Troubleshooting FRU Replacement High Capacity Coolant

Troubleshooting FRU Replacement High Capacity Coolant

High Capacity Coolant Distribution Unit (CDU) Chiller

Jaguar Platform

Thermo Manual P/N U00918

Rev. 08/03/05

Troubleshooting

FRU Replacement

Table of Contents

Preface

After-sale Support .....................................................................................3

Warranty ..................................................................................................3

Section I Safety

Warnings ..................................................................................................5

EMO Circuit..............................................................................................6

Lockout/Tagout (LOTO) .............................................................................6

Section II Troubleshooting

Error Code Troubleshooting.......................................................................7

VFD Faults ............................................................................................. 21

Monitoring Fluid Loss ............................................................................. 23

Section III FRU List

FRU List ................................................................................................. 25

Section IV FRU Replacement

Electrical Components ........................................................................... 42

Electrical Box Assembly......................................................................... 44

Keypad ................................................................................................... 45

Drier Tube ............................................................................................... 46

Fill Port Screen ...................................................................................... 47

HFE Filter Bag Kit .................................................................................. 48

Pump Inline Drier .................................................................................... 53

Tank Level Switch ................................................................................... 54

Pump ..................................................................................................... 55

Temperature Control Valve Assembly ...................................................... 58

Temperature Control Valve Actuator ........................................................ 60

Water Flow Transducer ........................................................................... 61

HFE Side Temperature Sensor (rtd1) ...................................................... 62

Pressure Transducers ........................................................................... 63

Drip Pan Level Switch Kit ....................................................................... 64

Pressure Regulator ................................................................................. 65

Plumbing, Pressure Regulator to Temperature Control Valve .................. 67

Plumbing, Facility Inlet Pipe ................................................................... 68

H2O Side Temperature Sensor (rtd2) ...................................................... 69

Return Pipe Assembly, Process Flow ..................................................... 70

Supply Pipe Assembly, Process Flow .................................................... 72

PRV Cartridge ........................................................................................ 74

VFD Filter, Contactor, Transformer .......................................................... 75

EMO Thermostat .................................................................................... 76

VFD ........................................................................................................ 77

VFD Settings .......................................................................................... 78

Pump Motor Overloads ........................................................................... 79

Circuit Breaker........................................................................................ 80

Temp Option Board ................................................................................. 81

Chip Replacement .................................................................................. 82

- 1 -

TC-400 Controller .................................................................................... 83

LON Adapter Board ................................................................................. 85

Torque Specification Sheet ...................................................................... 86

Swagelok Tube Fitting Instructions ......................................................... 87

Section V Controller Loops

Main Loop .............................................................................................. 89

Engineering Loop .................................................................................... 90

Factory Reset ......................................................................................... 91

Section VI Drawings

FRU Exploded Views .............................................................................. 92

Flow Diagram ......................................................................................... 95

Electrical Diagram .................................................................................. 96

WARRANTY

- 2 -

Preface

After-sale Support

Thermo Electron Corporation is committed to customer service both during and after the sale. If you have questions concerning the CDU operation, contact our

Sales Department. If your CDU fails to operate properly, or if you have questions concerning spare parts contact our Service Department.

(800) 258-0830

(603) 436-9444

Fax: (603) 436-8411

Before calling, please obtain the following information:

- CDU BOM number

- CDU serial number

- CDU software version

- voltage of power source

The CDU’s BOM and serial number label are located on the label on the fronttop of the CDU. See Service Manual for instructions on how to display the software version.

Warranty

CDUs have a warranty against defective parts and workmanship for 24 months from date of shipment. See back pages for more details.

- 3 -

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- 4 -

Section I Safety

Warnings

DANGER

WARNING

CAUTION

Make sure you read and understand all instructions and safety precautions listed in this manual before installing or operating your CDU. If you have any questions concerning the operation of your CDU or the information in this manual, contact our Sales Department for assistance.

DANGER indicates an imminently hazardous situation which, if not avoided, will result in serious injury or death. This signal word is limited to the most extreme situations.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in serious injury or death.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

Performance of installation, operation, or maintenance procedures other than those described in this manual may result in a hazardous

situation and may void the manufacturer’s warranty.

Transport the CDU with care. Sudden jolts or drops can damage the

CDU.

Do not attempt to defeat any of the interlock switches or safety features built into the CDU.

Observe, and never remove, all warning labels.

Never operate damaged or leaking equipment.

Never operate the CDU without cooling fluid in the fluid reservoir.

Process fluid are subject to environmental regulatory restrictions. Do not dispose into the environment. In the United States use proper OSHA approved location for disposal.

Use remote lockout tag-out procedures prior to servicing the CDU. Make sure the CDU is off before connecting or disconnecting the power cord or other cables.

Always turn off the CDU and disconnect the power cord from the power source before performing any service or maintenance procedures, or before moving the CDU.

Always empty the fluid reservoir before moving the CDU.

Never operate equipment with damaged power cords.

Refer service and repairs to a qualified technician.

- 5 -

EMO Circuit

Each of the following safeties is part of the test system Emergency Off (EMO) circuit. The tripping of either of these safeties will cause power to be dropped to the CDU by the test system. The EMO circuit should not exceed 10A @

24VDC.

High Air Temperature (TSH-101)

This safety opens the EMO circuit when the air temperature safety switch detects a temperature inside the CDU greater than 70°C. The temperature switch is self-resetting at a temperature of 54°C or below.

Lockout/Tagout (LOTO)

Before performing Chiller maintenance, the energy sources associated with the

Chiller system must be lockout and tagged out (LOTO).

Since the CDU itself has no electrical LOTO, lock out power remotely.

Electrical LOTO can be provided by:

Disconnecting main power at the facility power source prior to the system controller cabinet.

The unit does not provide LOTO for the facility water flow. An external usersupplied device is required.

In addition, follow all local facility LOTO directives.

- 6 -

Error Code

Troubleshooting

Section II Troubleshooting

Also see Monitoring

Fluid Loss on page 23.

54

91

83

- 7 -

48

91

83

50.

- 8 -

NOTE: I If a pump shut down due to an overload condition than the corresponding MOL error message will also be on. Otherwise, measure the amperage of each pump to determine if it is running.

21

63

- 9 -

55

91

83

- 10 -

54

91

83

- 11 -

Also see Monitoring

Fluid Loss on page 23.

60

66

91

83

- 12 -

60

91

83

- 13 -

64

91

83

- 14 -

91

83

- 15 -

21

- 16 -

69

65

65

- 17 -

83

91

- 18 -

82

82

83

- 19 -

83

91

75.

- 20 -

- 21 -

- 22 -

Monitoring for Fluid

Loss

Each line on the Reservoir Gauge represents approximately 1/10 of a gallon.

On a routine basis check and record the fluid level. If the fluid level is dropping at a rate faster than indicated by the specification then perform the following:

1. Ensure the Tank Fill Port and the Tank Auxiliary Port Cap are properly installed and on hand tight.

2. Check all sanitary gaskets to insure that they are properly installed and

are on according to the Torque Specification Sheet on page 86.

3. Look for signs of a leak at all connections and solder joints.

4. If none of the above yield any results, use a Halogen Leak detector on each connection and joint.

5. Check for leaks at the Test Equipment per your procedures.

Reservoir Gauge

- 23 -

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- 24 -

Description

SYS HFE -30CDU

FRU CDU RETURN PIPE ASSY

FRU CDU FILTER BAG

FRU CDU FILTER O-RING

FRU CDU PUMP W/ GASKETS

FRU CDU PUMP SUCT LINE

FRU CDU INLINE DRIER

FRU CDU SUPPLY PIPE ASSY

FRU CDU FILL PORT SCREEN

FRU CDU PRESS REGULATOR

FRU CDU FLOW XDUCER

FRU CDU TEFLON PASTE

FRU CDU FACIL INLET PIPE

FRU CDU VALVE W/ACTUATOR

FRU CDU VLV ACTUATOR ONLY

FRU CDU INSUL TAPE

FRU CDU TANK LVL SWITCH

FRU CDU PRESS XDUCER

FRU CDU DRIP PAN SWITCH

FRU CDU RTD H2O SIDE

FRU CDU DRIER TUBE

FRU CDU RTD HFE SIDE

FRU CDU FILL PORT CAP

FRU CDU FILL PORT O-RING

FRU CDU PETES PLUG

FRU CDU CIRCUIT BREAKER

FRU CDU CONTACTOR

FRU CDU TRANSFORMER

FRU CDU VAR FREQ DRIVE

FRU CDU LON ADAPT BOARD

FRU CDU TEMP OPTION BRD

FRU CDU VFD FILTER

FRU CDU EMO THERMOSTAT

FRU CDU 1.5" SANIT GASKT

FRU CDU 2" SANIT GASKET

FRU CDU 1.5" SANIT CLMP

FRU CDU 2" SANIT CLMP

FRU CDU TC400 CNTRL BRD

FRU CDU EPROM SOFTWARE

FRU CDU PIPING TO MOD VLV

FRU PRV CARTRIDGE

FRU KEYPAD

FRU CDU DRIP PAN PLUG

FRU CDU ELECT BOX ASSY

FRU VFD BOX ASSY

FRU MOTOR OVERLOAD

093497

087774

093388

087775

087782

087820

087777

093362

087821

093397

093363

093384

087835

087836

087779

087837

Thermo

603099991707

093354

093355

093385

093356

093542

093449

093543

093386

093359

093544

093387

093496

087786

087787

087838

087788

093380

093381

093382

093383

087790

087791

093499

015779

015781

093498

087839

087840

087841

Section III FRU List

360-900-53

360-900-13

360-900-14

360-900-15

360-900-16

360-900-54

360-900-18

360-900-19

360-900-55

360-900-21

360-900-22

360-900-23

360-900-74

360-900-75

360-900-26

360-900-76

Teradyne

873-612-00.

360-900-00

360-900-01

360-900-02

360-900-03

360-900-70

360-900-05

360-900-71

360-900-07

360-900-08

360-900-72

360-900-10

360-900-52

360-900-28

360-900-29

360-900-77

360-900-31

360-900-32

360-900-33

360-900-34

360-900-35

360-900-38

360-900-39

360-900-59

360-900-41

360-900-42

360-900-57

360-900-79

360-900-80

360-900-81

- 25 -

360-900-72 Transducer,Water Flow

360-900-13 Valve Actuator Only

360-900-15 Tank Level Switch

- 26 -

360-900-54 Sensor Kit, Drip Pan Level

360-900-18 RTD H2O Side

360-900-55 RTD HFE Side

- 27 -

360-900-26 Transformer

360-900-77 VFD Filter

360-900-16 Pressure Transducer

- 28 -

360-900-74 Circuit Breaker

360-900-75 Contactor

360-900-76 Var Freq Drive

360-900-80 VFD Box Assembly

360-900-81 Motor Overload

NOTE: The VFD box,

360-900-80, consists of a VFD, two motor overloads, and the associated wiring.

- 29 -

360-900-28 LON Adapter Board

360-900-29 Temp Option Board

360-900-31 EMO Thermostat

- 30 -

360-900-79 Electrical Box Assembly

360-900-38 TC400 Control Board

360-900-00 Return Pipe Assembly, Process Flow

- 31 -

360-900-01 Filter Bag Kit

360-900-03 Pump with Gaskets

360-900-70 Pump Suction Line, with Gaskets

360-900-71, Supply Pipe Assembly

- 32 -

360-900-08 Pressure Regulator

360-900-52 Facility Inlet Pipe

360-900-53 Valve Assembly, Temperature Control

- 33 -

360-900-19 Drier Tube

360-900-32 Gasket 1½" / 360-900-33 Gasket 2"

360-900-34 Clamp, Sanitary Fitting 1½" / 360-900-35 Clamp, Sanitary Fitting 2"

- 34 -

360-900-23 Petes Plug

360-900-41 Pressure Relief Valve Cartridge

360-900-22 Service Kit, Fill Port Cap

- 35 -

360-900-02 O-ring, Filter Housing

360-900-07 Fill Port Screen

360-900-10 Teflon

®

Paste

- 36 -

360-900-14 Tape, Insulating

360-900-57 Fitting, Drip Pan Plug

360-900-21 Fill Port Cap

- 37 -

360-900-59 Piping to Mod Valve

360-900-05 Pump Inline Dryer

360-420-00 Programmable Chip Extractor

- 38 -

360-900-42 Keypad

- 39 -

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- 40 -

CAUTION

Section IV FRU Replacement

For personal safety and equipment reliability, the following procedures should only be performed by a qualified technician. The following steps assume the technician is knowledgable of all Swagelok initial tightening and retightening procedures. Contact our Service Department for assistance.

WARNING

Contact with hazardous voltage inside the chiller can cause severe injury of death. Turn off and Lockout/Tagout (LOTO) power before servicing. Have a qualified technician verify that line voltage is no longer present within the unit after performing a LOTO procedure and before working on system.

CAUTION

Performance maintenance and service procedures other than those described in this manual may result in a hazardous situation.

- 41 -

Electrical Components

To access any of these electrical components you must remove the control box assembly and the side panel.

Circuit Breaker see page 78

Temp Option Board

seepage 81

TC-400 Controller Board

see page 83

Programmable Chip

see page 82

LON Adapter

Board see

page 85

VFD Filter see

page 75

EMO Thermostat

see page 76

Contactor see page 75

Transformer see

page 75

Bottom View (See Next Page)

- 42 -

Device

Coolant RTD

Facility RTD

Connector Action

J102 Check resistance pins 1 and 7

P103

Level Switches J1

Check resistance pins 1 and 7

Values

100 Ohms @ 0°C

~110 Ohms @ room temp

100 Ohms @ 0°C

~110 Ohms @ room temp

Check resistance

Pins 1 and 2 warning

Pins 3 and 4 shut down

0 Ohms = closed

Ohms = open

Drip Pan

Switch

Facility Flow

Transducer

Motor Valve

J2

J4

J5

Pressure

Transducers

J6

Check resistance

Pins 1 and 2

0 Ohms = closed

Ohms = open

See chart below Check Voltage

Pins 1 and 2

Measure Voltage

Pins 1 and 2

100% open => 9.5 VDC

0% open = < 6.0 VDC

Measure voltage 37.5 psi per volt plus 0.5 volts

Pins 2 and 3 supply(example - 150 psi = 4.5 volts)

Pins 5 and 6 return

200.00

150.00

100.00

50.00

5 10 15 20

Flow Rate (gpm)

25 30 35

- 43 -

ElectricalBox Assembly

(360-900-79)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

#2 Philips Head Screwdriver

11/32" wrench

Wiring Diagram

Procedure:

1. Using #2 Philips Head, remove the 4 screws securing the electrical box assembly to the front of the unit.

2. Remove the single screw securing the base of the control box to the unit's midframe.

3. Remove the 8 connectors at the bottom of the control box.

4. At the pump motor, remove the wiring running from the base of the control box.

5. Remove the 11/32 nut securing the ground wire at the rear of the unit.

6. Slide the control box assembly out from the unit.

7. Swap out the LON Adapter board from the replaced assembly into the new

assembly, see page 85.

8. To reinstall, reverse the procedure.

Torque Control Box to Mid Pan, Bottom 14 - 16"-lbs

Torque Control Box to Mid Pan, Top 24 - 28"-lbs

Torque Control Box Assembly to Sides 24 - 28"-lbs

9. Rewire according to the wiring diagram.

10. Return the replaced assembly to Thermo Electron.

- 44 -

360-900-42 Keypad

Tools Required:

Screwdriver

11/32" wrench

Procedure:

1. Remove the 4 screws securing the keypad panel to the front of the unit.

2. Disconect ribbon cable from control board.

3. Remove the 11/32 grounding nut.

4. Peal the keypad off the panel.

5. When reinstalling, tighten gounding nut 14-16"-lbs.

- 45 -

Drier Tube

(360-900-19)

When the cartridge color-change feature (blue to pink) reaches the bottom of the top cap, the dryer tube needs changing.

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

Tywrap cutter/scissors

Procedure:

1. Remove the top and bottom tubes from the dryer tube nipples.

2. Cut the ty-wrap.

3. Reverse the procedure to install a new dryer tube.

4. Once the unit is restarted check for leaks.

- 46 -

Fill Port Screen

(360-900-07)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

None

Procedure:

1. Remove the fill port cap by turning counterclockwise.

2. Remove the screen.

3. Replace the screen.

4. Reinstall the fill cap.

5. Once the unit is restarted check for leaks.

- 47 -

HFE Filter Bag Kit

(360-900-01)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

None

Procedure:

1. Crack open the reservoir fill to allow air into the tank.

2. Locate and then loosen the black knob on the clamp at the top of the filter housing.

3. Remove the clamp. Note how the "T" is locked into position on the clamp.

T

- 48 -

4. Remove the lid and gasket.

5. Remove the spacer, handle up.

- 49 -

6. Pull out the old bag to remove it.

7. Install a new bag. Ensure that the paper tag is removed from the bag.

- 50 -

8. Reinstall the spacer, handle up.

9. Replace the lid gasket and reinsall the lid.

- 51 -

10. To reinstall a new bag push down on the lid and gasket when tightening the black knob. Hand tighten until the gap matches the other two gaps.

11. Once the unit is restarted check for leaks.

12. Ensure the LED and error message on the controller are both extinguished.

- 52 -

Pump Inline Drier

(360-900-05)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

9/16" wrench

Procedure:

For easier access to the assembly remove the unit from the cabinet.

1. Note orientation of dryer assembly.

2. Crack open the reservoir fill to allow air into the tank.

3. Use the 9/16" wrench to remove the Swageloks securing the dryer assembly to the unit. To make removing the outer Swagelok easier, bend the inner dryer line down to get it out of the way.

Inner Swagelok

Outer Swagelok

Top View

4. Undo the two Velcro straps and remove the dryer assembly.

Dryer

5. Install a new dryer assembly. Secure the Velcro straps first to prevent bending the lines.

6. Connect the two ¼" lines and tighten the Swageloks per the tightening procedure on page 87.

7. Once the unit is restarted check for leaks.

- 53 -

Tank Level Switch

(360-900-15)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

Adjustable wrench

Tywrap cutter/scissors

Procedure:

1. For easier access to the switch, remove the electrical box assembly, see

page 44.

2. Undo the electrical "D" connector on the rear of the unit.

3. Remove the ty wraps.

4. Undo the green plastic fitting and remove the switch assembly from the reservoir.

5. To reinstall a new assembly reverse the procedure. NOTE: To prevent cross threading, install the new assembly into the reservoir only hand tight.

6. Once the unit is restarted check for leaks.

7. Ensure the LED and error message on the controller are both extinguished.

- 54 -

Pump (360-900-03)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

CAUTION Crack the fill cap to relieve any tank/system pressure.

Tools Required:

11/16" wrench

7/16" wrench

1/2" wrenchet.

Procedure:

For easier access to the pump remove the unit from the cabin

1. Drain the water. Refer to Teradyne Service Documentation for proper procedure.

2. Remove the electrical box assembly, see page 44.

3. Remove sanitary clamps from both suction and discharge lines to the plate exchanger.

- 55 -

4. Using a 11/16" wrench, remove the fitting from the pump's drain line.

5. Using a 7/16" wrench, remove the 6 bolts securing the pump plate to the unit.

CAUTION

6. Remove the pump and plate from the unit.

The pump weighs at least 80 pounds.

7. Using a 1/2" wrench, remove the nuts and washers securing the pump to the pump plate.

8. When reinstalling a new pump do not tighten any of the nuts, bolts, or clamps until all plumbing lines are properly aligned. Also, use new gaskets when reinstalling the sanitary clamps.

9. Reorrect pump discharge line to pump. Recheck the alignment.

- 56 -

10. Using a 11/16" wrench, install the fitting from the pump's drain line.

11. Install the sanitary clamps on the pump suction and discharge line.

12. Tighten all connections.

Torque Pump to Pump Plate

Torque Pump Plate to Case

Torque Sanitary Fittings

13. Reconnect all the wiring.

100-110"-lbs

75"-lbs

25"-lbs

Torque Pump Motor Ground Wires (3) 24 - 28"-lbs

14. Reinstall the electrical box assembly, see page 44.

15. Once the unit is restarted check for leaks.

16. Return the replaced pump to Thermo Electron.

- 57 -

Temperature Control

Valve Assembly

(360-900-53)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

1 3/4" wrench

Two 1 1/4" wrenches

Copper tubing cutting tool

Tywrap cutter/scissors

Tape, Insulating

Procedure:

For easier access to the valve remove the unit from the cabinet.

1. Drain the water. Refer to Teradyne Service Documentation for proper procedure.

2. Remove the insulation around the valve.

3. Use a 1 3/4" wrench to disconnect the Swageloks.

4. Unplug the 6-pin connector and disconnect the ground wire.

5. Open the clamp securing the valve to the unit.

- 58 -

6. To reinstall a new valve first connect the 1 3/4" Swageloks - finger tight.

7. Install the clamp.

8. Tighten the two Swageloiks. Refer to the Swagelok Installation on page 87.

Torque clamp 50"-lbs.

9. Reinstall the 6-pin connector and the ground wire.

Torque ground wire 24 - 28"-lbs.

10. Once the unit is restarted check for leaks.

11. Ensure the LED and error message on the controller are both extinguished.

12. Install insulation.

- 59 -

Temperature Control

Valve Actuator

(360-900-13)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

1 5/8" wrench

Tape, Insulating

Procedure:

For easier access to the actuator remove the unit from the cabinet.

1. Drain the water. Refer to Teradyne Service Documentation for proper procedure.

2. Use the 1 5/8" wrench to disconnect the actuator from the valve.

3. Unplug the 6-pin connector and disconnect the ground wire.

4. Reverse the procedure to install the actuator. Torque actuator to 20-25"-lbs.

5. Once the unit is restarted check for leaks.

6. Install insulation.

- 60 -

Water Flow Transducer

(360-900-72)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

Adjustable wrenches

Teflon Sealant (FasSeal-ATS

TM

)

Insulating Tape

Procedure:

For easier access to the assembly remove the unit from the cabinet.

1. Drain the water. Refer to Teradyne Service Documentation for proper procedure.

2. Remove the insulation.

3. Use a wrench to hold the bottom fitting in place and a second wrench to undo the top hose.

4. Remove the bottom Swagelok.

5. Unplug the wiring from under the electrical box.

6 The new flow transducer can be installed in either direction.

7. Connect both fittings, hand tight. NOTE: Use supplied thread sealant on upper connection.

8. Tighten the fittings, refer to the Swagelok Installation Sheet on page 87.

9. Connect the wiring to the control box.

10. Once the unit is restarted check for leaks.

11. Ensure the LED and error message on the controller are both extinguished.

12. Install insulation.

- 61 -

HFE Temp Sensor (rtd1)

(360-900-55)

Tools Required:

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

1/2" wrench

Tywrap cutters/Scissors

Procedure:

1. Use the 1/2" wrench to disconnect the sensor.

2. Slide the sensor down and through the unit's midpan.

3. Unplug the sensor from below the control box.

4. Reverse procedure to install new sensor. Refer to the Swagelok Installation

Sheet on pages 87.

5. Once the unit is restarted check for leaks.

- 62 -

Pressure Transducers

(360-900-16)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

5/8" wrench

Tywrap cutters/Scissors

Procedure:

1. Unsnap the black plastic cap(s) on the transducer(s).

2. Use the 5/8" wrench to disconnect the transducer(s).

3. Unplug the wiring.

4. Reverse the procedure to install a new transducer. To tighten the fittings,

refer to the Swagelok Installation Sheet on pages 87.

5. Once the unit is restarted check for leaks.

- 63 -

Drip Pan Level

Switch Kit

(360-900-54)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

3/8" wrench

Tywrap cutters/Scissors

Procedure:

1. Remove the 3/8" nut securing the kit to its bracket.

2. Undo wiring from below the electrical box.

3. To reinstall, reverse the procedure.

- 64 -

Pressure Regulator

(360-900-08)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

Two 2 1/16" wrenches or adjustable wrenches

1/8" diameter test probe (Peterson Equip. Co. Inc. #500 Gauge Adapter or equivalent).

Insulating Tape

Procedure:

For easier access to the assembly remove the unit from the cabinet.

1. Drain the water. Refer to Teradyne Service Documentation for proper procedure.

2. Remove insulation around the regulator.

3. Loosen top union fitting.

4. Undo bottom union fitting.

5. Undo top union fitting.

6. When installing new regulator and washers ensure the arrow on the side of the regulator points down.

7. Install both unions, hand tight.

8. Tighten both unions, one full turn past hand tight.

9. Install new insulation.

10. Once the unit is restarted check for leaks.

11. Ensure the LED and error message on the controller are both extinguished.

12. Adjust the pressure differential, see next page.

- 65 -

Using the test probe, verify the differential pressure across the temperature control valve using the two pressure test ports (Petes Plugs) PP-102 and

PP-103.

With the unit off and facility water on, measure the pressure at PP-102. The pressure should match the facility water pressure. NOTE: If the pressure is 0 ensure that the facility water is on and that the facility supply valve is open.

Next measure the pressure at PP-103. The difference between the two readings should be 30 - 33 PSI.

PP-102

PP-103

If adjustment is necessary loosen the locknut on the pressure regulator and then turn the adjustment bolt clockwise to increase the pressure, counterclockwise to decrease the pressure. Tighten the locknut.

Pressure Regulator

13. Install insulation.

- 66 -

Plumbing, Pressure Regulator to Temperature

Control Valve (360-900-59)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

Two 2 1/16" wrenches or adjustable wrenches

One 1 3/4" wrench or adjustable wrench

Insulating Tape

Procedure:

For easier access to the assembly remove the unit from the cabinet.

1. Drain the water. Refer to Teradyne Service Documentation for proper procedure.

2. Remove insulation around the connections.

3. Undo the bottom union fitting on pressure regulator.

4. Use a 1 3/4" wrench to disconnect the Swagelok.

5. To reinstall tighten union, one full turn past hand tight.

6. Tighten the fitting, refer to the Swagelok Installation Sheet on page 87.

7. Once the unit is restarted check for leaks then install insulation.

- 67 -

Facility Inlet Pipe

(360-900-52)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

Two 2 1/16" wrenches or adjustable wrenches

One 1 3/4" wrench or adjustable wrench

Insulating Tape

Procedure:

For easier access to the assembly remove the unit from the cabinet.

1. Drain the water. Refer to Teradyne Service Documentation for proper procedure.

2. Remove insulation.

3. Undo top union fitting on pressure regulator.

4. Undo the u-bolts securing the plumbing to the bottom of the unit's midpan.

5. To reinstall, reverse the procedure.

6. Tighten u-bolts until split washers on both sides are flat.

7. Once the unit is restarted check for leaks then install insulation.

- 68 -

H2O Side

Temperature Sensor

(rtd2) (360-900-18)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

Tywrap cutters/Scissors

Insulating Tape

Procedure:

1. Remove the electrical box assembly, see page 44.

2. Remove the insulation covering the sensor.

3. Cut the aluminum tape securing the sensor to the facility line.

4. Undo the wiring from below the electrical box.

5. Attach new sensor with hose clamp.

6. Install new tape and insulation.

7. Connect wiring.

8. Ensure the LED and error message on the controller are both extinguished.

9. Install insulation.

- 69 -

Return Pipe Assembly, Process Flow

(360-900-00)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

One 1/2" wrench or adjustable wrench

One 9/16" wrench or adjustable wrench

One 5/8" wrench or adjustable wrench

Procedure:

1. Drain the HFE. Refer to Teradyne Service Documentation for proper procedure.

2. Unsnap the black plastic cap on the transducer

3. Use the 5/8" wrench to disconnect the transducer.

4. Use the 1/2" and 9/16" wrenchs to disconnect the two process flow lines.

- 70 -

5. Use the 1/2" wrench to disconnect the process lines from the dryer.

6. Undo the u-bolts securing the line to the unit.

7. Undo the sanitary fitting at the tank.

8. Reverse the procedure to install a new line. Tighten all connection. Refer to the Swagelok Installation on page 87.

Sanitary Fitting

U-bolts

25"-lbs.

Hand tighten and 3 turns

9. Once the unit is restarted check for leaks.

- 71 -

Supply Pipe Assembly, Process Flow

(360-900-71)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

One 1/2" wrench or adjustable wrench

One 9/16" wrench or adjustable wrench

One 5/8" wrench or adjustable wrench

Procedure:

1. Drain the HFE. Refer to Teradyne Service Documentation for proper procedure.

2.Unsnap the black plastic cap on the transducer

3. Use the 5/8" wrench to disconnect the transducer.

4. Use the 1/2" wrench to disconnect the temperature sensor.

5. Use the 1/2" and 9/16" wrenchs to disconnect the two process flow lines.

- 72 -

6. Undo the u-bolts securing the line to the unit.

7. Undo the sanitary fitting at the heat exchanger.

8. Reverse the procedure to install a new line. Tighten all connection. Refer to the Swagelok Installation on page 87.

Sanitary Fitting 25"lbs.

U-bolts

9. Once the unit is restarted check for leaks.

Hand tighten and 3 turns

- 73 -

PRV Cartridge (360-900-41)

Tools Required:

Adjustable wrench

Two screwdrivers

Procedure:

1. Loosen locknut and turn adjusting screw counterclockwise to remove the spring tension.

2. Remove the bonnet using the adjustable wrench.

3. Remove the cartridge using two screwdrivers as levers.

4. When installing new cartridge ensure the o-rings and washers are properly installed.

Washer

O-rings

- 74 -

VFD Filter (360-900-77)

Contactor (360-900-75)

Transformer(360-900-26)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

McMaster Carr 8554A26, or equivalent torque screw driver

Wiring Diagram

Procedure:

1. Remove the electrical box assembly, see page 44.

2. Remove wiring and screws from transformer and contactor to access the RFI.

3. Remove wiring and screws securing RFI to the unit.

4 To reinstall components, reverse the procedure.

Torque Transformer Mounting Screws 14 - 16"-lbs

Torque Contactor/RFI Mounting Screws 24 - 28"-lbs

5. Reconnect wiring, refer to wiring diagram.

Torque RFI Wiring

Torque RFI Ground Wire

15½"-lbs

22 - 26"-lbs

Torque RFI Filter Wires to Contactor 25"-lbs

6. Ensure the LED and error message on the controller are both extinguished.

- 75 -

EMO Thermostat

(360-900-31)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

#6 Wrench or adjustable wrench

Loctite

®

threadlocker or equivalent

Procedure:

1. Remove the electrical box assembly, see page 44.

2. Remove the control box assembly side panel.

3. Locate the thermostat and remove the wiring and #6 nut.

4. To reinstall reverse the procedure. Hand-tight nut and secure with Loctite

®

.

- 76 -

Var Freq Drive VFD

(360-900-76)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

McMaster Carr 8554A26, or equivalent torque screw driver

Wiring Diagram

Procedure:

1. Remove all wiring to the VFD.

2. Remove the four screws securing the VFD to the box assembly.

3. When installing, torque all four screws to 24 - 28"-lbs.

4. Reconnect all wiring. Refer to wiring diagram.

Torque VFD Wire Connection Screws

Torque VFD Ground Nut

16 - 19"-lbs

14 - 16"-lbs

Torque VFD Signal Wires

Torque VFD Jumper Wires

Torque VFD Power Wires

Torque VFD Controller Panel

4.4 - 7"-lbs

4.4 - 7"-lbs

16 - 19"-lbs

10 - 12"-lbs

5. Calibrate the VFD and install default settings, see next page.

6. Check for error codes on the VFD and controller.

- 77 -

VFD Settings

Viewing and Editing Parameter Steps.

1. When Power is applied, the last user-selected Display Group parameter number is briefly displayed with flashing characters. The display then defaults to that parameter’s current value.

2. Press Esc once to display the Display Group parameter number shown on powerup. The parameter number will flash.

3. Press Esc again to enter the group menu. The group menu letter will flash.

4. Press the Up Arrow or Down Arrow to scroll through the group menu (d, P and A).

5. Press Enter or Sel to enter a group. The right digit of the last viewed parameter in that group will flash.

6. Press the Up Arrow or Down Arrow to scroll through the parameters that are in the group.

7. Press Enter or Sel to view the value of a parameter. If you do not want to edit the value, press Esc to return to the parameter number.

8. Press Enter or Sel to enter program mode to edit the parameter value. The right digit will flash and the Program LED will illuminate if the parameter can be edited.

9. Press the Up Arrow or Down Arrow to change the parameter value. If desired, press Sel to move digit to digit or bit to bit. The digit or bit that you can change will flash.

10. Press Esc to cancel a change. The digit will stop flashing, the previous value is restored and the Program LED will turn off.

Or

Press Enter to save a change. The digit will stop flashing and the Program LED will turn off.

11. Press Esc to return to the parameter list. Continue to press Esc to back out of the programming menu. If pressing Esc does not change the display, then d001

[Output Frequency] is displayed. Press Enter or Sel to enter the group menu.

Settings

Display Group and Number Setting

P031

P033

208

29.4

P036

P038

A051

A052

2

2

7

5

- 78 -

Pump Motor Overloads

(360-900-81)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

McMaster Carr 8554A26, or equivalent torque screw driver

Wiring Diagram

Procedure:

1. Remove all wiring to the overload.

2. Remove the two screws securing the overload to the box assembly.

3. When installing, torque all screws to 24 - 28"-lbs.

4. Reconnect all wiring. Refer to wiring diagram.

5. Check for error codes on the controller.

- 79 -

Circuit Breaker

(360-900-74)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

Tools Required:

McMaster Carr 8554A26, or equivalent torque screw driver

Wiring Diagram

Procedure:

1. Remove the electrical box assembly, see page 44.

2. Remove the four nuts securing the circuit breaker to the unit.

3. Remove all wiring to the circuit breaker.

Spring

4. Press the spring on the circuit breaker to separate it from the bracket.

5. To reinstall, reverse the procedure.

Torque Circuit Breaker 11/32 Mounting Nuts

6. Reinstall wiring, refer to wiring diagram.

14 - 16"-lbs

Torque Circuit Breaker Wire Connections 20"-lbs

- 80 -

Temp Option Board

(TC-400 to LON Adapter)

(360-900-29)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

WARNING

Use proper ESD (Electro Static Discharge) procedures when handling

the chip and controller. Typically a grounded wrist strap is used to ground the individual so static discharge is released prior to and during handling.

Tools Required:

Small pair of needle nose pliers

Wiring Diagram

Procedure:

1. Remove the electrical box assembly, see page 44.

2. Remove wiring

3. Using the pliers, press the "ears" on the four corners of the board and pull it out.

4. Snap new board back into position.

5. Install wiring, refer to wiring diagram.

6. Ensure the LED and error message on the controller are both extinguished.

- 81 -

Chip Replacement

(390-900-39)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

WARNING

Use proper ESD (Electro Static Discharge) procedures when handling

the chip and controller. Typically a grounded wrist strap is used to ground the individual so static discharge is released prior to and during handling.

Tools Required

Plastic Leaded Chip Carrier (PLCC) extraction tool (not supplied) or equivalent.

Procedure

1. Remove electrical box assembly, see page 44.

2. The chip is located on the TC-400 Control Board, beneath the Communications Board. Remove the Communications Board.

3. Remove old programmed chip with the

PLCC extraction tool. If one is not available a suitable tool is available from

Thermo under part number 082166.

Additional instructions are provided with the tool.

4. Insert new programmed chip by placing the chip over the socket with the orientation dot on the chip aligned with the orientation arrow on the board. Note that sometimes dot may be covered by a label, see below. Do not rely on the chip label since its orientation can be random. You may also notice that a corner of the chip and socket are slightly flattened. Press chip onto the socket by applying equal pressure to the chip until the chip completely snaps into the socket.

5. Replace the Communications Board and the control box assembly.

6. Start the unit and skip through any error messages using the controller’s

NEXT key. (Error 3 may appear when the new chip is powered up for the first time.)

7. Unit must be recalibrated for proper operation. Refer to Teradyne Service

Documentation for proper procedure.

- 82 -

TC-400 Control Board

(360-900-38)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

WARNING

Use proper ESD (Electro Static Discharge) procedures when handling

the chip and controller. Typically a grounded wrist strap is used to ground the individual so static discharge is released prior to and during handling.

Tools Required:

Small pair of needle nose pliers

Screwdriver

Phillips Screwdriver

¼" Nut driver

Plastic Leaded Chip Carrier (PLCC) extraction tool (not supplied) or equivalent.

Wiring Diagram

Procedure:

1. To allow the panel to fold down, remove the 4 screws securing the keypad panel to the front of the unit.

- 83 -

2. Remove all wiring to the board.

3. Remove the Temp Option Board and Programmable Chip, see previous two pages.

4. Undo the four corner mounting nuts securing the board to the unit.

TB2

TB1

TB4

5. To reinstall, reverse the procedure. Refer to wiring diagram. NOTE: Ensure jumper settings on new board match the settings on the wiring diagram.

Torque mounting nuts

Torque 1TB/2TB Wires

Torque 4TB Wires

6 - 8"-lbs

8 -10"-lbs

4.4 - 7"-lbs

6. Ensure the error message on the controller is extinguished.

- 84 -

LON Adapter Board

(360-900-28)

WARNING

Turn off and Lockout/Tagout (LOTO) power before servicing.

WARNING

Use proper ESD (Electro Static Discharge) procedures when handling

the chip and controller. Typically a grounded wrist strap is used to ground the individual so static discharge is released prior to and during handling.

Tools Required:

Small pair of needle nose pliers

Wiring Diagram

Procedure:

1. Remove the SMC Rider Board.

2. Remove the wiring to the LON.

3. Press the "ears" on all four corners of the board and pull it out.

4. To reinstall, reverse the procedure. Refer to wiring diagram.

5. Install the SMC Rider Board.

6. Calibrate the new board. Refer to Teradyne Service Documentation for proper procedure.

7. Ensure the LED and error message on the controller are both extinguished.

- 85 -

Torque Specification Sheet

Mechanical Assemblies

Pump Plate to Case

Pump to Pump Plate

Hose Clamps

Unions (Pressure Regulator)

CAM Lock Fittings

Sanitary Fittings

Facility Water Outlet Assembly

75"-lbs

100-110"-lbs

50"-lbs

One full turn past hand tight

70'-lbs

25"-lbs

75"-lbs

Process side U-bolts ¼-20 (084302)

Facility side U-bolts 3/8-16 (084292)

Temperature control valve actuator

Electrical Assemblies

Hand tighten and then 3 turns

Hand tighten until split washers are flat on both sides

20-25"-lbs

For phillips head screws we recommend using a McMaster Carr 8554A26, or equivalent

Float Switch

Motor Valve Ground Wire

Pump Motor Ground Wires (3)

Control Box Assembly to Mid Pan, Bottom

Control Box Assembly to Mid Pan, Top

Control Box Assembly to Sides

Contactor Connecting Screws

VFD Mounting Screws

Hand tight

24 - 28"-lbs

24 - 28"-lbs

14 - 16"-lbs

24 - 28"-lbs

24 - 28"-lbs

25"-lbs

24 - 28"-lbs

VFD Wire Connection Screws

VFD Ground Nut

VFD Signal Wires

VFD Jumper Wires

VFD Power Wires

VFD Controller Panel

Control Board Mounting #4 Nuts

16 - 19"-lbs

14 - 16"-lbs

4.4 - 7"-lbs

4.4 - 7"-lbs

16 - 19"-lbs

10 - 12"-lbs

6- 8"-lbs

1TB Wires

2TB Wires

4TB Wires

Key Pad Ground 11/32 Nut

8 -10"-lbs

8 -10"-lbs

4.4 - 7"-lbs

14 - 16"-lbs

RFI Filter Wires to Contactor

RFI Filter Mounting Screws

RFI Wiring

RFI Ground Wire

25"-lbs

24 - 28"-lbs

15½"-lbs

22 - 26"-lbs

Transformer Mounting Screws (8 - 32 x

1

/

4

") 14 - 16"-lbs

Contactor Mounting Screws (10 - 32 x

3

/

8

")

Circuit Breaker 11/32 Mounting Nuts

Circuit Breaker Wire Connections

24 - 28"-lbs

14 - 16"-lbs

20"-lbs

- 86 -

Swagelok Tube Fitting

Instructions

1

Installation

1. Insert tubing into the Swagelok tube fitting.

2. Make sure that the tubing rests firmly on the shoulder of the tube fitting body and that the nut is finger-tight.

3. Scribe the nut at the 6 o’clock position.

4. While holding fitting body steady, tighten the nut 11/4 turns to the 9 o’clock position. Note: For 1/16, 1/8, and 3/16 in; 2, 3, and 4 mm tube fittings, tighten the nut 3/4 turn to the 3 o’clock position.

Installation in High-Pressure Applications and High Safety-Factor

Systems

1. Follow steps 1 and 2 of the Swagelok Tube Fitting Instructions.

2. Tighten the nut until the tubing will not rotate freely by hand.

3. Follow steps 3 and 4 of the Swagelok Tube Fitting Instructions.

Gageability — On initial installation, the Swagelok gap inspection gauge assures the installer or inspector that a fitting has been sufficiently tightened.

Position the Swagelok gap inspection gauge next to the gap between the nut and body.

• If the gauge will not enter the gap, the fitting is sufficiently tightened.

• If the gauge will enter the gap, additional tightening is required.

- 87 -

Reassembly Instructions — You may disassemble and reassemble a

Swagelok tube fitting, port connector, cap, and plug many times.

1. Insert tubing with pre-swaged ferrules into the fitting body until the front ferrule seats.

2. Rotate the nut with a wrench to the previously pulled-up position. At this point, a significant increase in resistance will be encountered.

3. Tighten slightly with a wrench. Note: Do not use the gap inspection gauge with reassembled fittings.

Do not mix or interchange parts with those of other manufacturers.

1. Swagelok Pocket Catalog of Tube Fittings MS-13-58

- 88 -

Section V Controller Loops

Main Loop

An alphanumeric display presents numeric readings of various operating conditions within the chiller. Display function is selected by pressing the appropriate keys to move through a menu of available information.

Main Loop

When the controller is first powered up it goes through a short self-test, and then enters the Main Loop and displays the unit configuration.

Unit Configuration

NEXT

Process Fluid Supply

Temperature

NEXT

Facility Fluid Supply

Temperature

NEXT

Facility Water Flow Rate

NEXT

Process Fluid Differential

Pressure

NEXT

Main Loop

- 89 -

Engineering Loop

The Engineering Loop allows you to open or close the temperature control valve. Use the YES button to enter the valve condition. The display will then flash between the position of the valve and the facility flow value. Use the YES or the NO buttons to open or close it in 10% increments. When the desired value is displayed press ENTER and then NEXT to sequence through the displays.

Press NEXT to sequence the display through the cool duty cycle, the coolant return pressure, the coolant supply pressure, the facility water temperature, and the ambient air temperature. Press NEXT again to return to the Main Loop.

HICAPACITY

ENTER

NEXT

NO

ENTER

NEXT

NO

YES or

YES

NO

NEXT

NEXT ENTER

NEXT

NEXT

NEXT

NEXT

NEXT

- 90 -

Engineering Loop

Factory Reset

A Factory Reset returns all the controller settings to its factory preset values.

HICAPACITY

ENTER

NO YES

NO

+

ENTER SILENCE

After the Reset a controlller calibration is required. Refer to Teradyne Service

Documentation for proper procedure.

- 91 -

WARRANTY

Thermo Electron Corporation warrants for 24 months from date of shipment any Thermo Electron unit according to the following terms.

Any part of the CDU manufactured or supplied by Thermo Electron and found in the reasonable judgment of

Thermo Electron to be defective in material or workmanship will be repaired at an authorized Thermo Electron

Repair Depot without charge for parts or labor. The CDU, including any defective part must be returned to an authorized Thermo Electron Repair Depot within the warranty period. The expense of returning the CDU to the authorized Thermo Electron Repair Depot for warranty service will be paid for by the buyer. Thermo Electron’s responsibility in respect to warranty claims is limited to performing the required repairs or replacements, and no claim of breach of warranty shall be cause for cancellation or recision of the contract of sales of any CDU. With respect to CDUs that qualify for field service repairs, Thermo Electron’s responsibility is limited to the component parts necessary for the repair and the labor that is required on site to perform the repair. Any travel labor or mileage charges are the financial responsibility of the buyer.

The buyer shall be responsible for any evaluation or warranty service call (including labor charges) if no defects are found with the Thermo Electron product.

This warranty does not cover any CDU that has been subject to misuse, neglect, or accident. This warranty does not apply to any damage to the CDU that is the result of improper installation or maintenance, or to any

CDU that has been operated or maintained in any way contrary to the operating or maintenance instructions specified in Thermo Electron’s Instruction and Operation Manual. This warranty does not cover any CDU that has been altered or modified so as to change its intended use.

In addition, this warranty does not extend to repairs made by the use of parts, accessories, or fluids which are either incompatible with the CDU or adversely affect its operation, performance, or durability.

Thermo Electron reserves the right to change or improve the design of any CDU without assuming any obligation to modify any CDU previously manufactured.

THE FOREGOING EXPRESS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR

IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE.

Thermo Electron’s OBLIGATION UNDER THIS WARRANTY IS STRICTLY AND EXCLUSIVELY LIMITED TO THE

REPAIR OR REPLACEMENT OF DEFECTIVE COMPONENT PARTS AND Thermo Electron DOES NOT

ASSUME OR AUTHORIZE ANYONE TO ASSUME FOR IT ANY OTHER OBLIGATION.

Thermo Electron ASSUMES NO RESPONSIBILITY FOR INCIDENTAL, CONSEQUENTIAL, OR OTHER DAM-

AGES INCLUDING, BUT NOT LIMITED TO LOSS OR DAMAGE TO PROPERTY, LOSS OF PROFITS OR

REVENUE, LOSS OF THE UNIT, LOSS OF TIME, OR INCONVENIENCE.

This warranty applies to CDUs sold in the United States. Any CDUs sold elsewhere are warranted by the affiliated marketing company of Thermo Electron. This warranty and all matters arising pursuant to it shall be governed by the law of the State of New Hampshire, United States. All legal actions brought in relation hereto shall be filed in the appropriate state or federal courts in New Hampshire, unless waived by Thermo Electron.

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