of the Touch Screen.
U S E R I N T E R F A C E Section Overview Section B: Repair ........Section Overview Introduction The following topics are described in this Section:...
U S E R I N T E R F A C E OCM Assembly Replacement OCM Assembly Replacement Procedure To replace the OCM, use P/N SA173640. WARNING WARNINGS 1,2,3,7,9 in Chapter 1 Safety. Step Action Power down the TP04300 and disconnect power cord. Remove facility supplied air connection from the TP04300.
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U S E R I N T E R F A C E OCM Assembly Replacement Step Action Label and Disconnect the following: • OCM Main Power Cable • SW1 Power Cable • Printer Ribbon Cable (2 standoffs) • Accessories Cable(s), USB, Mouse, Keyboard (4 nuts) •...
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U S E R I N T E R F A C E OCM Assembly Replacement Step Action Once all the cabling has been disconnected, the OCM Assembly can be removed from the OCM Chassis. Remove the (4) screws securing the OCM Assembly to the Chassis. (4) Screws LM02290_319.jpg Store the OCM Assembly in a safe place.
U S E R I N T E R F A C E OCM Touch Screen Replacement OCM Touch Screen Replacement Touch Screen Replacement (4) Nuts Detailed Touch Screen LCD Display Touch Screen Comm. Cable Cable Power Cable LM02290_317.jpg Procedure To Replace the Touch Screen: Step Action...
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U S E R I N T E R F A C E OCM Touch Screen Replacement Step Action Disconnect the: • Touch Screen Power Cable • LCD Display Cable • Touch Screen Comm. Cable Remove the (4) screws securing the Touch Screen to the OCM Assembly. Remove the Touch Screen.
U S E R I N T E R F A C E OCM Motherboard Replacement OCM Motherboard Replacement Introduction The OCM Motherboard is a non-repairable unit. It must be returned to the nearest sales representative or to the factory for depot maintenance repairs. Motherboard Replacement OCM Motherboard...
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U S E R I N T E R F A C E OCM Motherboard Replacement Step Action Remove the Touch Screen to gain access to the OCM’s internal components. Refer to OCM Touch Screen Replacement, page 3-11 as needed. Disconnect the following from the Motherboard: •...
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U S E R I N T E R F A C E OCM Motherboard Replacement LM02290_311.jpg Step Action Remove the (9) screws securing the board to the OCM frame - (7) #6 screws - (2) #4 screws Retain the Hardware LM02290_313.jpg Remove the Motherboard.
U S E R I N T E R F A C E OCM Hard Drive Replacement OCM Hard Drive Replacement Introduction The OCM Hard Drive is a non-repairable unit. It must be returned to the nearest sales representative or to the factory for depot maintenance repairs. Hard Drive Replacement (1) 6-32 X 1/4 screw...
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U S E R I N T E R F A C E OCM Hard Drive Replacement Step Action Remove the (1) 6-32 X 1/4 screw securing the Mounting Bracket to the OCM Frame. Retain the Hardware. Remove the (2) Nuts and (2) Washers securing the Mounting Bracket to the frame’s studs.
U S E R I N T E R F A C E Diskette Drive Replacement Diskette Drive Replacement Introduction The floppy disk drive is a non-repairable unit. A faulty disk drive should be replaced by a new unit. Procedure To replace the floppy disk drive, use P/N ZZ08500.
U S E R I N T E R F A C E Power On/Off Switch (SW1) Replacement Power On/Off Switch (SW1) Replacement Introduction The following procedure gives instructions for removing and replacing the Power On/Off Switch (SW1). SW1 Replacement Detailed Pry Up Bezel (4 sides)
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U S E R I N T E R F A C E Power On/Off Switch (SW1) Replacement Procedure To replace SW1 use P/N SS01840. WARNING WARNINGS 1,2,3,7,9 in Chapter 1 Safety. Step Action Turn off (power down) the TP04300, then disconnect power cord from facility power supply.
U S E R I N T E R F A C E EMO Switch (SW2) Replacement EMO Switch (SW2) Replacement Introduction The following procedure gives instructions for removing and replacing the EMO Switch (SW2). SW2 Replacement Detailed Unlock SW2 by moving the tab EMO Button on top...
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U S E R I N T E R F A C E EMO Switch (SW2) Replacement Step Action To remove the Red EMO Button, reach behind the button and remove the black plastic washer that secures the button to the frame. BUTTON AND WASHER (shown Removed from Frame) Washer Button...
M A C H I N E I N T E R F A C E Section Overview Section A: Parts Pictorial ........Section Overview In this Section The following topics are covered in this Section:...
M A C H I N E I N T E R F A C E Rear Input/Output (I/O) Ports Rear Input/Output (I/O) Ports Rear I/O Ports Input Air Pressure Gauge I/O Ports Purge Flow Valve (PFV) Purge Air Out (PO) LM01990_404.JPG Descriptions PART...
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M A C H I N E I N T E R F A C E Rear Input/Output (I/O) Ports PART DESCRIPTION DUT T Interface for a Type T thermocouple DUT K Interface for a Type K thermocouple DUT RTD/Diode Interface for an RTD/Diode sensor.
M A C H I N E I N T E R F A C E Flow/Linear Actuator Board Flow/Linear Actuator Board Flow/Linear Actuator Board Flow/Linear Actuator Board FRONT VIEW LM02290_421.jpg ATTENTION This graphic displays the latest version of the Flow/Linear Actuator Board. Older TP04300 models equipped with dual flow boards may be upgraded with Service Kit CS160070.
M A C H I N E I N T E R F A C E Cutout Board Cutout Board Cutout Board Thermal Head Cutout Board (Overheat Safety) LM01990_406.JPG CUTOUT BOARD Cutout Board DETAILED Terminal Strip Fuse (1/4 amp) Primary Secondary Type K Thermocouple Type K Thermocouple...
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M A C H I N E I N T E R F A C E Cutout Board Descriptions PART DESCRIPTION Cutout Board The Cutout Board, located in the Thermal Head, is used to prevent a (Overheat Safety) main heater overtemperature condition, as a result of loss of programmed control.
M A C H I N E I N T E R F A C E Watlow PC Assembly Watlow PC Assembly Watlow PC Assembly TP10 - TP11 Watlow Board 1 (main board) DUT (Type T) port Watlow DUT (Type K) port Board 3 (RTD/Diode)
M A C H I N E I N T E R F A C E Communications Board Communications Board Communications Board LM01990_408.jpg Ground Terminal RS232 I/O port IEEE-4888 I/O port LEDs (6) LM01990_409.jpg TP04300 Series Service Manual...
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M A C H I N E I N T E R F A C E Communications Board Descriptions Communications Board, P/N EE00130. PART DESCRIPTION Must be jumpered east-west to enable DTE. Jump to reset firmware. Ground Terminal referenced here for troubleshooting. RS232 I/O port RS232 Serial Communications I/O port.
M A C H I N E I N T E R F A C E Section Overview Section B: Repair ........Section Overview In this Section The following topics are covered in this Section:...
M A C H I N E I N T E R F A C E Flow/Linear Actuator Board Replacement Flow/Linear Actuator Board Replacement Introduction The Flow/Linear Actuator Board is a non-repairable unit. It must be returned to the nearest sales representative or to the factory for depot maintenance repairs.
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M A C H I N E I N T E R F A C E Flow/Linear Actuator Board Replacement CAUTION CAUTION 8: When removing the flow control board, be extremely careful to avoid flexing the board when disconnecting the inlet and outlet air hoses. Even a slight flexing of the board can damage delicate components and/or wiring on the board.
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M A C H I N E I N T E R F A C E Flow/Linear Actuator Board Replacement Step Action Disconnect the Poly Flow Line (out) from the Flow/Linear Actuator Board. Poly Flow Line (out) Manifold Flow Board LM01990_419.JPG Remove the connections on: •...
M A C H I N E I N T E R F A C E Cutout Board Replacement Cutout Board Replacement Introduction The Cutout Board is a non-repairable unit. It must be returned to the nearest sales representative or to the factory for depot maintenance repairs. Cutout Board Replacement Detailed...
M A C H I N E I N T E R F A C E Watlow PC Assembly Replacement Watlow PC Assembly Replacement Introduction The Watlow PC Assembly is a non-repairable unit. It must be returned to the nearest sales representative or to the factory for depot maintenance repairs.
M A C H I N E I N T E R F A C E Comm Board Replacement Comm Board Replacement Introduction The Comm Board assembly is a non-repairable unit. It must be returned to the nearest sales representative or to the factory for depot maintenance repairs. Procedure To replace the Comm Board assembly, use P/N EE00130 WARNING...
Arm and Manipulator (TP04300A) ........Chapter Overview The thermal head manipulator is a mechanical support for manually and electrically positioning the thermal head assembly to the DUT site.
A R M A N D M A N I P U L A T O R ( T P 0 4 3 0 0 A ) Section Overview Section A: Parts Pictorial ........Section Overview In this Section The following topics are covered in this Section:...
A R M A N D M A N I P U L A T O R ( T P 0 4 3 0 0 A ) Thermal Head Manipulator, Locks Thermal Head Manipulator, Locks Locks Horizontal Assembly: Head Pivot Lower Arm Lower Arm Lock...
A R M A N D M A N I P U L A T O R ( T P 0 4 3 0 0 A ) Linear Actuator Assembly Linear Actuator Assembly Linear Actuator Flexline Hose Vertical Stand Vertical Stand Lock (SW3) Support Brace Actuator Assembly:...
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A R M A N D M A N I P U L A T O R ( T P 0 4 3 0 0 A ) Linear Actuator Assembly PART DESCRIPTION Support Brace secures and supports the vertical stand Linear Actuator fastened (by the actuator pin) inside the Vertical Stand.
A R M A N D M A N I P U L A T O R ( T P 0 4 3 0 0 A ) Linear Actuator Motor Linear Actuator Motor Motor, Front View LM01990_414.jpg Motor, Cover Removed LM01990_415.jp Descriptions PART...
A R M A N D M A N I P U L A T O R ( T P 0 4 3 0 0 A ) Section Overview Section B: Repair ........Section Overview In this Section The following topics are covered in this Section:...
A R M A N D M A N I P U L A T O R ( T P 0 4 3 0 0 A ) Vertical Stand Lock Switch (SW3) Replacement Vertical Stand Lock Switch (SW3) Replacement Vertical Stand Lock Detailed (4) Allen Head Screws...
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A R M A N D M A N I P U L A T O R ( T P 0 4 3 0 0 A ) Vertical Stand Lock Switch (SW3) Replacement Step Action Remove the (4) Allen Head Screws securing the Collar to the frame. Loosen the Collar to gain access to the SW3 wire COLLAR LOOSENED (4) Allen Head Screws...
T H E R M A L H E A D Section Overview Section A: Parts Pictorial ........Section Overview In this Section The following topics are covered in this Section:...
T H E R M A L H E A D Thermal Head, Front Thermal Head, Front Front View FlexLine Hose Switches (Buttons): STAND UP HEAD Up/Down STAND Down Main Air Output Nozzle LM01990_601.JPG Descriptions PART DESCRIPTION FlexLine Hose Carries main air flow, and electrical connections for the Cutout Board and Heater P/N VV04400 STAND Up...
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T H E R M A L H E A D Thermal Head, Front PART DESCRIPTION Main Air Nozzle main output for heated air, (3) Thermocouples monitor the temperature at the nozzle: (1) Type T, the main temperature sensor (2) Type K, overtemp cutout sensors P/N SA149360 TP04300 Series Service Manual...
T H E R M A L H E A D Thermal Head, Left Thermal Head, Left Left View, Cover Removed FlexLine Hose Head Purge Air Heater Connector (to STAND and HEAD buttons) K4 Relay Air Lines (to Up/Down Cylinder) Purge Air Out Head Purge Air (to thermal cap)
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T H E R M A L H E A D Thermal Head, Left PART DESCRIPTION Air Lines carry air flow to the main cylinder (for HEAD Up/Down) Purge Air Out Supplies purge air to the thermal cap to keep DUT moisture free. Flow is controlled by the PFV (Purge Flow Valve).
T H E R M A L H E A D Thermal Head, Right Thermal Head, Right Right View, Cover Removed Pressure Regulator Head Purge Air Heater Power Connector Heater Cutout Board Type K Thermocouples Main Air Output Nozzle LM01990_603.JPG Descriptions PART DESCRIPTION...
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T H E R M A L H E A D Thermal Head, Right PART DESCRIPTION Type K Monitor temperature at the Main Air Output Nozzle for overtemp/ Thermocouple safety cutout. The primary cutout is 250 C, the secondary cutout is C.
T H E R M A L H E A D Thermal Head, Rear Thermal Head, Rear Rear View, Cover Removed Up/Down Slider Calibration Jack Up/Down Cylinder Purge Air Port Main Air Output Nozzle LM01990_604.JPG Descriptions PART DESCRIPTION Up/Down Slider Connects the Up/Down Cylinder to the Lower Arm and Locks.
T H E R M A L H E A D Nozzle Plunger Replacement Nozzle Plunger Replacement Nozzle Replacement Detail Extract Pins (3) LM01990_620.JPG Procedure To replace the Nozzle Plunger, use P/N SS145510 WARNING WARNINGS 1, 2, 3, 5, 6, 7,9 in Chapter 1 Safety Step Action Turn off (power down) the TP04300A, then disconnect power cord from...
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T H E R M A L H E A D Nozzle Plunger Replacement Step Action When installing the new Nozzle, use the thermocouple centering tool to align the thermocouple in the center of the positioning wires. ATTENTION The thermocouple should NOT touch the sides of the nozzle. For accurate temperature reading, the thermocouple must be centered in the positioning wires.
T H E R M A L H E A D Heater Replacement (TP04300A) Heater Replacement (TP04300A) Procedure To replace the Heater, use P/N SA149370. WARNING WARNINGS 1, 2, 3, 5, 6, 7,9 in Chapter 1 Safety. Step Action Turn off (power down) the TP04300A, then disconnect power cord from facility power supply.
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T H E R M A L H E A D Heater Replacement (TP04300A) Step Action Disconnect the membrane switch plug from the cover assembly. Loosen the nut that secures the ground wire to the frame of the head. Remove the ground wire. LM01990_606.JPG Cut the insulation along the dotted line.
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T H E R M A L H E A D Heater Replacement (TP04300A) Step Action Loosen the compression fitting that secures the Poly - Flow input airline. Slide the airline away from the heater. Compression Fitting LM01990_608.JPG Remove the two slotted screws that hold the thermocouple connectors to the PCB.
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T H E R M A L H E A D Heater Replacement (TP04300A) Step Action Remove the black tape from around the insulation. Cut the insulation vertically along the two dotted lines. Use caution not to damage the thermocouples. LM01990_610.JPG Remove the red/orange tape from around the base of the Isolator Plate.
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T H E R M A L H E A D Heater Replacement (TP04300A) Step Action Remove the white fiber woven tape from around the base of the heater flange. LM01990_612.JPG Disconnect the Molex connector. Loosen the nut on the stud securing the ground wire.
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T H E R M A L H E A D Heater Replacement (TP04300A) Step Action Remove the three Allen head screws from the bottom of the heater flange. LM01990_614.JPG At this point the heater can be removed from the head assembly. Install the new heater into the head assembly.
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T H E R M A L H E A D Heater Replacement (TP04300A) Step Action Apply glue to the pieces of insulation that were cut in step 10. Allow the glue to set -up for a few moments before attaching the two pieces. LM01990_616.JPG Wrap the joint between the upper and lower pieces with some black electrical tape.
T H E R M A L H E A D Heater Replacement (TP04300B) Heater Replacement (TP04300B) Procedure To replace the Heater, use P/N CS17530 WARNING WARNINGS 1, 2, 3, 5, 6, 7,9 in Chapter 1 Safety. Step Action Turn off (power down) the TP04300B, then disconnect power cord from facility power supply.
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T H E R M A L H E A D Heater Replacement (TP04300B) Step Action Remove the (4) bolts securing the Turret Collar and Flex Extender Adapter. Bolts turret and collar removal 4 bolts.jpg Set the Turret Collar, Flex Extender Adapter, and (4) bolts aside: turret and collar removed.jpg TP04300 Series Service Manual 6-21...
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T H E R M A L H E A D Heater Replacement (TP04300B) Step Action Loosen the Pneumatics Drive Shelf: (6) screws secure the Pneumatics drive shelf loosen drive shelf.jpg Step Action The Pneumatics Drive Shelf is secured by (6) screws (3 on each side).
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T H E R M A L H E A D Heater Replacement (TP04300B) Step Action Remove and retain the (3) bolts that secure the Internal Head Assembly to the frame: CAUTION The Internal Head Assembly will no longer be secured once the (3) Bolts have been Removed.
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T H E R M A L H E A D Heater Replacement (TP04300B) Step Action With the drive shelf loosened and the Internal Head Assembly unbolted, extract the Internal Head Assembly as shown: NOTE: cut tie wraps securing the flexline hose as needed. Internal Head Assembly, remove thru top.jpg 6-24 TP04300 Series Service Manual...
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T H E R M A L H E A D Heater Replacement (TP04300B) Step Action Place the Internal Head Assembly on the top of the ThermoStream as shown: Heater (2) Type K Type T Heater Power Thermocouples Thermocouple Ground Connector (Main TC) Wire...
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T H E R M A L H E A D Heater Replacement (TP04300B) Step Action Disconnect the Purge Flow tubing at the t-fitting and quick disconnect Purge tubing Purge tubing t-fitting quick disconnect disconnect purge ring.jpg Remove the Cutout Board Mounting Bracket as follows: a.
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T H E R M A L H E A D Heater Replacement (TP04300B) Step Action Using a flathead screwdriver, carefully remove the (white) Thrust Bearing from the Isolator Plate: Isolator Plate Thrust Bearing Thrust Bearing.jpg TP04300 Series Service Manual 6-27...
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T H E R M A L H E A D Heater Replacement (TP04300B) Step Action To gain access to the Main Air Compression Fitting, cut the insulation along the dotted line (shown below). Use caution to not damage the Poly - Flow line inserted through the insulation.
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T H E R M A L H E A D Heater Replacement (TP04300B) Step Action Remove the black tape from around the insulation. Cut the insulation vertically along the two dotted lines. Use caution not to damage the thermocouples. Black Tape vertically...
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T H E R M A L H E A D Heater Replacement (TP04300B) Step Action Remove the white fiber woven tape from around the base of the heater flange. LM01990_612.JPG Remove the three Allen head screws from the bottom of the heater flange. CAUTION DO NOT dislodge the thermocouple mounting rings from the nozzle.
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T H E R M A L H E A D Heater Replacement (TP04300B) Install the new Heater Step Action Install the new heater into the head assembly. Re-install the three Allen head screws that secured the Heater Flange. Insert the Poly - Flow line into the Main Air Compression fitting. Tighten the fitting securely.
T H E R M A L H E A D Membrane Switch Replacement Membrane Switch Replacement Membrane Switch Detailed Thermal Head Cover, Removal LM01990_605.JPG Thermal Head Cover, Inside View Membrane Switch (under backing plate) Ground 5-pin Strap power connector (4) Nuts Backing Plate...
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T H E R M A L H E A D Membrane Switch Replacement Procedure To replace the Membrane Switch use P/N SS145510 WARNING WARNINGS 1, 2, 3, 5, 6, 7,9 in Chapter 1 Safety Step Action Turn off (power down) the TP04300A, then disconnect power cord from facility power supply.
T H E R M A L H E A D Relay K4 Replacement Relay K4 Replacement K4 Replacement Detailed Standoffs (2) Electrical Connections (4) LM01990_617.JPG Procedure To replace Relay K4, use P/N KK02060. WARNING WARNINGS 1, 2, 3, 5, 6, 7,9 in Chapter 1 Safety Step Action Turn off (power down) the TP04300, then disconnect power cord from facility...
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T H E R M A L H E A D Relay K4 Replacement Step Action The Heater Assembly may be loosened for easier access to Relay K4. To loosen the Heater Assembly, remove the (4) screws on the back of the Thermal Head: Screws (2) Screws (2)
T H E R M A L H E A D Type “T”, Main Thermocouple Replacement Type “T”, Main Thermocouple Replacement Thermocouple Replacement Detailed Thermocouple Ground Wires (purple) Isolator Plate LM01990_622.JPG Procedure To replace the Type “T” Thermocouple, use P/N SA151810 WARNING WARNINGS 1, 2, 3, 5, 6, 7,9 in Chapter 1 Safety Step...
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T H E R M A L H E A D Type “T”, Main Thermocouple Replacement Step Action Disconnect the (blue) thermocouple connectors and remove the (2) screws securing them to the Isolator Plate THERMOCOUPLE SHOWN WITH HEATER Screws Isolator Thermocouple Plate Connectors (blue)
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T H E R M A L H E A D Type “T”, Main Thermocouple Replacement Step Action Use a small screwdriver to remove the (blue) O-Ring (P/N OO00210) STAINLESS THERMAL DISC REMOVED Ground Wires Thermocouple Connectors O-Ring Glue LM01990_625.JPG Gently pull up on the thermocouple to separate it from the (red) RTV Glue (P/N GM00380).
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T H E R M A L H E A D Section C: Parts List ........PART STOCK#, (Description)
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T H E R M A L H E A D 6-40 TP04300 Series Service Manual...
P N E U M A T I C S Section Overview Section A: Parts Pictorial ........Section Overview In this Section The following topics are covered in this Section:...
P N E U M A T I C S Flow/Linear Actuator Board Flow/Linear Actuator Board Flow/Linear Actuator Board Flow/Linear Actuator Board Pneumatics Assembly LM01990_701.JPG Descriptions PART DESCRIPTION Flow/Linear Has two functions: Actuator Board • Serves as a mass air flow meter. This board communicates flow volume to the Watlow board which then sets flow rate and volume according to OCM inputs.
P N E U M A T I C S Pneumatics Assembly, Front View Pneumatics Assembly, Front View Flow/Linear Actuator Board Particle Coalescing Filter Filter Refrigerant Gauge Valves, Regulators (obscured view) LM01990_702.JPG Descriptions PART DESCRIPTION Particle Filter Removes larger particular matter from the air flow. P/N CS158580 Coalescing Filter Removes smaller particular matter and moisture from the air flow.
P N E U M A T I C S Pneumatics Valves, Regulators Pneumatics Valves, Regulators Pneumatics Valves, Regulators, Front View Manifold Assy: Manifold Assy: Low Pressure Trickle Flow Switch (SW4) Valve (SV3) Button Main Flow Manifold Assy: Manifold Assy: Head Up/Down Main Flow Valve Valve Assy:...
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P N E U M A T I C S Pneumatics Valves, Regulators PART DESCRIPTION Air Manifold Part of the Main Air Manifold Assembly, a stainless steel air distribution block. Low Pressure Part of the Main Air Manifold Assembly Switch (SW4) Sends a low input air pressure signal/warning to the main board (and OCM display) if the main air pressure is less than 10psi.
P N E U M A T I C S Pneumatics Filter Element Replacement Pneumatics Filter Element Replacement Filter Replacement Detail Filter Element Unscrew here Filter Cover (push down and twist to remove) LM01990_704.JPG Procedure To replace the Filter Element, use P/N CS158580. WARNING WARNINGS 1, 2, 3, 8, 9 in Chapter 1, Safety.
P N E U M A T I C S Air Manifold Assembly (SV3, SV5, SW4) Replacement Air Manifold Assembly (SV3, SV5, SW4) Replacement Air Manifold Replacement Detail Air Out (4) Screws Pneumatics securing Line manifold SV3 Electrical Connection (1 screw) Low Pressure Switch (SW4) SV3 Pneumatics...
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P N E U M A T I C S Air Manifold Assembly (SV3, SV5, SW4) Replacement Step Action Remove the Air Manifold Install the new manifold assembly in the reverse order of the above procedure. 7-10 TP04300 Series Service Manual...
P N E U M A T I C S Main Flow Valve Assembly (SV2, SV4) Replacement Main Flow Valve Assembly (SV2, SV4) Replacement Main Flow Valve Replacement Detail Pneumatics line: Pneumatics line: (4) screws Air In from Dryer Air out to SV3 Pneumatics line: Air Out to Flow Board...
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P N E U M A T I C S Main Flow Valve Assembly (SV2, SV4) Replacement Step Action Disconnect both Air Out (to SV3 and to Flow Board) pneumatics line. Remove the (4) screws securing the Main Flow Valve Assembly to the frame. NOTE: the screw heads are on the back side of the frame.
P N E U M A T I C S SV1, Head Up/Down Valve Replacement SV1, Head Up/Down Valve Replacement SV1 Replacement Detail Electrical Connection (3)Pneumatic Connections (2) Screws LM01990_705.JPG Procedure To replace the SV1, use P/N KK01810. WARNING WARNINGS 1, 2, 3, 8, 9 in Chapter 1, Safety. Step Action Power down the TP04300 and disconnect power cord.
P O W E R C O N T R O L General Power Distribution General Power Distribution General Power General power distribution is as follows: Distribution • Facility line voltage (AC) enters the system through CB1, the Line Filter, and the Auto Overview Transformer.
P O W E R C O N T R O L Section Overview Section A: Parts Pictorial ........Section Overview In this Section The following topics are covered in this Section:...
P O W E R C O N T R O L Power Distribution: Right, Full View Power Distribution: Right, Full View Power Distribution Voltage Terminal Block Power Supply 2 (PS2) Power Supply 1 (PS1) Line Filter High Voltage Terminal Block Compressor Auto Transformer...
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P O W E R C O N T R O L Power Distribution: Right, Full View PART DESCRIPTION Circuit Breaker 1, a 32 amp circuit breaker, the Main Power breaker P/N KK02740 a 12vdc relay, supplies 24vdc to the Low Voltage Terminal Block. P/NKK03060 Power Supply 2 The +24vdc power supply...
P O W E R C O N T R O L Low Voltage Terminal Block Low Voltage Terminal Block Low Voltage Terminal Block LM02290_817.JPG Descriptions Terminal Block DESCRIPTION TB7a +24vdc, System Shutdown TB7b Ground TB7c +24vdc +24vdc, EMO Shutdown Ground (jumpered to TB10) TB10 Ground (jumpered to TB9, TB11)
P O W E R C O N T R O L High Voltage Terminal Block High Voltage Terminal Block High Voltage Terminal Block TB29 thru TB23 TB6 thru TB1 Relay GB3 GB2 F2 F1 TB31, TB30 LM02290_818.JPG Descriptions PART DESCRIPTION Ground Block 3, chassis ground connection Ground Block 2, chassis ground connection...
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P O W E R C O N T R O L High Voltage Terminal Block PART DESCRIPTION Circuit Breaker 5, 16amp (Heater) P/N KK01950 TB31 extension block, CB4 output (Neutral) TB30 extension block, CB4 output (Hot) Circuit Breaker 4, 16 amp (Compressor and Power Supplies) P/N KK01950 Ground Block 1, chassis ground connection TP04300 Series Service Manual...
P O W E R C O N T R O L Wiring for Input Voltage of 235V to 250V: Section B: Voltage Configurations ........Introduction The optimal voltage for the TP04300 System is 230V.
P O W E R C O N T R O L Wiring for Input Voltage of 215V to 224V: Wiring for Input Voltage of 215V to 224V: Wire Marker # Wire Color From Blue TB23-1 Gray TB24-1 Orange TB25-1 Yellow TB26-1 Brown...
P O W E R C O N T R O L Section Overview Section C: Repair ........Section Overview In this Section The following topics are covered in this Section:...
P O W E R C O N T R O L Circuit Breaker CB1 Replacement Circuit Breaker CB1 Replacement Introduction The following procedure gives instructions for removing and replacing the Circuit Breakers (CB1 and CB2). Circuit Breaker Detailed Shunt Trip Breaker Screws (2) Bracket...
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P O W E R C O N T R O L Circuit Breaker CB1 Replacement WARNING WARNINGS 1,2,3,7,9 in Chapter 1 Safety. Step Action Turn off (power down) the TP04300, then disconnect power cord from facility power supply. Mark and remove all electrical connections from the circuit breakers. Remove the (2) screws securing the Circuit Breaker bracket to the frame.
P O W E R C O N T R O L Circuit Breakers CB4, CB5 Replacement Circuit Breakers CB4, CB5 Replacement Introduction The following procedure gives instructions for removing and replacing the Circuit Breakers (CB4, CB5) on the High Voltage Terminal Block. Circuit Breaker Bracket and Clips Clips...
P O W E R C O N T R O L Relay K1 Replacement Relay K1 Replacement Introduction The following procedure gives instructions for removing and replacing the Relays K1. K1 Removal Detailed Clip LM02290_822.jpg Procedure To replace K1, use P/N KK01980. WARNING WARNINGS 1,2,3,7,9 in Chapter 1 Safety.
P O W E R C O N T R O L Relay K3 Replacement Relay K3 Replacement Introduction The following procedure gives instructions for removing and replacing Relay K3. Relay K3 Removal Detail Relay K3 (2) Screws Snubber LM02290_823.jpg Procedure To replace K3, use P/N KK03050.
P O W E R C O N T R O L Fuses F1, F2 Replacement Fuses F1, F2 Replacement Introduction The following procedure gives instructions for removing and replacing the Fuses (F1, F2). Fuses Detail Unfasten Clip from DIN Rail and Lift Fuse Holder LM02290_824.jpg Procedure To replace F1 and F2, use P/N FF00420.
P O W E R C O N T R O L Transformer, T1 Replacement Transformer, T1 Replacement Introduction The following procedure gives instructions for removing and replacing Transformer T1. T1 Removal Detail Screws (2) LM02290_825.jpg Procedure To replace T1, use P/N TT00280. WARNING WARNINGS 1,2,3,7,9 in Chapter 1 Safety.
P O W E R C O N T R O L Power Supplies (PS1 and PS2) Replacement Power Supplies (PS1 and PS2) Replacement Introduction The following procedure gives instructions for removing and replacing the Power Supplies. Power Supply Replacement Detailed Lock Nuts 119 Black, common...
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P O W E R C O N T R O L Power Supplies (PS1 and PS2) Replacement WARNING WARNINGS 1,2,3,7,9 in Chapter 1 Safety. Step Action Turn off (power down) the TP04300, then disconnect power cord from facility power supply. Make a note of each Power Supply’s orientation on the electrical shelf.
P O W E R C O N T R O L Line Filter Replacement Line Filter Replacement Introduction The following procedure gives instructions for removing and replacing the Line Filter. Line Filter Removal Detail Nuts (4 total) Line Filter Nuts (4 total) LM01990_816.JPG Procedure...
A I R D R Y E R M O D U L E Section Overview Section A: Parts Pictorial ........Section Overview In this Section The following topics are covered in this Section:...
A I R D R Y E R M O D U L E Air Dryer Assembly, Full View Air Dryer Assembly, Full View Air Dryer Assembly Desiccant Desiccant Tower Tower Upper Valves Purge Baffle Post Filter Muffler Lower Valves, Cycle Timer Air Out Air In...
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A I R D R Y E R M O D U L E Air Dryer Assembly, Full View PART DESCRIPTION Post Filter Removes particular matter and desiccant from the air supply. P/N ZZ10100 Muffler Muffles the exhaust noise of purged air. P/N ZZ09300 Lower Valves, Cycle Timer and (3) Pilot Valves.
A I R D R Y E R M O D U L E Air Dryer: Upper Valves Air Dryer: Upper Valves Upper Valves Switching Purge Valve Valve Desiccant Desiccant Tower Tower Bleed Valve LM01990_902.JPG Descriptions PART DESCRIPTION Switching Valve Redirects the inlet air between each Desiccant Tower.
A I R D R Y E R M O D U L E Air Dryer: Lower Valves, Cycle Timer Air Dryer: Lower Valves, Cycle Timer Upper Valves Cycle Timer Pilot Air In Power Cord Valves (3 valves) LM01990_903.JPG Descriptions PART DESCRIPTION Air In...
A I R D R Y E R M O D U L E Section Overview Section B: Repair ........Section Overview In this Section The following topics are covered in this Section:...
A I R D R Y E R M O D U L E Air Dryer Assembly Replacement Air Dryer Assembly Replacement Air Dryer Assembly Replacement AIR DRYER ASSY. SHOWN REMOVED FROM TP04300 Detailed Bolts (2) Bolts (2) Pneumatics Connection (Air In) Pneumatics Electrical Connections...
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A I R D R Y E R M O D U L E Air Dryer Assembly Replacement Step Action Power down the TP04300 and disconnect power cord. Disconnect the facility air supply from the TP04300. Disconnect the Pneumatics Connections (Air In and Air Out). Remove the electrical connections as follows: Step Action...
A I R D R Y E R M O D U L E Purge Baffle Replacement Purge Baffle Replacement Purge Baffle Replacement Bleed Valve Detailed Brass Fitting Purge Baffle 7/8” Nut Muffler LM01990_909.JPG Procedure To replace the Purge Baffle, use P/N ZZ10130. WARNING WARNINGS 1, 2, 3, 8, 9 in Chapter 1, Safety.
A I R D R Y E R M O D U L E Switching Valve Replacement Switching Valve Replacement Switching Valve Replacement Pneumatic “Quick” Disconnects (4) Detailed Allen Head Screws (2) Allen Head Screws (2) LM01990_905.JPG Procedure To replace the Switching Valve, use P/N VA00650. WARNING WARNINGS 1, 2, 3, 8, 9 in Chapter 1, Safety.
A I R D R Y E R M O D U L E Pilot Valve Replacement Pilot Valve Replacement Pilot Valve Replacement (2) Screws Detailed on each Valve Cycle Timer Valve (removed) Electrical connections Tie Wraps (to Cycle Timer) LM01990_907.JPG Procedure To replace the Pilot Valve, use P/N KK02670.
A I R D R Y E R M O D U L E Cycle Timer Replacement Cycle Timer Replacement Cycle Timer Replacement Main Electrical Detailed Screw (1) Connections Screw (1) Pilot Valves Connections LM01990_908.JPG Procedure To replace the Cycle Timer, use P/N KK02680. WARNING WARNINGS 1, 2, 3, 8, 9 in Chapter 1, Safety.
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A I R D R Y E R M O D U L E Cycle Timer Replacement Step Action Remove the (2) screws securing the Cycle Timer to the frame. Remove the Cycle Timer. Install in the reverse order of the above procedure. 9-14 TP04300 Series Service Manual...
A I R D R Y E R M O D U L E Bleed Valve Replacement Bleed Valve Replacement Bleed Valve Replacement Detailed Switching Valve Pneumatic “Quick” Disconnects Mounting Block Screws (2) Mounting Block Bleed Valve LM01990_910.JPG Procedure To replace the Bleed Valve, use P/N VA00810. WARNING WARNINGS 1, 2, 3, 8, 9 in Chapter 1, Safety.
A I R D R Y E R M O D U L E Purge Valve Replacement Purge Valve Replacement Purge Valve Replacement Detailed Pneumatics “Quick” disconnects (3) Screws (2) Purge Valve LM01990_906.JPG Procedure To replace the Purge Valve, use P/N VA00630. WARNING WARNINGS 1, 2, 3, 8, 9 in Chapter 1, Safety.
A I R D R Y E R M O D U L E Filter Replacement Filter Replacement Procedure To replace the Filter, use P/N ZZ10110. WARNING WARNINGS 1, 2, 3, 8, 9 in Chapter 1, Safety. Step Action Power down the TP04300 and disconnect power cord. Disconnect the facility air supply from the TP04300.
A I R D R Y E R M O D U L E Muffler Replacement Muffler Replacement Procedure To replace the Muffler, use P/N ZZ09300. WARNING WARNINGS 1, 2, 3, 8, 9 in Chapter 1, Safety. Step Action Power down the TP04300 and disconnect power cord. Disconnect the facility air supply from the TP04300.
A I R C H I L L E R M O D U L E Section Overview Section A: Parts Pictorial ........Section Overview In this Section The following topics are covered in this Section:...
A I R C H I L L E R M O D U L E Air Chiller, Left Side View Air Chiller, Left Side View Chiller, Left Side Thermocouples (3) Compressor Condenser Fan Assembly FRONT Electrical Box LM01990_1001.JPG Descriptions PART DESCRIPTION Compressor...
A I R C H I L L E R M O D U L E Air Chiller, Electrical Box Air Chiller, Electrical Box Electrical Box (Cover Removed) Start Relay Terminal Block Start Capacitor Capacitor LM01990_1002.JPG Descriptions PART DESCRIPTION Start Relay when energized, will start the compressor P/N ZZ09620, 50hz Electrical Kit P/N ZZ09790, 60hz Electrical Kit...
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A I R C H I L L E R M O D U L E Air Chiller, Electrical Box PART DESCRIPTION Start Capacitor Compressor Start Capacitor P/N ZZ09620, 50hz Electrical Kit P/N ZZ09790, 60hz Electrical Kit Run Capacitor Compressor Run Capacitor P/N ZZ09620, 50hz Electrical Kit P/N ZZ09790, 60hz Electrical Kit TP04300 Series Service Manual...
A I R C H I L L E R M O D U L E Section Overview Section B: Repair ........Section Overview In this Section The following topics are covered in this Section:...
A I R C H I L L E R M O D U L E Refrigerant Charging Procedure Refrigerant Charging Procedure Procedure WARNING WARNING 10: If service of the Air Chiller Module is required, only a licensed (and/or EPA Certified) refrigeration service person, authorized by the Temptronic Corporation, is qualified to perform any charging or handling of the refrigerants in the System.
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A I R C H I L L E R M O D U L E Refrigerant Charging Procedure Step Action Plug in chiller to allow compressor to suck in remaining refrigerant from tank. Monitor manifold gauges: • close high side port of manifold when high side gauge reaches 0 psig (about 5 to 8 minutes).
A I R C H I L L E R M O D U L E Air Chiller Module Replacement Air Chiller Module Replacement Procedure To remove and replace the Air Chiller Module: Use P/N SA145211, 50hz Air Chiller Assembly Use P/N SA145210, 60hz Air Chiller Assembly WARNING WARNING 12: The Air Chiller Module acts as a counterbalance for the Thermal Head...
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A I R C H I L L E R M O D U L E Air Chiller Module Replacement Step Action At the right side of the unit, remove the bolt (1/4” SHCS) securing the Air Chiller Module to the unit’s frame: High Voltage Terminal Block Bolt (1/4”...
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A I R C H I L L E R M O D U L E Air Chiller Module Replacement Step Action Carefully remove the insulation from the Air In and Air Out lines: NOTE: the insulation may be retained for use during installation of new Air Chiller Module.
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A I R C H I L L E R M O D U L E Air Chiller Module Replacement Step Action Using (2) 7/8” wrenches, disconnect the Air Out line. CAUTION when disconnecting the Air Out Line, DO NOT break the Static Ground Line.
A I R C H I L L E R M O D U L E Compressor Replacement Compressor Replacement Air Chiller Module, Right Side View Compressor Electrical Box Suction Line (4) 1/4” Allen Head Screws Discharge Line LM01990_1011.jpg Procedure To replace the Compressor, use: P/N ZZ09600 (50Hz Compressor) P/N ZZ09570 (60Hz Compressor)
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A I R C H I L L E R M O D U L E Compressor Replacement Step Action Remove the Air Chiller Module from the TP04300. Air Chiller Module Replacement in this Section. Evacuate refrigerants from the system. WARNING WARNING 10: If service of the Air Chiller Module is required, only a licensed (and/or EPA Certified) refrigeration service person,...
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A I R C H I L L E R M O D U L E Compressor Replacement Step Action Unsolder the joint on the Compressor’s discharge line. Cut tie wraps and remove the thermocouple if needed. Unsolder (discharge line) LM01990_1010.jpg Remove the (4) 1/4”...
A I R C H I L L E R M O D U L E Filter Replacement Filter Replacement Filter Replacement Detailed Remove Solder Remove Screw and Clamp Remove Solder LM01990_1016.jpg Procedure To replace the Filter use, P/N ZZ09480. WARNING WARNINGS 1,2,3,7,9 in Chapter 1 Safety.
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A I R C H I L L E R M O D U L E Filter Replacement Step Action Install the new Filter in the reverse order of the above procedure. TP04300 Series Service Manual 10-17...
A I R C H I L L E R M O D U L E Fuse and Fuse Holder Replacement Fuse and Fuse Holder Replacement Fuse Replacement Detailed F1 Electrical Connections (2) 9/16” Nut (obscured from view) Unscrew HERE to extract fuse 9/16”...
A I R C H I L L E R M O D U L E Capacitor Replacement Capacitor Replacement Capacitor Replacement Detailed 5/16” Nut and Clamp Run Capacitor Start Capacitor LM01990_1015.jpg Procedure To replace a Capacitor, use: P/N ZZ09620 (50Hz Electrical Kit) P/N ZZ09790 (60 Hz Electrical Kit) WARNING WARNINGS 1,2,3,7,9 in Chapter 1 Safety.
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A I R C H I L L E R M O D U L E Capacitor Replacement Step Action Remove the Capacitor. Install the new Capacitor in the reverse order of the above procedure. 10-20 TP04300 Series Service Manual...
A I R C H I L L E R M O D U L E Start Relay Replacement Start Relay Replacement Start Relay Replacement Screw (1) Detailed LM01990_102.jpg Procedure To replace the Start Relay, use: P/N ZZ09620 (50Hz Electrical Kit) P/N ZZ09790 (60 Hz Electrical Kit) WARNING WARNINGS 1,2,3,7,9 in Chapter 1 Safety.
Troubleshooting ........Chapter Overview Introduction This Chapter details General Troubleshooting for the TP04300. In this Chapter This Chapter is divided into the following Sections Topic...
T R O U B L E S H O O T I N G Section A: Start Up Troubleshooting ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Symptom Possible Cause Remedy OCM Motherboard faulty • Verify voltages on K8 and SW1: - K8, pin3 (5vdc to 0vdc when SW1 pressed) - SW1, pins 3 & 2 (5vdc to 0vdc when SW1 pressed) •...
T R O U B L E S H O O T I N G Section B: Cooling Troubleshooting ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Symptom Possible Cause Remedy Leak in refrigeration • Check Balance Pressure. Should be approx. 135 to 155 psi. • Replace Air Chiller Module as needed, see Chapter 10, Air Chiller Module Replacement Air Chiller Start/Run Capacitor faulty...
T R O U B L E S H O O T I N G Section C: Remote Communications Troubleshooting ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Symptom Possible Cause Remedy No Power to Comm Board • Verify +5vdc at P1 connection • Verify that W4 in jumped to enable DTE Mode •...
T R O U B L E S H O O T I N G Section F: Error Message Air Open Loop ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Symptom Possible Cause Remedy Relay K4 faulty • Verify K4 LED is illuminated while heating (and OFF while in Error Mode) • Check Voltage: While Heating pins3 and 4 (24 VDC) In Error Mode pins 3 and 4 (0 VDC)
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T R O U B L E S H O O T I N G Section G: Error Message Low Temp. Limit ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Section H: Error Message High Temp. Limit ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Section I: Error Message Main T/C Failure ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Section J: Error Message Low Pressure ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Section K: Error Message Low Flow Limit ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Section L: Error Message High Flow Limit ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Section M: Error Message DUT Sensor Failure ........Symptom Possible Cause Remedy...
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T R O U B L E S H O O T I N G Section N: Error Message DUT Failure ........ATTENTION This Error Message is NOT a failure of the TP04300.
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T R O U B L E S H O O T I N G 11-20 TP04300 Series Service Manual...
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Materials Safety Data Sheets ........MSDS Overview Introduction The Materials Safety Data Sheets (MSDS) for storing, handling, or disposing the following fluids used in the System are presented in the TP04300 Interface &...
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MSDS Overview TP04300 Series Service Manual...
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Drawings ........Drawings Overview In this Chapter The following drawings and schematics are detailed: Drawing/Schematic Drawing #...
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Drawings Overview TP04300 Series Service Manual...
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Revisions Revisions Revisions Zone Zone Zone Description Description Description Date Date Date Approved Approved Approved CBL 24 24 T-T/C CBL 25 24 T-T/C T-T/C SS SHIETH INITIAL RELEASE, ECO 050115 1/12/05 4310 BOARD SET FIX P18 WIRING, ADD NOMENCLATURE TO BOARDS HEAD 2/2/05 KEYPAD...
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Index ........ADVERTENCIA 1-16 dessicant towers 9-3 Dew Point Connect Facility 2-3 Controlled Environment Enclosure.
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I N D E X Model Number iii-xi SV4 7-6 Muffler 9-4 SV5 7-6 SW4 7-6 switching valve 9-5 System Model Number iii-xi nameplate iii-xi T1 8-5 post filter 9-4 technical support iii-x Power Temperature Range. see Specifications. AC Standards 2-3 Temptronic Support iii-x Power Supply 1 8-5 Terminal Block, High Voltage 8-7...
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Model TP04300A X-Stream The High Power ThermoStream Maximize Thermal Capacity and Throughput Easy Touch Screen Control Advanced Thermal Precision Create up to 18 Thermal Profiling Sequences at the Cycling Screen View Real-Time Temperature Status Graphically Document with Color Graphing and Data Logging Features User-Friendly Color Touch Screen Simple, Efficient Setup and Thermal Testing From - 80º...
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Monitor temperature status from across the room Streamlined and Full-Featured Control Flexibility to Adapt to Each Application Perform production testing, design verification and characterization at precise temperature. Create and then view up to 18 ramp/soak/cycle thermal profile routines at one screen. Control via front panel touch screen or remote interface (IEEE-488, RS232, ST/ET/SFF, Ethernet).
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Patented DUT Thermal Precision + / - 0.1ºC precision is provided by Temptronic patented DUT Dual Loop Control™ which performs direct temperature control at the device case. Flexibility to choose from four DUT sensors: new Internal Diode Sensor, Type T or Type K Thermocouple, or 100 ohm RTD. Temperature Sensors at the DUT (Device Under Test) assure optimum thermal accuracy (to within 1.0ºC) and efficiency.
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Automated Data Logging Enhances Documentation Automated data logging is simple from Windows -based menus. ® View and store current and historical data and graphs. Adjust graph axes at the touch screen. Save and recall thermal test routines and test results. Save data logging of up to 75 sets of data (9 hours each) to the hard disk.
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ThermoStream Accessories Expand Thermal Test Capabilities Test Larger PCBs and Modules from -80 º to +225 º C Perform Moisture-free Thermal Testing for Longer Test Times Turnkey ATE Interface ThermoFixture ® — The Complete Thermal Test Solution Test the smallest device to the largest PCB, MCM, hybrid, digital, high speed and high power devices (from RF to microwave to 40 GHz) and assemblies from -80º...
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Precise DUT Thermal Control Greater Thermal Test Accuracy and Reliability Provides a moisture-free environment to -80ºC in a 24/7 test setting with the ThermoStream thermal source. Improves load board performance and reliability, maximizing your investment. Prevents condensation at the test site, which can lead to erroneous test results.
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Applications requiring modification of electrical, thermal or mechanical characteristics should be discussed with the factory for possible accommodation at additional cost. Printed in USA. PART NO. SL10280 R/C Rev. 9/02 Delivering Essential Solutions for the Semiconductor Test Floor Thermal Solutions POSITIONER AND interface solutions www.intest.com www.temptronic.com DOCKING SOLUTIONS www.intest.com...
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TP04300A Mobile Temperature System for testing components, parts, hybrids, modules, subassemblies and printed circuit boards at precise temperature. TEMPERATURE PERFORMANCE AND AIRFLOW CAPACITY Temperature Range: -80° to +225°C (60 Hz System) -75° to +225°C (50 Hz System) Typical Temperature Transition Rate (air) -55°...
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Model TP04300A ThermoStream ® System Specifications ENVIRONMENTAL AND SERVICE FEATURES Over-Temperature Protection +235°C (factory-set) (Also uses user-settable high and low air temperature limit) Mobility 4 swivel caster wheels with locks (10.16 cm (4-inch) diameter, static dissipative); rear handle for ease of transport Refrigerants HCFC-free and CFC-free, non-toxic, non-flammable Noise level...
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TP04300B Mobile Temperature System for testing components, parts, hybrids, modules, subassemblies and printed circuit boards at precise temperature. TEMPERATURE PERFORMANCE AND AIRFLOW CAPACITY Temperature Range: -80° to +225°C (60 Hz System) -75° to +225°C (50 Hz System) TP04300B with Typical Temperature Transition Rate (air) -55°...
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Model TP04300B ThermoStream ® System Specifications Compact Chamber (optional) TP04300B is shown with Turret Assembly connecting Base to Flexible Extender air transfer hose, to ThermoFixture ® thermal enclosure. ThermoFixture, also available from Temptronic, is sold separately. ENVIRONMENTAL AND SERVICE FEATURES Over-Temperature Protection +235°C (factory-set) (Also uses user-settable high and low air temperature limit) Mobility...
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Temptronic Corporation Fax to: 781-688-2301 Attn: Customer Service Dept. Date: ________________________ USER INTERFACE PERFORMANCE REPORT Product Information To suggest any product enhancements or to report problems with the system hardware or System model number _________________ software, please complete all pertinent informa- System serial number ___________________ tion, including any additional information, and...
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Additional Information Please provide a brief description of the suggested enhancement or problem condition: If you are reporting a problem, please provide the following: 1) Describe the operation being performed in detail: 2) Provide keystroke sequence: 3) Describe suspect module or component operation associated with the problem. Name ______________________________ Date ________________________ Company ___________________________...
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Temptronic Corporation Fax to: 781-688-2301 Attn: User Group Administrator Date: ________________________ USER / OWNER REGISTRATION CARD Please help us to keep you up-to-date on all information regarding your system (feature updates, upgrades, and more..) by completing the following form and faxing this to Temptronic at (781) 688-2301. Thank you! User Name ____________________________________________________________ Title: _________________________________________________________________...
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Warranty Temptronic warrants all equipment from its manufacture to be free from defects in materials and workmanship for a period of one year from the date of shipment to the original buyer. The liability under this warranty is limited to replacement parts and labor on equipment when the equipment is returned prepaid to the factory or its authorized service center with prior authorization from Temptronic Corporation, and upon examination by Temptronic Corporation, is determined to be defective.
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