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Stand-Alone 2021 - LAUDA-Noah

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1. Thermoelectric Module Stainless Steel Tank i D I Cartridges Pump dl IE gt Process OUT Figure 3 1 Circulation of Process Fluid 3 2 Model 2021 Appendix D provides diagrams of process plumbing The pump and AUX 2 outputs usually stay on during process operation and the thermoelectric output is active during most of the operation However if the Process temperature setpoint is higher than the current process temperature the thermoelectric output remains off until the temperature reaches the Process setpoint minus the Cooling deviation PS CD This feature reduces system warmup time The Model 2021 uses a two stage cooling output routine When the system enters the ACTIVE Mode it initiates one stage of cooling and then begins counting down the stage delay Stage Delay is amount of time that must pass before another cooling stage can be activated or deactivated as required Temperature control heat cycling is based on the three part PID algorithm The two LEDs on the face panel of the controller indicate the immediate status of the heating and cooling outputs When the Heat LED is on the heater output is active When the Cool LED is on the thermoelectric output is active AN Note For operating temperatures above 60 0 C turn the cooling to OFF Operation is controlled through the 962 JG controller Refer to Figure
2. Figure 4 1 962 JG DIP Switch 4 Alarms HEATER FUSE This alarm indicates an open Heater fuse lt deactivates the heater output AN Caution Be sure the heater has cooled down before removing To clear 1 Disconnect the power cord 2 Turn the power off 3 Check the heater fuses and SSR 4 Remove the heater and check for a short or an open HIGH LIMIT T C This alarm indicates an over temperature condition on the High limit thermocouple input It deactivates the controller output To clear 1 2 Disconnect the power cord Check the jumper wire to the High limit thermocouple on the 962 JG board Be sure that the plus and minus terminals are shorted together HIGH PROCESS TEMP The High Temperature alarm is activated when the process temperature exceeds the High alarm setpoint This alarm deactivates the heater output 4 10 Model 2021 To clear 100 mV C Interface machines only 1 Wait The alarm sounds until the active temperature is within the High Deviation Temperature It automatically clears itself when it reaches the Setpoint plus the High Dev Temp 2 Increase the High Dev Temp value Other machines 1 Adjust the high temp alarm All machines 1 Disconnect the power cord Check the heater heater SSR and heater fuses Adjust the Maximum Setpoint to the desired temperature in Factory Setup 4 Check the connection into the thermoelectrics The red wires go to the or
3. Thermoelectric Temperature Control Unit Model 2021 User Manual Copyright 1995 Noah Precision Inc Publication 060 00703 Rev B Noah Precision Inc 6389 San Ignacio Avenue November 1997 San Jose CA 95119 This publication is subject to replacement by a later edition To determine whether a later edition exists or to request copies of publications contact Noah Precision Inc 6389 San Ignacio Avenue San Jose CA 95119 Telephone 408 281 7772 FAX 408 281 7797 All rights reserved on this document No part may be reproduced in any form or by any means or used to make any derivative work such as translation transformation or adaptation without permission from Noah Precision This document is provided without warranty of any kind either implied or expressed including but not limited to the implied warranties of merchantability and fitness for a particular purpose Noah Precision may make improvements or changes in the product s or program s described in this documentation at any time Lexan is a registered trademark of General Electric Molex is a registered trademark of Molex Company Teflon is a registered trademark of DuPont Contents 1 Overview Operating Principles Controller Interface Description Displays Lockout Tagout 2 Installation Hook up Hook up Procedure System Start up User Setup Factory Setup Com Link Start up RS422 Interface System Shut down 3 Operation Turning the System
4. Do NOT lift by the parts that protrude from the back of the unit If there are damages that are not apparent until after unpacking the unit file a written request for inspection by the carriers agent at once There is usually a fifteen 15 day time limit for concealed damage claims Contact Noah Precision to receive a Return Material Authorization RMA BEFORE returning the unit to the factory Save all packaging materials and be sure to include all name plate data including part number and serial number when communicating with the Noah Precision factory xiii xiv Overview The Model 2021 Temperature Control Unit TCU incorporates solid state thermoelectric technology which completely eliminates the use of Ozone Depleting Chemicals ODCs or toxic Freon substitutes Specifically developed for semiconductor wafer processing equipment its small footprint makes it ideal for cleanroom applications Designed and tested for reliable efficient and quiet operation the Model 2021 requires minimal maintenance and service to provide a continuous supply of cooling fluid at a constant temperature It comes equipped with pump controller power supply unit and cooling reservoir Operating Principles The Model 2021 operates on the principle of thermoelectric cooling based on the Peltier Effect Thermoelectric TE devices are small solid state heat pumps Their advantages include small space requirements and high reliability
5. NPT ODC PID PSI RAM RTD SSR T C TCU T E VAC VDC American Wire Gage British Thermal Unit Degrees Celsius Chemical Vapor Deposition Decibels Electrically Erasable Programmable Read Only Memory Emergency Machine Off Female National Pipe Thread Ground Fault Interrupt Gallons Per Minute Hertz Liquid Crystal Display Low Flow Facility Water Low Flow Pump Light Emitting Diode National Pipe Thread Ozone Depleting Chemical Proportional Integral Derivative Pounds per Square Inch Random Access Memory Resistance Temperature Detector Solid State Relay Thermocouple Temperature Control Unit Thermoelectrics Volts Alternating Current Volts Direct Current
6. RTD probe Diode bridges lt D Cartridges Solid state relays Fuses 30A main contactor 962 JG controller I i 1 2 HP motor 4 5 gallon 316 Stainless steel tank 962 LG communication board Resistivity box go Drain valve Circuit breaker Figure 1 4 Major Components of the Model 2021 Displays Model 2021 All programming and informational messages are displayed in the window on the front of the controller panel There are four types of display messages set up status alarm and diagnostic messages Each message contains two lines The first line of the display indicates the general mode of the system The upper left corner indicates one of the five basic system control modes ACTIVE IDLE ALARM SETUP and AUTOTUNE The upper right corner displays the temperature of the process water Out The second line displays the current setpoint of the system the current resistivity value or the current flow value These options are selected by the UP and DOWN keys A special scanning option causes these values to rotate continuously at a time interval programmed by the user The only time the display lines do not read this way is when the system is first turned on and the initial display from the factory appears The factory screen identifies the model number of the system This message lasts about 7 seconds while the system initi
7. The alarm sounds until the active temperature is within the Low Deviation Temperature It automatically clears itself when it reaches the Setpoint minus the Low Dev Temp 2 Change the Low Dev Temp to a bigger value Other machines 1 Adjust the Low Temp alarm All machines 1 Disconnect the power cord 2 Check the thermoelectrics T E SSRs and T E fuses 4 12 Model 2021 OPEN SENSOR HI LIM This alarm indicates a bad or missing thermocouple sensor in the High limit thermocouple input It deactivates the controller output To clear 1 Disconnect the power cord 2 Check sensor connections 3 Check the Hi Limit terminal wire jumper 4 Replace the RTD sensor PUMP FUSE This alarm indicates an open Pump fuse It deactivates the pump output To clear 1 Disconnect the power cord 2 Check the pump fuses 3 Check the pump for a short or an open SSR OVERTEMP This alarm indicates a High temperature condition on the Heater solid state relay This is sensed by an OPEN on the S OT input terminals It deactivates the controller output To clear 1 Disconnect the power cord 2 Check the Molex connector at the S OT on J16 on the 962 JG board 4 13 4 Alarms TANK OVERTEMP This alarm indicates an open Tank snap switch input This is sensed by an OPEN on the TOT input It deactivates the controller output To clear 1 Check the model number in the Factory Setup It must be set at
8. With the Model 2021 communication option the user is not confined to the Model 2021 control panel for temperature adjustment Temperature adjustment and temperature monitoring are controlled by the process equipment Several communication interfaces are available 10 mV C Analog Signal 100 mV C Analog Signal 10 mV C Analog Interface Special RS 422 10 mV C Communications Interface Temperature range 0 0 C to 45 0 C Voltage Temperature 0 10 volts 10 0 C Port 9 pin male circular plastic connector size 13 Amp 206705 1 See Figure 5 3 Pins 1 TX Transmits a DC voltage across Pins 1 and 2 to the process equipment corresponding to the current temperature of the 2021 reservoir 2 Common 3 RX Receives the DC signal from the process equipment across Pins 3 and 2 which corresponds to the Temperature setpoint to which the 2021 is set 4 amp 5 Flow switch Closed contact between Pins 4 and 5 indicates that the process flow rate is at least 2 0 gpm Open contact indicates a flow rate below 2 0 gpm and or a loss of process flow To use the internal flow switch disconnnect the flow switch and connect it to the com port 5 Optional Equipment At the same time jumper the wires to the board to avoid the alarm for Low flow 788 Emergency Off Open contact indicates that the Model 2021 EMO button is pressed in lo 10mv C Communication Port NN Figure 5 3 10 mV C Analog Signal Commun
9. setpoint 0 0 to max deg C T C 42 5 C 5 0 to max deg RTD HIGH DEV ALARM High deviation alarm 0 0 to 9 9 C 5 0 C LOW TEMP Low temp setpoint 0 0 to max deg C T C 9 0 C 5 0 to max deg RTD LOW DEV ALARM Low deviation alarm 0 0 to 9 9 C 5 0 C LOW RESIST Low resistivity setpoint 0 00 to 18 18 mohm 1 50M LOW FLOW Low flow setpoint 0 0 to 20 0 gpm 0 0 gpm STAGE DELAY Stage delay 0 to 250 seconds 60 sec CYCLE RATE Cycle rate 1 to 25 seconds 05 sec PROP BAND Proportional band 0 0 to 25 0 deg C 1 2 C RESET Reset integral 0 0 to 25 0 minutes 1 7 RATE Rate derivative 0 0 to 25 0 minutes 0 9 Model 2021 Display Parameter Range Factory Values 2ND HEATER Second heater On Off Off SENSOR CALI Sensor calibration 9 9 deg C varies SYSTEM ID System ID number 00 to 99 BAUD RATE Baud rate 300 to 19 200 9600 ACCESS CODE Access code 0 to 9999 01 AUTO TUNE Auto tune On Off Off SCAN TIME Scan time O to 5 seconds 03 sec FILLMONITOR Fill monitor display On Off Off A 100 mV C machines only i The temperature deviation setpoint must be programmed to activate at 2 5 degrees below the process setpoint This parameter must be ON when filling the cooling tank Refer to the parameter descriptions on the next page for detailed instructions User Setup Parameters SETPOINT This is the Process Setpoint for the system It is the target temperature for the three mode PID algorithm LOC SETPOINT if applicable This
10. 3 2 for key locations START ALARM STOP SILENCE O E ee E NOAH PRECISION INC MODE RETURN HEAT j COOL O Figure 3 2 Controller Key Locations 3 3 3 Operation Controller Keys There are six keys on the controller When pressed a short beep sounds if valid key inputs are received If inputs are invalid a razz tone sounds START STOP key This key starts and stops system operation If the system is in IDLE Mode pressing this key puts the system in ACTIVE Mode If the system is in ACTIVE Mode pressing this key puts the system back in IDLE Mode If the system is in ALARM Mode with active alarms pressing this key has no effect on the active alarms It does erase alarms that have been cleared and any active alarms are sounded again If the system is in ALARM Mode and reads Cleared pressing this key returns the system to ACTIVE Mode This key overrides the remote Start Stop option If pressed the Remote Start Stop sequence must be adjusted ALARM SILENCE Key This key eliminates the audio portion of an alarm or diagnostic display Because the system maintains an Alarm Diagnostic history this key can also be used to review all active alarms or diagnostics Just press repeatedly to sequence through After alarms are cleared pressing this key removes them from the alarm history All alarms must be cleared as well as silenced If an alarm is silenced but not cleared system start up automatic
11. A single stage thermoelectric cooling unit is a matrix of thermoelectric couples connected in series electrically and connected in parallel thermally The number of couples depends on the cooling requirement 1 Overview Each couple consists of p type and n type semiconductor pillars positioned between two ceramic plates These plates provide a rigid mounting structure and electrical insulation between the heat sink and the process being cooled Cooling capacity is proportional to the supply current and the number of couples Peltier discovered that heat is released or absorbed when two dissimilar materials that conduct electrical current are joined A positive voltage applied to the n type material drives electrons from the p type to the n type material and back to the voltage supply The temperature on the cold side decreases as heat is absorbed The heat is then conducted through the couple to the hot side to dissipate through a heat sink The heat dissipated is the sum of the heat removed from the cold side and the heat generated by the thermoelectric input power Reversing the voltage polarity changes the hot side of the couple to the cold side Heat absorbed from device being cooled a Tc Cold side p n Type Type me Rell Hot side Heat dissipated to Heat Sink Current gt F DC source Figure 1 1 Peltier Effect The applications of this principle to thermoelectr
12. Feature 1 9 2 1 Back View of the Model 2021 2 2 2 2 Model 2021 Reservoir 2 3 2 3 Location of Power Switch 2 5 2 4 Controller Interface 2 6 2 5 Fill Monitor 3 Level Switch Displays 2 14 3 1 Circulation of Process Fluid 3 2 3 2 Controller Key Locations 3 3 3 3 Temperature Oscillations 3 10 3 4 Oscillation Time 3 11 3 5 Final Temperature Deviation 3 11 3 6 Nomogram 3 12 3 7 Nomogram Il 3 13 3 8 Nomogram Ill 3 13 4 1 962 JG DIP Switch 4 9 Figures con t 5 1 5 2 5 3 5 4 5 5 5 6 D 1 D 2 D 3 E 1 E 2 E 3 E 4 E 5 E 6 E 7 E 8 E 9 Remote Port Liquid Pressure By Pass 10 mV C Analog Signal Communication Port 100 mV C Analog Signal Communication Port Transistor Output RS422 Communication Port Liquid Pressure By Pass Option Facility Plumbing Process Plumbing Electrical Panel Layout Output Wiring EMO Circuit Wiring Solenoid flow Facility Wiring 2021 Wiring DC Output Wiring RS 422 Interface Wiring 962 LE Circuit Wiring Remote Display Wiring Diagram E 10 RS422 Board Tables 2 1 User Setup Parameters 2 2 Factory Setup Parameters 4 1 Information Only Alarms 4 2 Output Deactivation Alarms 4 3 Master Relay Alarms vi 5 2 5 4 5 6 5 9 5 12 D 1 D 2 D 3 E 3 8 4 E 5 8 6 E 7 E 9 E 10 E 11 E 12 E 13 E 14 Preface Manual Objectives This manual describes the installation operation and maintenance of the Model 2021 Temperature Control Unit Intended Audienc
13. ON Process Operation Controller Keys Modes of Operation AutoTune Tuning the PID Controller Turning the System OFF 3 1 3 4 3 6 3 7 3 14 4 Alarms Types of Alarms 4 2 Alarm Descriptions 4 4 Information Only Alarms 4 5 Output Deactivation Alarms 4 9 Master Relay Alarms 4 15 5 Optional Equipment Remote Display 5 1 Digital Flow Meter 5 2 Liquid Pressure By Pass Option 5 3 Communication Interface 5 5 10 mV C Communications Interface 5 5 100 mV C Communications Interface 5 6 10 mV C Analog Interface Special 5 9 RS 422 Communication Interface 5 10 6 Troubleshooting LEDs 6 1 Master Relay Safety Switches 6 2 Fuses 6 3 Standard Temperature Inputs 6 3 Open Collector Transistor Inputs 6 4 System Outputs 6 4 Back Door 6 6 AutoTuning 6 6 Troubleshooting Guide 6 7 7 Maintenance Process Fluid 7 2 Pump Motor 7 2 Model 2021 Appendices A Engineering Specifications for the Model 2021 B Model 2021 Major Components C Engineering Specifications for the 962 JG Controller D Process Plumbing E Electrical Circuitry F Circuit Markings on the 962 JG Board G Acronyms Figures 1 1 Peltier Effect 1 2 1 2 The 962 JG Controller Interface 1 3 1 3 Model 2021 1 5 1 4 Major Components of the Model 2021 1 6 1 5 Initial Factory Display 1 7 1 6 Example IDLE Mode Display 1 8 1 7 Example ACTIVE Mode Display 1 8 1 8 Heater Fuse Alarm Display 1 8 1 9 Cleared Heater Fuse Alarm Display 1 8 1 10 2021 Lockout Tagout
14. ae 4 OVERTEMP 3 J9 Connector R Relay 220V Switched F4 Fuse Open Sense 3 F5 Fuse Open Sense 4 Hot 2 J10 Power Connector 1 H 2 H2 2opvac 3 fl J11 SSR Connector 1 Heater SSR 2 220 VAC side 3 Pump SSR 4 220 VAC side 5 Thermoelectric SSR s SL o vance J12 Heater Connector 1 Heater 2 GND 3 J13 Pump Connector 1 Pump 2 GND 3 J14 Thermoelectric Connector 1 Thermoelectric GND F4 Board Fuse Ge F1 Heater Isolated Power LED isolated Power LED O J15 Resistivity Connector 1 Hi 2 G 220VAC 3 H2 10VAMax J17 Output Connector 1 2nd Heater 2 12 VDC 3 T E 3 Aux 2 4 12 VDC 5 m T E 2 Aux 1 6 12 VDC 7 T E 1 8 Pump SSR 9 Heater SSR 10 J18 Thermocouple or RTD Connector 1 gt gt 3 NC 4 NC 5 ae J18 Thermocouple or RTD Connector w p NC RTD ource 19 Resistivity Connector wre ee ofhwnM 1 2 3 4 Function Position C c O O T C 0 0 CICIRTD Position ONon CO Safety LED O J6 14 Appendix G Acronyms The following acronyms are used in this document AWG BTU C CVD db EEPROM EMO FNPT GFI GPM Hz LCD LFC LFP LED
15. diode bridge N Check the plug phases Disconnect the power cord Check fuses Check SSRs and replace if necessry Check diode bridge and replace if necessary Safety cover is active _ Front panel cover is open Magnet switch is defective Loose wiring a SP4 _ Disconnect power cord Close cover Disconnect power cord Check the SP4 wiring on the J6 Molex connector 962 JG Problem Possible Cause Model 2021 Possible Solution T E fuse is active o T E fuse is blown Shorted T E SSRs Shorted diode bridge Capacitors are not wired correctly T E bank is grounded or open 1 Disconnect power cord Check all the T E fuses check the SSrs Replace if necessary Check diode bridges Check the capacitors Check for a loose connection on the board and the thermoelectric unit Heater fuse is active h Heater fuse is blown Loose wiring or connectors Heater is open or worn out _ Disconnect power cord Check heater fuses Check connectors for loose wiring or loose contact Check the heater for shorts or opens by measuring the resistance of each leg Low flow facilities are active 1 Facility plumbing is reversed Not enough flow rate Filter is clogged h Check the facility plumbing connection for proper orientation of the Facility IN and OUT lines Check the flow sensor There must
16. display responds with a message to enter a user access code This is initially set to 01 at the factory ENTER ACCESS CODE XXXX Use the UP and DOWN keys to enter a four digit code Then press the MODE key again to continue programming user parameters If a user code is not required simply press the MODE key a second time without using the UP and DOWN keys The following display appears SETUP USER SETPOINT XXX XC The second line of this screen begins a series of parameters that must be set or adjusted for individual use Use the MODE key to advance through the various parameters Use the UP and DOWN keys to change the settings Pressing and releasing the key 2 Installation immediately changes the setting of the least significant digit pressing and holding the key down increments values automatically and rapidly To exit the SET UP Mode press the RETURN key Table 2 1 lists the screen displays for the User Setup the parameters associated with the display the range allowed within each parameter and the factory programmed value Descriptions of each parameter follow Table 2 1 User Setup Parameters Display Parameter Range Factory Values SETPOINT Process setpoint 0 0 to max deg C T C varies 5 0 to max deg RTD LOC SETPOINT Local process setpoint 0 0 to max deg C T C varies 5 0 to max deg RTD REM SETPOINT Remote process 0 0 to max deg C T C varies setpoint 5 0 to max deg RTD HIGH TEMP High temp
17. energy consumption The Model 2021 incorporates the following features e State of the art microprocessor temperature controller Solid state thermoelectric cooling module e High pressure turbine pump Independent DC power supply Measuring just 31 inches long by 14 inches wide by 27 inches high the Model 2021 provides continuous cooling with minimal space requirements See Figure 1 3 for a frontal view of the Model 2021 Model 2021 A AA 27 E FA FA FA FA mm FA E Y E E Aa E FA m FA IS 3 1 Figure 1 3 Model 2021 Constructed with a steel chassis stainless steel cooling reservoirs and Buna N plumbing the Model 2021 s tank capacity is 4 5 gallons Temperature range is 0 C to 90 C The six key tactile keypad located on the front panel allows user adjustments and system set up Directly below the message display window two LEDs show the current status of the heating and cooling outputs Two 2000 watt immersion heating modules are mounted on top of the tank 1 Overview The power supply is a direct AC rectified to DC Figure 1 4 provides a diagram of major components Unit specifications are listed in Appendix A and component parts are itemized by part number in Appendix B Appendix C has the engineering specifications for the 962 JG controller Thermoelectric Module Snap tite plug 3 float liquid level sensor Bleed resistors 2000 watt heater 2
18. from the Resistivity monitor to the proper controller displays FLOW ACTIVE This parameter activates or deactivates the Flow reading option If set to YES the unit relays information from the 962 L to the proper controller displays SENSOR TYPE This parameter identifies the type of sensor T C to RTD used as the Process sensor This setting MUST BE COORDINATED with DIP switch settings on the 962J board For correct DIP switch settings refer to Figure 4 1 When changing sensor type all other temperature setpoint values must be changed There is a 25 degree offset between the RTD and T C sensor types because of the temperature ranges obtainable by the different sensors RTD is standard on the Model 2021 RS232 ACTIVE This parameter activates or deactivates the R8232 communications function Settings O removes the SYSTEM ID NUMBER and BAUD RATE parameters 2 18 Model 2021 1 activates all functions of the RS232 2 the WRITE command is restricted to the Process setpoint parameter 3 the WRITE command is restricted to the Flow reading parameter 4 the WRITE command is restricted to the Process setpoint and Flow reading parameters MODEL DISPLAY Controls the system model number display screen when the system is turned on the first time Noah Precision customizes the controller display to the correct model number AN Caution This number is also used to set up the specific logic for individual con
19. motor automatically reset to the OFF idle state when the system is powered up The system enters the IDLE Mode The controller display screen shows the current discharge temperature and the Setpoint temperature IDLE MODE XX XC SETPOINT XX XC 3 Operation 4 Press the START key to enter the ACTIVE Mode This key is located on the controller face plate The thermoelectric cooling and heating outputs and the pump come on according to the Set up parameters Process Operation Heater Sensor A four and one half gallon mixture of 50 deionized water and 50 ethylene glycol or Galden heat transfer fluid is recirculated from a stainless steel tank to the chamber that is being cooled A regenerative turbine pump draws the process water from the tank to the chamber Some of the flow goes to the dual DI cartridges The DI cartridges are parallel to the unit being chilled The process fluid flowing back to the chamber is then pumped through the thermoelectric module Here the heat from the process fluid is transferred to the facility water The process fluid then goes to the reservoir where an immersion heater regulates the process fluid to the desired temperature See Figure 3 1 for the circulation flow of process fluid Liquid level L Process IN L
20. parameter is the Process setpoint for 100mV C machines in local mode REMOTE SETPOINT if applicable This parameter is the Process setpoint for 100mV C machines in remote mode Once the temperature is programmed with this parameter the temperature is controlled by the process chamber via a 24 VAC signal to the 2021 TCU If the 24 volt signal is active the process temperature is controlled by the Remote setpoint If the 24 volt signal is inactive the process temperature is controlled by the 2 Installation Local setpoint This parameter excludes the need to change the program setting of the RS232 parameter in the Factory Setup HIGH TEMP This is the High temperature alarm setpoint The Process temperature is continually compared with this setting If exceeded the High Temperature alarm is activated To eliminate this alarm set the respective setpoint to its lowest obtainable value This value depends on the SENSOR selection For the T C sensor the value is 0 0 C for the RTD sensor 25 0 C HIGH DEV ALARM if applicable This parameter changes the High temperature alarm setpoint from a direct setpoint to a relative setpoint The High temp alarm will activate when the process temperature exceeds the process setpoint plus the High deviation alarm setpoint For example if the High dev alarm is set at 5 C and the Process temperature is set at 18 0 C and the ACTIVE Mode temperature is above 23 0 C the High
21. process control Noah Precision recommends that the user use the Autotune parameter at its specific operating process temperature SCAN TIME The second line of the ACTIVE Mode display can be set to display alternately current flow and resistivity values The display time of each value is set with this parameter FILL MONITOR This parameter activates the Fill Monitor mode to allow for precise filling of the cooling tank or reservoir Press the UP key The top line of the display reads FILL MONITOR and the second line shows the level of the reservoir fluid At the initial start up and when fluid levels are low the following screen appears FILL MONITOR ADD FLUID The level is sensed by a 3 level switch wired to the LLT LLR and SP5 input If the fluid level is below full the lower display line reads Model 2021 ADD FLUID When the reservoir is full the display changes to FULL A full tank is sensed by a closed switch at the LLR input Figure 2 5 shows the displays activated by the 3 level switch FILL MONITOR FILL MONITOR FILL MONITOR ADD FLUID NEEDS FLUID ADDED FULL Figure 2 5 Fill Monitor 3 Level Switch Displays To add fluid open the small hinged door located on the top center of the unit Unscrew the small 2 inch diameter stainless steel plug Do NOT use anti freeze automotive liquid AN Warning Ethylene glycol is a hazardous chemical Dispose of properly Reservoir capacity is 4 5 gallons not i
22. the RS 422 board Refer to Appendix E for diagram The protocol for the serial link consists of the following two basic commands R for Read W for Write Data format is standard ASCII and all data are decimal values 5 10 Model 2021 READ Command Format for the Read command is CXXR32 Return C indicates that the channel Indentification number follows XX is the Identification number R indicates a READ command 32 two numbers indicate the information to be read The carriage return activates the command Data locations 32 Resistivity 33 Flow in gom Data is returned in ASCII format with decimal values If the controller displays information in tenths the information is transmitted in tenths WRITE Command The Write command overwrites the information in the programming stack Format for the Write command is CXXW3601 Return C indicates that the channel Indentification number follows XX is the Identification number W indicates a WRITE command 36 two numbers indicate the location 01 two numbers indicate the data value to be written The carriage return activates the command Data is returned in ASCII format with decimal values 5 11 5 Optional Equipment Data locations Local Remote Local remote locks out WRITE commands when 01 is written to Location 36 To enable WRITE commands again a 00 must be written to Location 36 A 25 pin D sub mini receptacle is provided a
23. thermal snap switch input This is sensed by an OPEN on the H OT input The master relay is deactivated and the system goes into ALARM Mode To clear 1 Disconnect the power cord 2 Check the Molex connector at the H OT on J16 on the 962 JG board 4 15 4 Alarms LL RESERVOIR This alarm indicates a Low Liquid level condition in the reservoir This is sensed by an OPEN on the LLR input terminal To clear 1 Fill the tank with the specified process water 2 Check for leaks 3 Disconnect the power cord 4 Check the 22AWG red wire crimps and the connectors for loose wiring 5 Check the Molex connector at the LLR on J16 on the 962 JG board 6 Check the 3 liquid level sensor on the tank SAFETY COVER OFF This alarm indicates an OPEN on the SP4 input terminal The enclosure safety cover is not closed To clear 1 Disconnect the power cord 2 Check the Molex connector at the SP4 on J16 on the 962 JG board Check that the magnet is attached to the front panel cover Place a magnet on top of the switch and check for continuity T E OVERTEMP This alarm indicates an OPEN on the Thermoelectric snap switch input This is sensed by an OPEN on the TEOT input Model 2021 To clear 1 Check that the ACTIVE Mode temp is not above 50 C Check the facility water for flow and check that the temperature is not above 25 C N Disconnect the power cord Check the snap disc Check the wire
24. 2021 T E FUSE 1 This alarm indicates that the fuse for Thermoelectric cooler 1 is open It deactivates the controller output To clear 1 Disconnect the power cord 2 Check the TE 1 fuse on the 962 JG board 3 Check the power going into the TCU 4 Check the other fuses 5 Check the wire crimps going into the TE1 SSR T E FUSE 2 This alarm indicates that the fuse for Thermoelectric cooler 2 is open It deactivates the controller output To clear 1 Disconnect the power cord 2 Check the TE 2 fuse located below the heat sink that holds the SSRs Labels are on the wire insulation Check the power going into the TCU Check the other fuses 5 Check the wire crimps going into the TE2 SSR Model 2021 T E FUSE 3 This alarm indicates that the fuse for Thermoelectric cooler 3 is open It deactivates the controller output To clear 1 Disconnect the power cord 2 Check the TE 8 fuse located below the heat sink that holds the SSRs Labels are on the wire insulation Check the power going into the TCU Check the other fuses 5 Check the wire crimps going into the TE3 SSR Master Relay Alarms Vit Al Danger High Voltage High voltage is active in the system Safety covers provide protection for the user and the machine If bypassed only authorized and qualified personnel should repair or test the machine HEATER OVERTEMP This alarm indicates an OPEN on the Heater
25. AUX 2 output is active EA 2nd heater output is active Master Relay Safety Switches The Model 2021 has four inputs for safety switches that shut off the master relay These inputs have the following markings on the circuit board H OT Heater overtemperature TEOT Thermoelectric overtemperature LLR Low level reservoir SP4 Safety cover off They are normally closed switches wired in series with the power supply for the coil of the board master relay Each input is monitored via an opto coupler If the switch opens it turns off the master relay and alerts the microprocessor An alarm appears on the controller display If more than one of these safety switches is open the microprocessor announces the most significant OPEN Once that OPEN is closed the next significant OPEN is displayed Model 2021 Fuses The Model 2021 can monitor up to five fuses Opto couplers detect the voltage on the secondary sides of the fuses This is a diagnostic feature so they do not affect other system functions These inputs have the following markings on the circuit board Heater Heater fuse Pump Pump fuse These inputs have the following markings on the cable T E Thermoelectric fuse 1 TE2 Thermoelectric fuse 2 TE3 Thermoelectric fuse 3 Heater Heater Pump Pump The system monitors these fuses only when the master relay is active If a fuse blows and the master relay is inactive the condition is not detected by the circuitry T
26. C of the setpoint 2c Set the Prop Band parameter to 1 2 C the Reset parameter to 1 7 minutes and the Rate parameter to 0 9 minutes Low temp alarm turns on repeatedly 1 Low temp alarm is set too low 2 Heater inoperative 6 11 1 Adjust the Low temp alarm to at least 2 5 C below the Setpoint If the cooling and heating lights are on reset the TCU by turning it Off Wait at least 10 seconds then turn back On 2 Disconnect power cord Check the heater fuses heater SSR and the heater itself 6 Troubleshooting 12 Maintenance The Model 2021 requires minimal maintenance however the process fluid must be changed periodically and moving parts do wear out Replace the process fluid every two years or every time the TCU is inoperative allow six months usage The only moving parts the pump and motor must also be replaced every two years as bearings and couplings undergo continuous cycling The following parts should also be checked Fuses SSRs Diode bridge rectifiers Crimps and connectors DI cartridges change when resistivity is below 3 0 Mohm cm Vi el Danger High Voltage High voltage is active in the system Safety covers provide protection for the user and the machine If bypassed only authorized and qualified personnel should repair or test the machine 7 Maintenance Process Fluid Pump Always check for leaks The process fluid deionized water Eth
27. MO button located on the left side of the controller front panel is protruding If pressed in twist clockwise to reset The start up procedure includes e User Setup Factory Setup Correct filling procedures for the cooling tank e Temperature calibration All start up functions are programmed through the controller From the side panel circuit breaker turn the power switch to ON See Figure 2 3 The thermoelectric module heater element and pump motor are automatically reset to the Off idle state when the system is powered up Model 2021 LMM Figure 2 3 Location of Power Switch The factory model number appears on the controller display for approximately seven seconds while the unit initializes and executes a set of self diagnostics NOAH PRECISION MODEL 2021 2 Installation User Setup When diagnostics are complete the screen displays the current IDLE Mode and Setpoint IDLE MODE xxC SETPOINT xxC If the display does not respond check that the 9 pin circular connector at the back of the unit is plugged in correctly If the display still fails to respond refer to Section 6 Troubleshooting Refer to Figure 2 4 for the location of keys on the controller interface to program the unit i NOAH PRECISION INC HEAT j COOL START ALARM STOP SILENCE Figure 2 4 Controller Interface Model 2021 Press the MODE key to enter the User Setup parameters The
28. RESIST COMO ERROR SP3 SYSTEM FAILURE Flow input falls below Low flow parameter Resistivity falls below Low resistivity parameter Reservoir needs fluid Resistivity communication error Open switch in input SP3 Malfunction in a circuitry component Table 4 2 Output Deactivation Alarms Alarm Display BAD PROCESS SENSOR HEATER FUSE HIGH LIMIT T C HIGH PROCESS TEMP LOW FLOW HOUSE WATER LOW FLOW PUMP LOW PROCESS TEMP OPEN SENSOR HI LIM PUMP FUSE SSR OVERTEMP TANK OVERTEMP T E FUSE 1 T E FUSE 2 T E FUSE 3 Description Bad or missing main temp sensing input Open heater fuse Over temperature condition on the High limit thermocouple input Process temp exceeds high alarm setpoint Low flow condition in facility water supply Low flow condition in process flow loop Process temp falls below low alarm setpoint Bad or missing thermocouple sensor on High limit thermocouple input Open pump fuse High temp condition on Heater SSR Open Tank snap switch input Open fuse for thermoelectric cooler 1 Open fuse for thermoelectric cooler 2 Open fuse for thermoelectric cooler 3 4 Alarms Table 4 3 Master Relay Alarms Alarm Display Description HEATER OVERTEMP Open Heater thermal snap switch input LL RESERVOIR Low liquid level condition in reservoir SAFETY COVER OFF Open SP4 input safety cover not closed TE OVERTEMP Open Thermoelectric snap switch input Alarm Descriptionst The troubleshooter must follow
29. STOP key on the display If an alarm is active and operation must be stopped the alarm automatically appears when the system is turned on again Be sure to turn off power to all circuits with the power switch located on the side of the front panel 3 14 Alarms The Model 2021 s alarm system automatically and continually monitors for alarm conditions If an alarm occurs system status immediately changes to ALARM Mode and the specific alarm is displayed on the controller screen As an added precaution an audio alert sounds When the alarm is cleared the system recovers as if no alarm had occurred An AutoSilence feature turns off the audio alarm after six seconds Sound remains off for sixty seconds while the operator reads the display screen If any of the controller keys are used the audio remains off for sixty seconds from the last key stroke Except for fuse alarms all alarms have a ten second delay period This means that the alarm must exist for ten consecutive seconds before the system enters ALARM Mode Fuse alarms have a fifteen second delay Alarm displays have two lines The top line identifies the type of alarm The second line indicates whether the alarm is active or cleared For example T E OVERTEMP ACTIVE When an alarm is cleared the display changes T E OVERTEMP CLEARED 4 Alarms Types of Alarms Once an alarm has been cleared it must also be silenced by pressing the Alarm Silenc
30. Weight 140 lbs Tank capacity 4 5 gallons 19 8 liters Materials Steel chassis Stainless steel tank Teflon amp Buna N plumbing Temperature range 0 0 C to 88 C Cooling power 2200 watts or 11 942 BTU hr at 20 C Circulating liquid Mixture of 50 Ethylene glycol and 50 deionized water OR Fluorinert OR Galden Pump Regenerative turbine pump 4 0 gpm 60 psi 0 5 hp electric motor Inlet outlet tube fittings 1 2 in FNPT Controller 962 JG microprocessor controller resolution of 0 1 C Electrical 208 volts 60 Hz three phase Delta 5 wire 30 amp service 10 ft 8 1 meter grounded power cord Protection Overcurrent Pump 2 fuses 10 amp T E 1 2 fuses 10 amp T E 2 2 fuses 10 amp Heater 4 fuses 15 amp Controller 1 fuse0 5 amp Liquid Flow Facility cooling loop flow sensor Process cooling loop flow sensor Thermal overload Snap disc on heat exchanger Appendix B Part Number 30 2275 230 42 2474 000 42 2627 010 42 2781 000 42 2780 000 40 1590 000 40 2718 000 42 0425 000 42 2782 000 42 2388 000 42 2031 240 42 2659 010 42 1370 010 42 1370 020 42 1156 010 42 0791 250 42 1964 000 42 2001 010 42 1513 030 42 2368 000 42 2413 000 42 2265 000 50 2126 020 30 2067 200 42 2498 000 42 2784 000 42 2790 010 Model 2021 Major Components Part Description Tank stainless steel Heater stainless 208V 2000W 2021 thermoelectric module 2 stage Controller 962 JG Controller board resi
31. alizes and runs a complete battery of self diagnostics See Figure 1 5 NOAH PRECISION MODEL 2021 Figure 1 5 Initial Factory Display 1 Overview IDLE MODE 25 5C SETPOINT 35 5C When the system has completed its diagnostics the screen changes to read IDLE Mode and the setpoint Figure 1 6 is an example of an IDLE Mode screen Figure 1 6 Example IDLE Mode Display When the Start Key is pressed the screen displays ACTIVE Mode the temperature of the process water Out and the setpoint The ACTIVE Mode display remains until the user enters another function or an alarm condition occurs See Figure 1 7 ACTIVE MODE 35 0 C SETPOINT 35 0 C Figure 1 7 Example ACTIVE Mode Display In case of an alarm the top line of the display indicates the type of alarm The second line indicates the status of the alarm Figure1 8 is an example of an active heater fuse alarm HEATER FUSE ACTIVE Figure 1 8 Heater Fuse Alarm Display Model 2021 Lockout Tagout When an alarm has been cleared the alarm display changes to indicate the cleared status See Figure 1 9 HEATER FUSE CLEARED Figure 1 9 Cleared Heater Fuse Alarm Display A cleared alarm screen remains until the user presses the Start Key The display changes to ACTIVE Mode If six seconds elapse before the Start Key is pressed the system goes into IDLE Mode The Model 2020g incorporates a Lockout Tagout safety feature to protect individual
32. ally reactivates the alarm If an alarm or diagnostic is inactive but not silenced the system automatically silences the alarm on start up Model 2021 UP Key This key is used during the SETUP Mode to advance the display setting Pressing once and releasing allows the user to set the least significant digit of the display Holding the key down causes the display to increment automatically Used in the IDLE ACTIVE or ALARM Modes the UP key toggles the second line of the display between SETPOINT FLOW and RESISTIVITY depending on what was selected DOWN Key This key is used during the SETUP Mode to decrease the display setting Pressing once and releasing allows the user to set the least significant digit of the display Holding the key down causes the display to decrement automatically Used in the IDLE ACTIVE or ALARM Modes the DOWN key toggles the second line of the display between SETPOINT FLOW and RESISTIVITY depending on what was selected MODE Key This key puts the system into the SETUP Mode and then advances through the setup parameters To exit the SETUP Mode use the RETURN key RETURN Key This key is used to exit the SETUP Mode When pressed it automatically activates an EEPROM SAVE 3 Operation Modes of Operation There are four basic operating modes on the Model 2021 IDLE ACTIVE SETUP ALARM IDLE Mode When the system is powered up it automatically enters IDLE Mode Pushing th
33. ange terminals the brown wires go to the blue terminals LOW FLOW HOUSE WATER This alarm indicates a Low flow condition in the facility water supply This is sensed by an OPEN on the LFC input It deactivates the heating and cooling outputs To clear 1 Check the facility water connection leading into the system IN indicates that water from the facility goes into the TCU OUT indicates that water from the TCU goes back to the facility Check the flow rate It must be at least 3 0 GPM Disconnect the power cord Check the LFC connection on the 962 JG board Check the in line flow sensor It should have a closed contact when the flow rate is above 2 0 gpm Replace if necessary Ol E 83 TO 4 11 4 Alarms LOW FLOW PUMP This alarm indicates a Low flow condition in the process flow loop This is sensed by an OPEN on the LFP input lt deactivates the controller output To clear 1 Disconnect the power cord Check the flow sensor connection 22 AWG orange Check the wires going to the LFP connector on the 962 JG board LOW PROCESS TEMP The Low Temperature alarm is activated when the process temperature falls below the Low alarm setpoint This alarm deactivates the cooling outputs by deactivating the T E output To eliminate false low alarms on start up the Process temperature is allowed to exceed the Low alarm setpoint one time during system warmup To clear 100 mV C Interface machines only 1 Wait
34. ated above the deionization cartridge The Process IN is the return line of the TCU Process fluid from the etcher CVD goes to the TCU 3 Connect the tubing for the Process OUT fluid Use 1 2 inch diameter tubing or equivalent Located to the right of the power cord plug The Process OUT is the supply line of the TCU Process fluid from the TCU goes to the etcher CVD machine Model 2021 4 Connect the Facility IN port Use 1 2 inch NPT tubing Located next to the Process OUT port 5 Connect the Facility OUT port Use 1 2 inch NPT tubing Located on the right side of the back of the unit 6 Remove the left side panel of the Model 2021 Verify that the drain valve is off by checking that the yellow covered lever is in a horizontal position This is located at the bottom of the the tank Refer to Figure 2 2 B WY a S ES cs ES S o o e NWN Figure 2 2 Model 2021 Reservoir 7 Lock the front two casters AN Warning For earthquake safety the unit must be bolted on to the ground 2 Installation System Start up 8 Connect the power cord Service must be 208 VAC 30 amp 5 wire Check the power distribution for proper phases x A phase y B phase z C phase w neutral g ground 9 Connect the communication port Reattach the left side panel and hook up is complete The tank is filled during the start up procedure Before activating the Model 2021 check that the E
35. ations for the Model 2021 Specifies sizes ranges and capacities for the Model 2021 including precautions Appendix B Model 2021 Major Components Lists major components by description and part number Appendix C Engineering Specifications for the 962 JG Controller Describes the specifications for the Model 2021 user interface Appendix D Process Plumbing viii Model 2021 Diagrams the process plumbing flow Appendix E Electrical Circuitry Provides schematics of the electrical panel and controller circuitry including EMO circuitry Appendix F Circuit Markings on the 962 JG Board Explains board layout and markings including switches and contacts Appendix G Acronyms Lists the acronyms used throughout the manual Related Documents RS422 Communication Supplement Part Number 060 00704 Safeguards This manual contains certain information labeled with danger warning and caution messages Read all information highlighted in this manner carefully Vil e Danger High Voltage A Danger message alerts the user of a possibility of a fatal injury For example high voltage AN Warning A Warning message alerts the user of a possibility of serious injury AN Caution A Caution message alerts the user of a possibility of equipment damage AN Note A Note alerts the user of the possibility of minor complications Operate the Model 2021 only with the type of power source indicated on
36. be 2 0 gpm Check filter 6 Troubleshooting Problem Possible Cause Possible Solution Low flow pump 1 Process line is frozen 2 Defective flow sensor 3 Loose wire at LFP port 4 Pump failure 1 Check the process flow sensor 2 Check flow sensor and check for contact 3 Disconnect power cord Check LFP connection 4 Check for power Replace if necessary The 2021 does not hold temperature _ PID parameters are not set correctly 2 Defective heater or T Es 3 Defective SSRs h Adjust PID parameters to compensate 2 Disconnect ppower cord Check the heater replace if necessary Check T Es 3 Check SSRs Replace if necessary Software communication does not work _ RS422 switch not set correctly 2 Loose wiring 3 Defective interface board 6 10 _ Refer to Appendix E for correct DIP switch settings 2 Disconnect power cord Check t he pin connection for the 9 pin connector and the 37 pin connector 3 Check and replace if necessary Model 2021 Problem Possible Cause Possible Solution 1 Autotune calculations take several minutes AutoTune does not work 2 Autotune was not set during ACTIVE Mode or software parameters were not set properly 1 Wait Autotune takes 15 to 60 minutes to finish 2a Check the Setpoint It must be between 10 C and 40 C 2b Checkthe Active temperature It must be within 2
37. de If it is an Information only alarm the system remains in its current mode The screen however always identifies the system as in ALARM Mode Alarm routines do not terminate cycle runs when an alarm occurs but initiate any necessary precautions The audio alert lasts six seconds followed by a sixty second auto silence if any of the face panel keys are pressed Refer to Section 4 for detailed explanations of Model 2021 alarms and correct procedures to clear alarms Pressing the Alarm Silence key while in the ALARM Mode causes the second line of the display to sequence through and display any current alarms The system can automatically tune the PID parameters of the unit to fit the specific requirements of a given system This procedure takes up to ninety minutes depending on system configuration 1 Set Setpoint and Cycle rate parameters before activating AutoTune 3 Operation To activate Auto Tune 2 Enter User Setup and change the AutoTune parameter to YES 3 Press the RETURN key to exit the SETUP Mode 4 Ifthe system is in IDLE Mode press the Start key If the system is in ACTIVE Mode it automatically starts AutoTune The system runs a test sequence to determine basic system characteristics then calculates the appropriate tuning values and automatically inserts them into the Prop Band Reset and Rate parameters When AutoTune is completed the system returns to ACTIVE Mode To cancel AutoTune with no effect on
38. e The user should be familiar with basic electronics and safety procedures and guidelines This manual is written for those who must install operate and maintain the Model 2021 Temperature Control Unit This audience includes support technicians manufacturing QA and field service Manual Organization Section 1 Overview Presents an overview of the thermoelectric control unit Explains operating principles and identifies major components Describes the user interface and provides examples of display messages Section 2 Installation Provides step by step instructions for physical hook up controller setup and programming system start up and communication linkages Also explains shut down procedures vii Section 3 Operation Explains how to turn the system on process operation operation modes including all controller key functions and how to turn the system off Sectin 4 Alarms Describes various alarm conditions and the ramifications of each alarm Provides detailed instructions for clearing and silencing individual alarms Section 5 Optional Equipment Describesoptionalequipmentavailableforspecialprocessrequirements Section 6 Troubleshooting Discusses problems that might occur with the Model 2021 Also contains a troubleshooting guide for easy reference Section 7 Maintenance Explains preventive maintenance procedures Provides time tables for changing coolant and moving parts Appendix A Engineering Specific
39. e Start key while the system is in ACTIVE Mode returns the system to IDLE Mode If an alarm occurs in IDLE Mode and is cleared the system automatically reverts to IDLE Mode ACTIVE Mode The system enters the ACTIVE Mode when the Start key is pushed if no alarms or diagnostics occur This is the Model 2021 s normal operating mode If an alarm occurs it must be cleared and silenced Alarm Silence key before the system be reactivated If the system enters the IDLE Mode press the Start key to return tor ACTIVE Mode SETUP Mode This mode is used to enter parameter values and options for both User Setup and Factory Setup The system must be in the SETUP Mode to fill the cooling tank Press the Start Stop key to enter IDLE Mode then press the Mode key to enter the SETUP Mode To exit the SETUP Mode press the RETURN key AutoTune Model 2021 If an alarm occurs while in the SETUP Mode the alarm display indicates the type of alarm but the system stays in the SETUP Mode ALARM Mode If the system senses a problem it exits ACTIVE Mode and enters an ALARM Mode The display screen identifies the type of alarm on the top line the second line indicates the status of the the alarm active or cleared An external audio also sounds unless it has been deactivated during User Setup Alarms act in conjunction with ACTIVE or IDLE Mode If the alarm is a Master relay alarm the system automatically changes from ACTIVE Mode to IDLE Mo
40. e key This key can also be used to read any other current alarms Depending on the alarm condition the system can have more than one alarm at a time Always clear the first alarm Some alarms have other alarms tied to them For example if a Heater Overtemp alarm occurs the following alarms appear on the display TE 3 Fuse TE 2 Fuse Heater Fuse Pump Fuse TE 1 Fuse If an alarm is present when the system is turned on the system stays in IDLE Mode If the alarm occurs while the system is in ACTIVE Mode the system remains in ACTIVE Mode or defaults to IDLE Mode depending on the type of alarm The following tables list the alarms that can occur Table 4 1 lists information only alarms They have no effect on system operation Table 4 2 lists alarms that deactivate the heater or T E cooling outputs They have no other effect on the system Table 4 3 lists alarms that deactivate the master relay These alarms result from external wiring problems and do not involve the controller microprocessor Descriptions of each alarm follow Refer to Appendix E for Electrical circuitry and Appendix F for circuit markings Appendix G is a list of acronyms used throughout this manual If an alarm appears that is not listed in these tables call Noah Precision immediately Model 2021 Table 4 1 Information Only Alarms Alarm Display Description FLOW COMO ERROR Flow communication error LOW FLOW LOW RESISTIVITY NEEDS FLUID ADDED
41. ed at the Stage delay interval This is set at 60 seconds at the factory A shorter time results in a faster response switching of the thermoelectrics but is not stable CYCLE RATE This parameter sets the Cycle rate for the system Because the controller is a standard proportional time base unit the Cycle rate sets the rate at which the heat output cycles on and off The amount of time the output is on during each period is controlled to match the heat requirements of the system PROP BAND Sofi 2 Installation The Proportional band parameter determines the cycling range for the controller in degrees Celsius This is the P parameter Proportional RESET The Reset parameter sets the integration time for the second mode in the three mode control scheme Setting this parameter to 0 0 eliminates the reset function This is the parameter Integral RATE The Rate parameter sets the differentiation constant for the third mode of the three mode control scheme Setting this parameter to 0 0 eliminates the rate function This is the D parameter Derivative 2ND HEATER This parameter eliminates or activates the second heater output When activated the heater turns on when the temperature setpoint is set to gt 40 C SENSOR CALI This is the digital calibration for the Process sensor and a direct digital offset to the Process temperature To calibrate place a thermometer or temperature calibrator in the tank Measu
42. er cord 2 Check the resistivity box connection 3 Check the pin connectors for miscrimps or loose wires 4 Alarms 4 Check the 3 wire connection to the 962 JG board D clear K red C black 5 Replace the resistivity box AN Note Wiring is subject to change when optional boards are installed Refer to Appendix E for wiring diagrams SP3 This is the Spare 3 alarm It is activated by an open switch on input SP3 The Model 2021 does not use SP3 1 Toclear Disconnect the power cord Check the Molex connector to the SP3 input on the 962 JG board SYSTEM FAILURE This is a catch all alarm to indicate when the system has detected a malfunction in one of the circuitry components For example EEPROM or RAM To clear 1 Disconnect the power cord 2 Replace the 962 JG board Model 2021 Output Deactivation Alarms BAD PROCESS SENSOR This alarm indicates a bad or missing main temperature sensor input T C or RTD When active the temperature reads 0 0 C for the T C sensor and 25 0 C for the RTD sensor This alarm deactivates the controller output To clear 1 Disconnect the power cord 2 Check the DIP switch on the 962 JG board See Figure 4 1 It should be set at RTD O O C C for pins 1 2 3 4 respectively T C should be set CC OO O Open C Closed 3 Check the RTD wires to the J18 connector Be sure the plus is red and the two R s are white 4 Replace the RTD sensor
43. he display panel 962 controller interface The main controller card is interconnected via a flat ribbon cable to the face panel that has the display keypad and audio 1 Overview Description The 962 JG has six optically isolated solid state relay SSR outputs and twelve optically isolated user inputs The master relay is controlled by the microprocessor but can also be turned off with four independent thermal snap switch inputs or by the Thermocouple High Limit input The redundant high limit temperature circuit uses a Type J thermocouple sensor Totally independent of the main microprocessor circuit it has its own optional independent power supply The Model 2021 has a two stage cooling routine Each stage consists of one bank of thermoelectric modules totaling two banks of modules The 962 JG controller calculates how many stages of thermoelectrics need to be activated at a given time If the setpoint is considerably lower than the actual temperature all banks go on with the proper stage delay until the temperature reaches the setpoint The heater then cycles on and off to counteract the cooling The controller calculates exactly how much cooling is needed If the heater is on at least 88 of the time it turns off a cooling stage If the heater is on less than 12 and is above the setpoint a cooling stage is added The controller calculates the most efficient operating stage for a particular setpoint thus minimizing overall
44. he main fuse for the circuit board is not monitored If it blows the circuit board loses power A Power LED on the main controller board is always on when the unit has power A quick glance at the Power LED can determine if the circuit board has power or not Standard Temperature Inputs The Model 2021 has two pre defined temperature inputs the Process sensor and the Overtemp sensor The Process sensor is the main temperature sensor feeding the 3 mode control loop It can be either a Type J thermocouple or a 3 wire 100 ohm 0 00385 platinum RTD Only one input sensor is used at a time A DIP switch on the circuit board selects either the thermocouple or RTD sensor RTD is standard 6 Troubleshooting AN Note The Sensor Type parameter in the Factory Setup must be set to the correct sensor either T C or RTD Open Collector Transistor Inputs The are seven additional inputs which all accept switch closure or open collector transistor input An Open condition is interpreted as an alarm condition These inputs have the following markings on the circuit board LFP Low flow Pump LFC Low flow House water LLT Low level Tank T OT Tank overtemp S OT SSR overtemp SP3 Spare 3 SP5 Needs fluid added System Outputs The Model 2021 has six outputs These are optically isolated open collector transistor drives rated at 500 mW 12 VDC Each has a 12 VDC supply on board and each has an individual LED on the circuit board to show whe
45. his procedure only needs to be done once unless a component has been replaced or the type of process fluid has been changed 1 Enter User Setup and change the following parameters to the indicated values Cycle rate CR Proportional band PB Reset RE Rate RA oon uo Save these values in memory and set the controller to control the tank temperature using an RTD probe Allow the process to run at a setpoint that allows the temperature to stabilize with the heat input required 3 Operation Temperature Primary Setpoint Time Divide PB by 2 if plot looks like this With the Rate and Reset parameters set to zero the temperature will stabilize with a steady state deviation between the setpoint and the actual temperature Observe the measurements on the display noting whether there are regular cycles or oscillations in the temperature An oscillation might be as long as 30 minutes Record and plot readings The tuning procedure is easier to follow if a strip chart recorder is used to monitor the process temperature If there are no regular oscillations on the temperature divide the PB by 2 Allow the process to stabilize and check for temperature oscillations If there are no oscillations divide the PB by 2 again Repeat until cycles or oscillations begin Refer to Figure 3 3 below Primary Setpoint g L 5 2 3 y 3 3 e Time Time This is close to Multiply PB by 2 if plot perfect tuning loo
46. hm platinum 00385 PID with anti reset windup Cycle rate 1 25 sec Proportional band 0 0 25 0 C Reset Integral 0 0 25 0 min Rate Derivative 0 0 25 0 min Calibration offset 9 9 C Operation Range Storage Range Construction Size Weight Connection Output Power 0 to 50 C 90 RH Non condensing MAX 40 to 60 C 90 RH Non condensing MAX Open board Display panel 3x7x2in H xW x L 25 x 177 x 50 mm Control card 6x9x21 2 in H xW x L 152 x 228 x 51 mm lt 3 lbs 1 8 kg Thermocouple 6 32 screw I O wiring 156 cc Molex 045 sq pin Control board to display IDC w locking ears Power wiring amp universal mate n lock 500 mw 12C VDC 15 VA 220 VAC 50 60 Hz Board only 16 5 amp 220 AC 50 60 Hz Max power load Appendix D Process Plumbing Figure D 1 Liquid By Pass D 1 Appendix E Electrical Circuitry Appendix F J5 Input Connector Circuit Markings on the 962 JG Board 1 Tank Full MN mais ULT 3 Low FLow House Water 4 LFC J6 Input Connector 1 Low FLow Pump 2 LFP 3 Needs Fluid Added 4 SP5 5 SSR Overtemp ri i 7 Safety Cover Off 8 SP4 9 Low Level Reservoir ie ed LR 11 Thermoelectric Overtemp 12 TEOT 13 Heater Overtemp 14 H OT J7 Hi Limit Connector 1 pp High Limit T C Type J 2 T C 3 T C J8 Input Connector Spare 2 3 4 SP3 1 TANK
47. ic cooling enables the temperature control unit to cool process fluids and maintain required temperatures with high reliability and low maintenance Model 2021 Controller Interface A microprocessor based controller Model 962 JG is the user interface and control for the Model 2021 cooling system It monitors temperature with a J type thermocouple sensor or an RTD sensor depending on the application An RTD sensor is more commonly used The control loop is a standard three mode Proportional Integral Derivative control algorithm PID control scheme with anti reset windup The 962 JG employs an autotune routine to determine three mode control parameters Proportional band Reset and Rate Status alarm and diagnostic functions are monitored and reported through both an audio buzzer and a 2 x 20 backlighted LCD display The LCD also displays set up parameters A six key tactile keypad provides for set up data and user adjustments A short beep acknowledges valid inputs and a razz tone sounds if the input is invalid See Figure 1 2 Two additional LEDs on the face panel indicate the immediate status of the heating and cooling outputs The audio buzzer also sounds if an alarm message appears START ALARM STOP SILENCE UP DOWN AN Vv l NOAH PRECISION INC MODE RETURN HEAT j COOL Figure 1 2 The 962 JG Controller Interface There are two circuit assemblies the main board located inside the system and t
48. ication Port 100 mV C Communications Interface Temperature range 0 0 C to 45 0 C Voltage Temperature 1 00 Volts 10 0 C Port 1 37 pin D subminiature receptacle labeled 72J1 See Figure 5 4 Pins 20 amp 1 TXand Common Channel 1 Transmit a DC voltage to the process equipment corresponding to the current temperature of the 2021 reservoir 24 amp 5 RX and Common Channel 1 Receives the DC signal from the process equipment which corresponds to the Temperature setpoint to which the 2021 is set 26 8 7 28 8 9 Port 2 Pins 1 amp 2 3 amp 4 586 Model 2021 Hard Alarm Closed contact indicates that there is no alarm condition Open contact indicates a hard alarm condition A hard alarm condition means a fail condition which causes the 2021 to shut down Soft Alarm Closed contact indicates that the 2021 is operating under normal conditions Open contact indicates a soft alarm or warning condition The 2021 is not totally shut down but will eventually shut down if the alarm is not cleared 9 pin male circular plastic connector size 13 labeled 72J2 Amp 206705 1 Chiller EMO Open contact indicates that the Model 2021 EMO button is pressed in Remote Local Switch A 24 VAC signal from the etcher triggers a relay that activates the Remote interface No voltage across Pins 3 and 4 switches the 2021 to Local operating mode Etcher EMO Open contact indicates that the Etcher EMO switch is pres
49. indicates a normal operating condition Open contact indicates an emergency off condition 6 Soft alarm 9 Soft alarm Return Closed contact between pins 6 and 9 indicates a normal operation condition Open contact indicates a soft alarm condition See Figure 5 5 4 6 5 9 Figure 5 5 Transistor Output 5 9 5 Optional Equipment RS 422 Communication Interface The RS 422 communications interface uses a standard RS 422 connection with multi drop capability It is a serial link with direct access to FLOW and RESISTIVITY values via a READ Command Connection is through any standard terminal or computer system with an RS 422 port The link is fixed at 8 bit 1 stop and 1 start bit no parity requiring 5 leads to function The internal ACIA uses a full duplex interrupt driven transmission scheme The unit can receive and transmit simultaneously while continuing to perform normal functions Baud rate is set at 9600 baud All commands must be prefixed by a channel selection indicator that corresponds to the identidication number programmmed into the controller with a 4 bit switch This ID number differentiates between controllers in a multi drop system The following format indicates Channel selection CXX C _ indicates that the following information is the Indentification number of the device receiving commands XX is the Identification number any number from 00 to 15 AN Note Channels are set via a dip switch on
50. ion with the critical PB setting by 1 65 or use Nomogram below in Figure 3 6 Try several settings of the PB to reach the required final temperature deviation Temperature Deviation with Critical PB Setting Example 3 Deviation with PB 1 2 4 5 10 15 20 30 40 50 70 100 Set PB to obtain Toa A A eal e A I I l 5 Final Deviation 23 5 10 1520 30 4050 100 150 Final Temperature Deviation 1 65 Deviation with Critcal PB Setting Figure 3 6 Nomogram 11 These are all measurements necessary to obtain optimum performance from the controller Use the oscillation time measurement above to calculate the value of the Reset Parameter in repeats per minute RESET 8 5 x 1 To To oscillation time in minutes Or use Nomogram II in Figure 3 7 to calculate the RESET value 3 12 Model 2021 Temperature Cycle Time in Minutes 0 1 0 2 0 3 10 20 30 100 5321 0 5 0 2 0 1 05 03 02 Correct Reset Time in Repeats per Minute Figure 3 7 Nomogram Il 12 Using the same oscillation time calculate the value for the Rate Parameter in minutes RATE To 10 To is oscillation time Or use Nomogram lll in Figure 3 8 to calculate the RATE value Temperature Cycle Time in Minutes 0 1 0 2 0 3 1 2 3 10 20 30 40 50 Rp 117 01 02 03 0 1 0 2 0 3 1 2 3 4 5 Correct Rate Setting in Minutes Figure 3 8 Nomogran Ill 3 13 3 Operation Turning the System OFF To turn the Model 2021 off press the
51. ks like this Figure 3 3 Temperature Oscillations If oscillations occur immediately multiply the PB by 2 Observe the resulting temperature for several minutes If the oscillations continue increase the PB by factors of 2 until the oscillations stop The PB is now near its critical setting Increase or decrease the PB setting carefully until the cycles or oscillations just barely appear in the temperature recording 3 10 Temperature Model 2021 8 Read the steady state deviation between the setpoint and the actual temperature with the critical PB setting Because the temperature cycles a bit use the average temperature 9 Measure the oscillation time in minutes between the neighboring peaks or valleys Use a chart recorder or read the measurements at one minute intervals to obtain the timing See Figure 3 4 Primary Setpoint Y o i Measure 5 this temp E O A 3 A gt lt i A A Measure Increase Critical PB this time Decrease PB PB gt Startup Time Figure 3 4 Oscillation Time 10 Increase the PB setting until the temperature deviation increases to 65 See Figure 3 5 Primary Setpoint Y Y Deviation temp 1 65 x Temp ee with PBg deviation UN with PBg A A A Critical PB tes a Time with PB gt Startup Time Figure 3 5 Final Temperature Deviation 3 11 3 Operation The required temperature deviation can be calculated by multiplying the initial temperature deviat
52. lity and clarity When installing the cable the Model 2021 must be reset To reset turn the circuit breaker Off and then turn back On Y DN Figure 5 1 Remote Port The Digital Flow Meter option is for processes that require an adjustable low flow alarm setting The standard Model 2021 uses an inline flow sensor switch to monitor the process flow rate Because the flow switch is set at 2 0 gpm if the flow rate is less than 2 0 gpm an alarm condition occurs which shuts off the temperature control operation The 2 0 gpm in line flow switch is usually removed if the flow meter option is used The RFO Rotor Flow Output type flow meter sends an on off pulse that varies according to the frequency of flow An input voltage from the communication interface board 962L is required for this option The active flow rate is displayed on the second line of the display screen For example ACTIVE MODE xx xC Flow x x gpm Model 2021 The Flow Resistivity and Setpoint readings cycle for time periods set in SETUP Mode The RS232 must be set at 04 in the Factory Setup The Low flow alarm is adjustable from 0 0 to 12 0 gpm This parameter is in User Setup The 2021 pump is rated at 4 0 gom so the maximum setting should not exceed 3 5 gpm Electrical Sensor VDC red Ground black Signal out white Board 962L Pin 9 voltage supply red 10 In signal white 11 Ground black Calibration is performed at the facto
53. n each output is on These output channels have the following markings on the circuit board HT Heater PMP Pump motor T E Thermoelectric cooler 1 A1 Thermoelectric cooler 2 6 4 Model 2021 A2 Thermoelectric cooler 3 EA 2nd heater The Heater output controls the electric heating SSRs The heaters act as the control elements in the system They cycle on and off to provide required temperature control Cycling is based on the output of the PID algorithm The Pump Motor output is a general purpose binary output that is turned on when the system is in ACTIVE Mode It typically drives an SSR that controls a pump motor The Thermoelectric Cooler 1 output runs thermoelectric cooler 1 It drives the first chiller stage and goes ON when cooling demand calls for one or more stages This output can be disabled for high temperature applications by setting the Cooling parameter in the Factory Setup to NO A 1 0 C hysteresis prevents fluctuation when the system is turned on Cooling starts at PS CD but turns off at PS CD 1 0 The Thermoelectric Cooler 2 output uses AUX 1 to run thermoelectric cooler 2 It drives the second chiller stage and is ON when cooling demand calls for two or more stages This output can be disabled for high temperature applications by setting the Cooling parameter in the Factory Setup to NO The Flow output uses AUX 1 The Low flow is compared to the flow reading from the 962 JG AUX 1 output is ac
54. ncial loss arising out of or in connection with the sale installation maintenance use performance failure or interruption of its products even if Noah Precision or its authorized reseller has been advised of the possibility of such damages xi Registration All Noah Precision products include the model number and the serial number on the nameplate This nameplate is found on back plate of the unit adjacent to the power cord o NOAH PRECISION INC C MODEL SERIAL VAC Amp Phase Wire Hz 6389 San Ignacio Avenue San Jose CA 95119 Please use the information from the nameplate to complete and return the registration card immediately Unpacking and Damage Noah Precision Inc inspects each product thoroughly before packaging Safe delivery is the responsibility of the carrier Please inspect the unit for damage and submit claims for loss or damage to the carrier itself Visible damage should be noted on the freight bill Be sure the carrier s agent signs the freight bill acknowledging the damage The carrier has the required forms for submitting damage claims Crates are reusable Please do not destroy AN Warning Heavy load Unit weighs 170 Ibs xii Model 2021 When unpacking do NOT turn crates on their sides 1 Unscrew the bolts at the bottom of the crate 2 Remove the top assembly 3 Unscrew the bolts on the side of the Temperature Control Unit TCU JN Caution
55. ncluding external plumbing and DI cartridge containers Fill until the water is visible to the bottom of the lid coupling approximately 1 3 8 inches from the top A special razz tone sounds when the tank is full Put the plug back and close the lid Check for leaks Press the RETURN key to save and the DOWN key to exit the Fill Monitor mode Save to go back to the ACTIVE or IDLE Mode display or to exit User Setup Press the RETURN key to exit the SETUP Mode The system is now in the ACTIVE Mode During warmup unless the Process temperature exceeds the Low alarm setpoint the alarm is not activated This feature eliminates nuisance alarms during start up 2 Installation Factory Set up Press the MODE Key to enter the Factory Setup Mode If access code protection is required enter a second access code using the UP and DOWN keys to enter a four digit code ENTER ACCESS CODE 2 XXXX Press the MODE key a second time to view or program factory parameters If an access code is unnecessary simply press the MODE key the second time without using the UP and DOWN keys If the access code matches the following screen appears SETUP FACTORY MAXIMUM SETPOINT The second line of this screen shows the first of a series of factory parameters Use the MODE key to advance through the parameters Use the UP and DOWN keys to adjust settings To exit the Factory Setup press the RETURN key Table 2 2 lists the screen displays f
56. nd automatically inserts them into the Prop Band Reset and Rate parameters When AutoTune is completed the system returns to ACTIVE Mode To cancel AutoTune with no effect on previous tuning parameters press the Stop Key or enter the SETUP Mode and change the AutoTune parameter back to NO Model 2021 Troubleshooting Guide Danger High Voltage High voltage is active in the system Safety covers provide protection for the user and the machine If bypassed only authorized and qualified personnel should repair or test the machine Problem Possible Cause Possible Solution Unit does not start 1 Now power to the unit 1 Check power cord and power outlet 2 EMO button is latched 2 Check emergency button Turn to reset 3 Fuse is blown 3 Cisconnect the power cord Check the fuses 6 Troubleshooting Problem Possible Cause Possible Solution Circuit breaker is on but display is not active 1 Loose ribbon cable No power to the main board Fuse is blown 1 Disconnect power cord Check ribbon cable Check connection J19 on the 962 JG board Disconnect power cord Check the fuses Pump does not start when unit is on Pump fuse is blown SSR is defective h Disconnect the power cord Check pump fuse Check pump SSR Replace if necessary Circuit breaker trips repeatedly h S Power cord is not wired correctly Fuse is blown Shorted SSRs Shorted
57. nect the power cord Check the wiring to the 962L board DO 2 0 Pin 9 Positive red Pin10 In signal input white Pin11 Gnd black LOW RESISTIVITY The Low Resistivity alarm is only active if the Resistivity parameter has been selected in Factory Setup When active the current resistivity input is continuously compared to the Low resistivity parameter The alarm is activated when resistivity falls below the parameter setting for 10 seconds To clear Change DI cartridges Disconnect the power cord Check resistivity probe connection Check resistivity box connection E US N Adjust the alarm to a proper setting at least 1 5 Mohm Model 2021 6 Replace resistivity probe 7 Replace resistivity box AN oteWarning Wiring is subject to change when optional boards are installed Refer to Appendix E for wiring diagrams NEEDS FLUID ADDED This alarm indicates that the reservoir needs fluid It is activated by an open switch on input SP5 To clear 1 Fill the tank 2 Check for leaks 3 Disconnect the power cord 4 Check the crimps and connectors 22AWG yellow from the float sensor to the 962 JG board SP5 input RESIST COMO ERROR The Resistivity Communication Error alarm is only active if the Resistivity parameter has been selected in Factory Setup This alarm is activated if the communication link between the Resistivity monitor and the unit is disrupted To clear 1 Disconnect the pow
58. or the Factory Setup parameters the parameters associated with each display and the range allowed within each parameter Descriptions of each parameter follow These parameters are set at the factory to configure the system to specific equipment AN Caution Changing a Factory Setup parameter can require a complete system reconfiguration 2 16 Model 2021 CALL Noah Precision before changing a parameter if uncertain of the results Table 2 2 Factory Setup Parameters Display Parameter Range MAX SETPOINT Maximum setpoint 10 0 to 90 0 C RTD COOLING Cooling Active Yes No RESISTIVITY Resistivity Active Yes No FLOW ACTIVE Flow option Active Yes No SENSOR TYPE Process sensory type T C or RTD RS232 ACTIVE RS232 Active 0 NO RS232 MODEL DISPLAY SOFTWARE Noah Model number Current software rev ACCESS CODEH2 Access code 2 PS Process setpoint Factory Setup Parameters MAX SETPOINT 1 Normal RS232 2 PS Write only 3 Flow Write only 4 PS amp Flow write only 2021 XXXX 0 9999 This parameter restricts the maximum setting ranges for all of the temperature parameters in the user setup parameters COOLING This parameter activates or deactivates the system cooling feature If set to NO the cooling outputs become inactive RESISTIVITY ACTIVE 2 17 2 Installation AN Note This parameter activates or deactivates the Resistivity reading option If set to YES the unit relays information
59. previous tuning parameters press the Stop Key or enter the SETUP Mode and change the AutoTune parameter back to NO Tuning the PID Controller The 962 J controller uses a PID control scheme to provide constant temperature control The controller references a temperature setpoint and then tries to match and maintain that setpoint To adjust PID controllers the following terms must be understood Proportional Band PB This is the value that produces constant amplitude cycling In other words PB is the percent change in measurement at a constant setpoint required to cause 100 change in output Integral This is the action of eliminating offset the difference between the setpoint and the actual temperature when it exceeds requirements Model 2021 Integral action is based on the principle that the response must be proportional to both the size and duration of the error AN Note Proportional and integral actions share one serious limitation a significant error must be detected before either produces a strong response Derivative This action is based on the principle that the controller must also respond to the rate at which the measurement is changing even though the actual error is still small When a measurement starts to change derivative action generates an immediate response proportional to its rate of change Each system must be tuned to obtain an acceptable ramp up in temperature from ambient to setpoint T
60. process temp alarm activates LOW TEMP This is the Low temperature alarm setpoint If the Process temperature falls below this setting after warmup the Low Temperature alarm is activated LOW DEV ALARM if applicable This parameter changes the Low temperature alarm setpoint from a direct setpoint to a relative setpoint The Low temp alarm will activate when the process temperature falls below the process setpoint minus the Low deviation alarm setpoint For example if the Low dev alarm is set at 5 C and the Process temperature is set 2 10 Model 2021 at 18 0 C and the ACTIVE Mode temperature is below 13 0 C the Low process temp alarm activates LOW RESIST This is the Low resistivity alarm setpoint If Resistivity is activated in Factory Setup this value is continuously compared with the Resistivity input If the Resistivity input falls below this level for 10 seconds a Low Resistivity alarm appears LOW FLOW This is the Low flow alarm setpoint If Flow is activated in Factory Setup this value is continuously compared with inputs from the 962 L If the flow falls below this level for 10 seconds a Low Flow alarm is activated STAGE DELAY This is the Stage delay time interval the time between adding or removing stages of cooling If heater output is operating above 88 output cooling stages are disabled at the Stage delay interval If heater output is operating at below 12 output cooling stages are enabl
61. re the value then adjust the calibration using the UP and DOWN keys Press the RETURN key to save Repeat these steps until the Process temperature matches the temperature on the thermometer Remember to press RETURN to save AN Note 2 12 Model 2021 The 2021 is temperature calibrated when shipped from the factory The USER MUST RECALIBRATE the temperature at the facility to verify the number settings SYSTEM ID NUMBER Used with the communications protocol the number identifies each unit in a system configuration that uses multiple controllers BAUD RATE This parameter sets the Baud rate for the communications protocol 300 600 1200 2400 4800 9600 19200 Default is 9600 baud ACCESS CODE This Access code must be matched to enter the USER Setup parameters If this parameter is set to zero no access code is required AUTO TUNE This parameter activates the AUTOTUNE mode If set to On the system automatically begins the AUTOTUNE routine the first time the system enters ACTIVE Mode AUTOTUNE adjusts the PID parameters for optimal process results The words AUTOTUNE flash during the AUTOTUNE routine During this procedure the system runs a test sequence to determine basic system characteristics Appropriate tuning values 2 Installation are calculated and automatically inserted into the PROP BAND RESET and RATE parameters AN Note The system is tuned to 18 C before leaving the factory For better
62. ry before shipping Liquid Pressure By Pass The Liquid Pressure By Pass option is normally used during a preventive maintenance session Instead of shutting down the Model 2021 this option allows the TCU to recirculate the process fluid at set temperature When the system is restarted and the equipment is ready to go back on line the TCU is already at temperature thus minimizing stabilization time at start up The Liquid Pressure By Pass option is mounted externally on the back of the Model 2021 See Figure 5 2 Refer to Figure D 4 for plumbing diagrams Using stainless steel components the piping has a pressure by pass set at 55 psi when it leaves the factory This setting is not fixed it can be adjusted by turning the set screw at the pressure valve to the required pressure Piping includes a pressure gauge 5 Optional Equipment Pressure relief valve A EZ ZB Process IN gt Ez ZB Z Pressure guage ZA ce 4 Z Z ZA E Process OUT lt Figure 5 2 Liquid Pressure By Pass To adjust the pressure setting 1 Remove both the cap screw slotted head and the lock set screw Hex head 2 Turn the adjusting screw Hex head to change the pressure setting 3 After setting the pressure be careful to tighten the lock set screw against the adjusting screw AN Note Flow into the machine must be off to use the by pass option Communication Interface Model 2021
63. s and crimps of the snap disc Be sure the T E wires are not reversed Check the Molex connector at the T E OT on J16 on the 962 JG board NILO a 4 17 4 Alarms 4 18 Remote Display Optional Equipment There are several options available with the Model 2021 They include the following e Remote Display Digital Flow Meter e Liquid Pressure By Pass e Communication Interface The 962 JE is a Remote Display that shows the same information displayed on the 962 JG controller interface It provides both remote key and display functions The Remote display communicates via a DB25 connection through an extension cable to the main controller Once installed both screens simultaneously display identical data and accept key functions from either display pad The Remote Display does NOT control any inputs or output but only receives display information from the 962 JG controller and sends key inputs to the 962 JG The end user simply monitors and controls the TCU from another location The 962 JE board is mounted on the front lower left hand corner of the 2021 chassis A 25 pin D sub miniature connector receptacle is located in the back of the Model 2021 Refer to Figure 5 1 The user need only plug in a 25 pin straight D sub mini connector between the 2021 TCU and the Remote Display A 35 foot 25 pin 5 Optional Equipment Digital Flow Meter cable is preferable A longer cable might result in problems with visibi
64. s during maintenance or service When the system is turned off a lock is inserted in the frame of the machine over the circuit breaker to prevent accidental power up See Figure 1 10 A lockout tag shows who locked the system along with time and date Figure 1 10 Model 2021 Lockout Tagout Feature 1 Overview 1 10 Hook up Installation Installing the Model 2021 takes about 30 minutes including Hook up System start up and Com link start The only items required are basic plumbing tools deionized water ethylene glycol and a power source AUTOTUNE requires an additional 15 to 60 minutes to execute Before beginning the installation test the facility supply water e lt 20 um filtered water Flow rate minimum 3 gpm e Temperature range 10 to 25 C e Water pressure 50 to 80 psi with minimum differential pressure of 30 psi Refer to Figure 2 1 on the following page for a back view of the Model 2021 and hook up procedures Assuming plumbing for both process and facility water are already in place 2 Installation FA Z VA ot Z Z PAE AAE E A AA AS 25 Pin Remote ZE A Process IN Z zB pi FGD EN Ed a Fg Process OUT a Facilities IN Facilities OUT Figure 2 1 Back View of the Model 2021 Hook up procedure 1 Check the DI cartridges Tighten until snug hand tight 2 Connect the tubing for the Process IN fluid Use 1 2 inch diameter tubing or equivalent Loc
65. s the user to set and adjust the Process temperature of the Model 2021 from a remote site Refer to Section 5 for optional equipment available on the Model 2021 The Model 2021 is connected to etcher CVD equipment which sends a voltage signal that translates its programmed temperature to the 2021 and the 2021 sends back a signal to the etcher CVD relating the current temperature of the TCU This eliminates the need to set both the etcher CVD and the Model 2021 temperatures There are two interface options on the Model 2021 100 mV C RS 422 Voltage requirements and pin connections are described below Start up procedures for each link follow 100 mV C Option Voltage requirements 2 5 to 7 5 VDC 1 0VDC 10 C Comm port A 37 pin D sub mini connector receptacle Pins 2485 RX receive signal from etcher CVD 20 amp 1 TX transmit signal to etcher CVD 26 8 7 fail signal 28 8 9 warning signal 378 19 remote Start 36 8 18 remote Stop B 9 pin circular plastic connector 2 Installation Pins 1 amp 2 EMO from chiller 2021 3 amp 4 remote local input 24 VAC 586 EMO from etcher 1 Check the connections on the 37 pin connector on the rear panel of the unit Pin 24 Positive voltage IN 5 Negative voltage IN 20 Positive voltage OUT 1 Negative voltage OUT 2 Applying voltage to pins 24 and 5 changes the temperature control units process temperature setpoint to a corresponding value For example applying 2 3
66. sed in Closed contact indicates a normal condition AN Note For processes that go below 0 0 C contact Noah Precision The communication interface board can not analyze a negative voltage input and or output Thus it cannot go below 0 0 C with the interface connected an additional board is required However the Model 2021 can go below 0 0 C in Local manual mode 5 Optional Equipment 100 mV C ComPort NN 100 mv C ComPort Figure 5 4 100 mV C Analog Signal Communication Port For Dual Channel Chiller only Port 1 37 pin D sub miniature receptacle Pins 21842 TX and Common Channel 2 Transmit a DC voltage to the process equipment corresponding to the current temperature of the 2021 reservoir 2586 RX and Common Channel 2 Receive the DC signal from the process equipment which corresponds to the temperature setpoint to which the 2021 is set Model 2021 10 mV C Analog Interface Special Temperature range 0 0 C to 75 0 C Conversion 0 010 VDC 1 0 C Port 9 pin circular plastic connector Std male size 13 Noah Precision P N 42 1547 000 AMP P N 206705 1 Pins 1 TX Temperature output 2 Common 3 RX Temperature setpoint 4 Hard alarm 5 Hard alarm Return Closed contact between pins 4 and 5 indicates a normal operating condition Open contact indicates a hard alarm conditon See Figure 5 1 7 TCU EMO 8 TCU EMO Closed contact between pins 7 and 8
67. stivity monitor 220V DI filter cartridge 10 Pump Regenerative 4 gom w motor Relay mercury 2 pole Transformer 24 VAC 220V Button emergency machine off EMO Cable ribbon 26 pin 24 long Contactor mechanical 40a 208V Fuse 10 Amp pump Fuse 15 Amp heater Rectifier diode metal housing 35 amp 600V Relay solid state SSR 25 amp Resistor Sensor RTD probe resistivity Sensor RTD probe temperature Switch flow in line 2 gom Switch 3 stage float liquid level add full Switch circuit breaker 30 amp 250V Valve drain ball stainless Bypass valve assembly optional Relay SPDT 24 VAC 100 mV C option only Relay dual 240V 25 amp Communication board 962 LH 529 220V RS 422 B 1 Quantity a _A 4 NN A XS YP W NM AB PNM HH HAH H H H Ad NAN H HAH oi Appendix C Engineering Specifications for the 962 JG Controller Range Temperature Resolution Temperature Noise Rejection Measuring Time Display Annunciator Setup Memory Memory Retention Sensor Control Adjustment 5 0 to 95 0 C 0 1 C NMR 60 db 60 Hz CMR 120 db 60 Hz 4 Conversions per second Two discrete LEDs red and green Alpha numeric display 2 x 20 LCD Backlit 2 in characters Audio tone 2500 Hz EEPROM All parameters 10 Years w o power Standard Type J thermocouple Cold junction compensation Up scale break protection or RTD or 100 o
68. t the back of the unit labeled RS 422 See Figure 5 6 for a rear view of the TCU Plug a standard RS422 cable into this port observing the following guideline Pin out Figure 5 6 Pin 2 100 mV C ComPort RS422 Port 5 12 TD from TCU 24 TX 3 RD to TCU 23 RD 7 Signal ground Z 100 mV C Fi ComPort ES Model 2021 5 13 Troubleshooting This section discusses the following topics to help troubleshoot any problems that might occur when operating the Model 2021 Refer to Appendix E for electrical circuitry A troubleshooting guide is provided at the end of the chapter If following these procedures does not solve the problem please do not hesitate to call Noah Precision LEDs e Master relay safety switches Fuses e Temperature inputs Open collector transistor inputs e System outputs Backdoor e Auto tuning LEDs There are two LEDs on the face panel The Heat LED indicates that the heater output is active and the Cool LED indicates that the thermoelectric output is active 6 Troubleshooting There are nine LEDs on the main circuit board These provide a quick scan of active channels PWR 5VDC 5VDC power supply is On PWR 12VDC 12 VDC power supply is On SRLY Master relay is active HT Heat output to the SSR is active PMP Pump output to the SSR is active T E Thermoelectric output to the SSR is active A1 T E 2 AUX 1 output is active A2 T E 3
69. the marking label 208 VAC 60 Hz 3 phase Delta 30 amp An Emergency Machine Off EMO button is provided on the front of the controller interface Model 2021 Limited Warranty Noah Precision warrants its products against defects in materials and workmanship under normal use and service for the period of warranty from the date of delivery If a product does not operate as warranted during the warranty period Noah Precision shall at its expense correct any such defect by repairing the defective product or part or at its option by delivering to the customer an equivalent product or part to replace the defective item All products that are replaced become the property of Noah Precision Replacement products may be new or reconditioned Any replaced or repaired product or part is guaranteed for the remainder of the initial warranty period Noah Precision shall not be liable under this warranty if its testing and examination disclose that the alleged defect in the product does not exist or was caused by the customer s or any third person s misuse neglect improper installation or testing unauthorized attempts to repair or any other cause beyond the range of the intended use or by accident fire lightning or other hazard Limitation of Liability In no event shall Noah Precision be liable for incidental consequential indirect special or punitive damages of any kind or for loss of revenue loss of business or other fina
70. the steps deliniated below in sequence The numbers are a level of hierarchy in themselves For example 1 Fix 3 gt YES NO i 2 Fix YES NO Model 2021 el Val Danger High Voltage High voltage is active in this system Troubleshoot components only if power has been TURNED OFF Information Only Alarms FLOW COMO ERROR The Flow Communication Error alarm is only active if the Flow parameter has been selected in Factory Setup This alarm is activated if the communication link between the resistivity monitor and the unit is disrupted To clear 1 Disconnect the power cord 2 Check the wiring to the 962L board Pin 9 Positive red Pin 10 In signal input white Pin11 Gnd black 3 Replace the 962 JG EEPROM AN Note Wiring is subject to change when optional boards are installed Refer to Appendix E for wiring diagrams 4 Alarms LOW FLOW The Low Flow alarm is active only if Flow Active has been selected in Factory Setup When active the Flow input is continuously compared to the Low Flow parameter The alarm is activated if the Flow falls below the parameter setting for 10 seconds This alarm is active if the optional flow meter is installed To clear The system must be in ACTIVE Mode Check on the loss of flow by opening the tank lid If the process water is moving there is flow N Check the lines for leaks Check the pump and motor Discon
71. tive when the flow reading is higher than the Low flow If the flow reading falls below the Low flow AUX 1 is inactive The Thermoelectric Cooler 3 output uses AUX 2 to run thermoelectric cooler 3 It drives the third chiller stage and is ON when cooling demand calls for all three stages This output can be disabled for high temperature applications by setting the Cooling parameter in the Factory Setup to NO The 2nd heater output controls the second heater SSRs Output is activated at the same time as the heater output and is activated only when the process setpoint is set at gt 40 C 6 Troubleshooting Back Door A special code has been incorporated into the software so that user functions can be accessed no matter what the customer has done with the access codes This code is 222 AutoTuning The system can automatically tune the PID parameters of the unit to fit the specific requirements of a given system This procedure takes up to ninety minutes depending on system configuration 1 Set Setpoint and Cycle rate parameters before activating AutoTune To activate AutoTune 2 Enter User Setup and change the AutoTune parameter to YES 3 Press the RETURN key to exit the SETUP Mode 4 Ifthe system is in IDLE Mode press the Start key If the system is in ACTIVE Mode it automatically starts AutoTune The system runs a test sequence to determine basic system characteristics then calculates the appropriate tuning values a
72. troller configurations The software automatically reconfigures the controller to match the model number designated in this parameter setting SOFTWARE This is a READ ONLY display indicating the current system software ACCESS CODE 2 This Access code must matched to enter the Factory Setup parameters lf this parameter is set to 00 no access code is 2 19 2 Installation required To change this code enter 222 for the access code Press the MODE key until the display reads SETUP FACTORY ACCESS CODE 2 XX Press the UP or DOWN key to change the access code then press RETURN to save Factory access code is set at 99 at Noah Precision Saving Parameter Changes The system automatically enters a SAVE Mode when the RETURN key is pressed to exit either User Setup or Factory Setup The following screen appears SAVE MODE PLEASE WAIT All setup parameters become stored into EEPROM memory This is a permanent 10 year minimum life memory that does not require battery backup The SAVE routine takes about 2 seconds to complete This feature allows OEM users to specify the initial condition parameters set at the factory It also allows the user to modify the appropriate parameters from the keyboard without the risks associated with manual adjustments When SAVE is complete the system is in ACTIVE or IDLE Mode Com Link Start up Model 2021 The Communication Link Start up procedure allow
73. volts sets the temperature to 23 C or when the TCU reaches 23 C the corresponding voltage of pins 20 and 1 is equal to 2 3 volts 3 Press the RETURN key to save and return to the IDLE Mode For processes that require temperatures below 0 0 C contact Noah Precision The interface is now complete Press the RETURN key to enter the ACTIVE Mode for the Model 2021 RS 422 Interface Comm port 25 pin D sub mini connector receptacle Pins 2 TD from TCU 24 TX 3 RD from etcher WD 23 RD 7 Signal ground Channel setting is hard wired Refer to Appendix E Model 2021 System Shut down System shut down requires three steps 1 2 Press the STOP key on the display Turn off power to all circuits with the power switch located on the right side of the Model 2021 Pull out the TCU plug Operation The Model 2021 temperature control unit is designed to operate automatically after the initial setup Refer to Section 2 for Setup procedures Turning the System ON To power up the system execute the following procedure 1 Plug in the power cord at the back of the unit This is the 208 VAC 30 amp 5 wire connector Check that the EMO button is protruding If not turn clockwise to reset The EMO button is located on the left side of the controller display Turn the power switch ON This is the circuit breaker on the side panel of the unit The thermoelectric module heater element and pump
74. ylene glycol must be replaced every two years or every time the TCU is down allow six months usage Replace the DI cartridges when the resistivity reads below 2 0 Mohm cm Procedure 1 Remove the left side panel 2 Drain the fluid by using the ball valve JN Warning Ethylene glycol is a hazardous chemical and must be disposed of properly 3 Remove and replace the DI cartridges 4 Refill with a new process fluid mixture Because the bearings and coupling undergo continuous cycling the motor and pump must be replaced every two years To replace the pump use the following procedure 1 Disconnect the main AC supply 2 Drain the system 3 Remove the DI cartridges Model 2021 Remove the DI cartridge bracket and the center rear panel Remove the right side panel Remove the two compression fittings Unplug the 3 pin connector from the motor Remove the four 1 4 20 bolts Remove the pump Disconnect the two hot wires and ground wire from the motor Rewire the two hot wires to the new motor Replace the bolts and tighten Replace the compression fittings Replace the center rear panel and the DI cartridges Replace the right side panel Refill with new coolant 7 Maintenance Appendix A Engineering Specifications for the Model 2021 Overall dimensions Length 31 inches with filters 26 inches w o filters Width 14 inches with filters 11 1 2 inches w o filters Height 27 inches

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