Troubleshooting FRU Replacement High Capacity Coolant
Contents
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3. i 00 L ALON 335 189r SH3dKN MUNG VNIHO 401 NMOUS ON TINE S 404 ILHM SI 40709 3UIM NS VNIHO 404 MOTIZA ANY Omg S N 404 N33Y49 SI 40709 3YIM Z O O O Q Q_2 Q _9 O O O O Q_9 Q Q O O O O O O AD al P 1407707 9 vid flat z r dr oid edt s r Zar 9dr S r dr car Zd s s sinoa SO a TO YOSNIS dWAL ATddNS AEN u s S NILIS 3dNNP 00b OL L vino Coos y 0389 19 79 038 2z 99 cinoa Gume zax ous SALON 99 L 30Vd 335 E es rel ee vere mer SE e 4 ung vias 1 AT ou ec 9 bu a38 19 09 3HOHOL NI u OWAPZ UATIOHINOD O0YOL q 1SNII q m ES s sr re sr 2428 093 9NBHA UMOIOSSY ON ZTSTT G3A0N33 MH Ga fensa HO use avg monde a T5807 TELT STI yao f Id re _ WARRANTY Thermo Electron Corporation warrants for 24 months from date of shipment any Thermo Electron unit according to the following terms Any part of the CDU manufactured or supplied by Thermo Electron and found in the reasonable judgment of Thermo Electron to be defective in material or workmanship will be repaired at an authorized Thermo Electron Repair Depot without charge for parts or labor The CDU including any defective part must be returned to an authorized Thermo Electron Repair Depot within the warranty period The expense of returning the CDU to the authorized Thermo
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5. 7 lbs Torque VFD Power Wires 16 19 Ibs Torque VFD Controller Panel 10 12 Ibs 5 Calibrate the VFD and install default settings see next page 6 Check for error codes on the VFD and controller ls VFD Settings Viewing and Editing Parameter Steps 1 When Power is applied the last user selected Display Group parameter number is briefly displayed with flashing characters The display then defaults to that parameter s current value Press Esc once to display the Display Group parameter number shown on power up The parameter number will flash Press Esc again to enter the group menu The group menu letter will flash Press the Up Arrow or Down Arrow to scroll through the group menu d P and A Press Enter or Sel to enter a group The right digit of the last viewed parameter in that group will flash Press the Up Arrow or Down Arrow to scroll through the parameters that are in the group Press Enter or Sel to view the value of a parameter If you do not want to edit the value press Esc to return to the parameter number Press Enter or Sel to enter program mode to edit the parameter value The right digit will flash and the Program LED will illuminate if the parameter can be edited Press the Up Arrow or Down Arrow to change the parameter value If desired press Sel to move digit to digit or bit to bit The digit or bit that you can change will flash 10 Press Esc to cancel a change The digit wi
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8. Remove the screen 3 Replace the screen 4 Reinstall the fill cap 5 Once the unit is restarted check for leaks 47 HFE Filter Bag Kit 360 900 01 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required None Procedure 1 Crack open the reservoir fill to allow air into the tank 2 Locate and then loosen the black knob on the clamp at the top of the filter housing 3 Remove the clamp Note how the T is locked into position on the clamp 48 4 Remove the lid and gasket 49 6 Pull out the old bag to remove it 7 Install a new bag Ensure that the paper tag is removed from the bag 50 8 Reinstall the spacer handle up 9 Replace the lid gasket and reinsall the lid 51 10 To reinstall a new bag push down on the lid and gasket when tightening the black knob Hand tighten until the gap matches the other two gaps 11 Once the unit is restarted check for leaks 12 Ensure the LED and error message on the controller are both extinguished 5 Pump Inline Drier 360 900 05 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required 9 16 wrench Procedure For easier access to the assembly remove the unit from the cabinet 1 Note orientation of dryer assembly 2 Crack open the reservoir fill to allow air into the tank 3 Use the 9 16 wrench to remove the Swageloks securing the dryer
9. message clear Replace controller 13 DRIPPAN LED Error Message Cause Drip pan level switch is open fluid in the drip pan NO N Is swilcrywirino defective NO YES Remove fluid Check for leaks Did message clear O YES Replace switcns wiling See pagg 64 NO Reset controlle see page 91 Did message clear YES Replace controller See pagg 83 14 message Did clear YES Return to normal operation VFDFAULT LED VFD FAULT Error Message Cause Open relay on VFD Does VFD display an error YES See pag 21 NO Did message clear NO YES defective YES NO Did message clear Return to normal operation Reset controller see page Did message clear Replace controller See page 83 15 MOL FAULT Eror Message Cause Tipped pump motor overload Is overload YES tipped Reset overload Did message clear Replace qvedoad Return to normal operation 16 These error messages require checking the applicable sensor ana its associated wiring If the error message does not clear reset and or replace the controller SENSOR FAIL RIDI FAIL Error Message The ER temperature probe RIDI input is open or shorted en D
10. on all four corners of the board and pull it out 4 To reinstall reverse the procedure Refer to wiring diagram 5 Install the SMC Rider Board 6 Calibrate the new board Refer to Teradyne Service Documentation for proper procedure 7 Ensure the LED and error message on the controller are both extinguished 85 Torque Specification Sheet Mechanical Assemblies Pump Plate to Case Pump to Pump Plate Hose Clamps Unions Pressure Regulator CAM Lock Fittings Sanitary Fittings Facility Water Outlet Assembly Process side U bolts 7 20 084302 Facility side U bolts 3 8 16 084292 Temperature control valve actuator Electrical Assemblies 75 Ibs 100 110 Ibs 50 Ibs One full turn past hand tight 70 Ibs 25 Ibs 75 Ibs Hand tighten and then 3 turns Hand tighten until split washers are flat on both sides 20 25 Ibs For phillips head screws we recommend using a McMaster Carr 8554A26 or equivalent Float Switch Motor Valve Ground Wire Pump Motor Ground Wires 3 Control Box Assembly to Mid Pan Bottom Control Box Assembly to Mid Pan Top Control Box Assembly to Sides Contactor Connecting Screws VFD Mounting Screws VFD Wire Connection Screws VFD Ground Nut VFD Signal Wires VFD Jumper Wires VFD Power Wires VFD Controller Panel Control Board Mounting 4 Nuts 1TB Wires 2TB Wires 4TB Wires Key Pad Ground 11 32 Nut RFI Filter Wires to Contactor RFI Filter Mounting Screws RFI Wirin
11. reverse the procedure Torque Transformer Mounting Screws 14 16 Ibs Torque Contactor RFI Mounting Screws 24 28 lbs 5 Reconnect wiring refer to wiring diagram Torque RFI Wiring 157 Ibs Torque RFI Ground Wire 22 26 Ibs Torque RFI Filter Wires to Contactor 25 Ibs 6 Ensure the LED and error message on the controller are both extinguished 15 EMO Thermostat 360 900 31 A es Turn off and Lockout Tagout LOTO power before servicing Tools Required 6 Wrench or adjustable wrench Loctite threadlocker or equivalent Procedure 1 Remove the electrical box assembly see page 44 2 Remove the control box assembly side panel 3 Locate the thermostat and remove the wiring and 6 nut 4 To reinstall reverse the procedure Hand tight nut and secure with Loctite 76 Var Freq Drive VFD 360 900 76 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required McMaster Carr 8554A26 or equivalent torque screw driver Wiring Diagram Procedure 1 Remove all wiring to the VFD 2 Remove the four screws securing the VFD to the box assembly M a ER Umum DN de e Ca L E gt 3 When installing torque all four screws to 24 28 Ibs 4 Reconnect all wiring Refer to wiring diagram Torque VFD Wire Connection Screws 16 19 Ibs Torque VFD Ground Nut 14 16 Ibs Torque VFD Signal Wires 4 4 7 lbs Torque VFD Jumper Wires 4 4
12. Electron Repair Depot for warranty service will be paid for by the buyer Thermo Electron s responsibility in respect to warranty claims is limited to performing the required repairs or replacements and no claim of breach of warranty shall be cause for cancellation or recision of the contract of sales of any CDU With respect to CDUs that qualify for field service repairs Thermo Electron s responsibility is limited to the compo nent parts necessary for the repair and the labor that is required on site to perform the repair Any travel labor or mileage charges are the financial responsibility of the buyer The buyer shall be responsible for any evaluation or warranty service call including labor charges if no defects are found with the Thermo Electron product This warranty does not cover any CDU that has been subject to misuse neglect or accident This warranty does not apply to any damage to the CDU that is the result of improper installation or maintenance or to any CDU that has been operated or maintained in any way contrary to the operating or maintenance instructions specified in Thermo Electron s Instruction and Operation Manual This warranty does not cover any CDU that has been altered or modified so as to change its intended use In addition this warranty does not extend to repairs made by the use of parts accessories or fluids which are either incompatible with the CDU or adversely affect its operation performance or durability
13. assembly to the unit To make removing the outer Swagelok easier bend the inner dryer line down to get it out of the way Inner Swagelok Dryer Outer Swagelok Top View 4 Undo the two Velcro straps and remove the dryer assembly 5 Install a new dryer assembly Secure the Velcro straps first to prevent bending the lines 6 Connect the two lines and tighten the Swageloks per the tightening procedure on page 87 7 Once the unit is restarted check for leaks 53 Tank Level Switch 360 900 15 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required Adjustable wrench Tywrap cutter scissors Procedure 1 For access to the switch remove the electrical box assembly see pagg 44 2 Undo the electrical D connector on the rear of the unit 3 Remove the ty wraps 4 Undo the green plastic fitting and remove the switch assembly from the reservoir 5 To reinstall a new assembly reverse the procedure NOTE To prevent cross threading install the new assembly into the reservoir only hand tight 6 Once the unit is restarted check for leaks 7 Ensure the LED and error message on the controller are both extinguished 54 Pump 360 900 03 AN Turn off and Lockout Tagout LOTO power before servicing CAUTION Crack the fill cap to relieve any tank system pressure Tools Required 11 16 wrench 7 16 wrench 1 2 wrenchet Procedure For easier acc
14. for proper proce dure 2 Remove insulation around the regulator 3 Loosen top union fitting 4 Undo bottom union fitting 5 Undo top union fitting 6 When installing new regulator and washers ensure the arrow on the side of the regulator points down 7 Install both unions hand tight 8 Tighten both unions one full turn past hand tight 9 Install new insulation 10 Once the unit is restarted check for leaks 11 Ensure the LED and error message on the controller are both extinguished 12 Adjust the pressure differential see next page 65 Using the test probe verify the differential pressure across the temperature control valve using the two pressure test ports Petes Plugs PP 102 and PP 103 With the unit off and facility water on measure the pressure at PP 102 The pressure should match the facility water pressure NOTE If the pressure is 0 ensure that the facility water is on and that the facility supply valve is open Next measure the pressure at PP 103 The difference between the two read ings should be 30 33 PSI PP 102 PP 103 If adjustment is necessary loosen the locknut on the pressure regulator and then turn the adjustment bolt clockwise to increase the pressure counter clockwise to decrease the pressure Tighten the locknut Pressure Regulator 13 Install insulation 66 Plumbing Pressure Regulator to Temperature Control Valve 360 900 59 AN Turn off and Locko
15. q 44 2 The chip is located on the TC 400 Control Board beneath the Communica tions Board Remove the Communications Board 3 Remove old programmed chip with the PLCC extraction tool If one is not available a suitable tool is available from Thermo under part number 082166 Additional instructions are provided with the tool 4 Insert new programmed chip by placing the chip over the socket with the orientation dot on the chip aligned with the orientation arrow on the board Note that sometimes dot may be covered by a label see below Do not rely on the chip label since its orientation can be random You may also notice that a corner of the chip and socket are slightly flattened Press chip onto the socket by applying equal pressure to the chip until the chip completely snaps into the socket 5 Replace the Communications Board and the control box assembly 6 Start the unit and skip through any error messages using the controller s NEXT key Error 3 may appear when the new chip is powered up for the first time 7 Unit must be recalibrated for proper operation Referto Teradyne Service Documentation for proper procedure slots for insertion tool empty socket chip chip in socket 82 TC 400 Control Board 360 900 38 A me AN Turn off and Lockout Tagout LOTO power before servicing Use proper ESD Electro Static Discharge procedures when handling the chip and controller Typically a grounded wrist
16. strap is used to ground the individual so static discharge is released prior to and during handling Tools Required Small pair of needle nose pliers Screwdriver Phillips Screwdriver a Nut driver Plastic Leaded Chip Carrier PLCC extraction tool not supplied or equivalent Wiring Diagram Procedure 1 To allow the panel to fold down remove the 4 screws securing the keypad panel to the front of the unit 83 2 Remove all wiring to the board 3 Remove the Temp Option Board and Programmable Chip see previous two pages 4 Undo the four corner mounting nuts securing the board to the unit TB2 181 TB4 5 To reinstall reverse the procedure Refer to wiring diagram NOTE Ensure jumper settings on new board match the settings on the wiring diagram Torque mounting nuts 6 8 Ibs Torque 1TB 2TB Wires 8 10 lbs Torque 4TB Wires 4 4 7 lbs 6 Ensure the error message on the controller is extinguished 84 LON Adapter Board 360 900 28 AA ess A sz Turn off and Lockout Tagout LOTO power before servicing Use proper ESD Electro Static Discharge procedures when handling the chip and controller Typically a grounded wrist strap is used to ground the individual so static discharge is released prior to and during handling Tools Required Small pair of needle nose pliers Wiring Diagram Procedure 1 Remove the SMC Rider Board 2 Remove the wiring to the LON 3 Press the ears
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19. 5 To reinstall reverse the procedure Torque Circuit Breaker 11 32 Mounting Nuts 14 16 Ibs 6 Reinstall wiring refer to wiring diagram Torque Circuit Breaker Wire Connections 20 Ibs 80 Temp Option Board TC 400 to LON Adapter 360 900 29 AN Turn off and Lockout Tagout LOTO power before servicing Use proper ESD Electro Static Discharge procedures when handling AN the chip and controller Typically a grounded wrist strap is used to ground the individual so static discharge is released prior to and during handling Tools Required Small pair of needle nose pliers Wiring Diagram Procedure 1 Remove the electrical box assembly see page 44 2 Remove wiring 3 Using the pliers press the ears on the four corners of the board and pull it out 4 Snap new board back into position 5 Install wiring refer to wiring diagram 6 Ensure the LED and error message on the controller are both extinguished 81 Chip Replacement 390 900 39 A ez A sz arrow mj E Turn off and Lockout Tagout LOTO power before servicing Use proper ESD Electro Static Discharge procedures when handling the chip and controller Typically a grounded wrist strap is used to ground the individual so static discharge is released prior to and during handling Tools Required Plastic Leaded Chip Carrier PLCC extraction tool not supplied or equivalent Procedure 1 Remove electrical box assembly see pag
20. D O D PRES Error Message The coolant return pressure sensor input is out of range see page PRES 2 error Message The coolant supply pressure sensor input is out of range see bage les HIGH PRES Eror Message The supply pressure is greater than 110 psi NEG PRES Eror Message The differential pressure equals a negative value for at least 3 seconds COMM DISC LED COMM DISC Eror Message Cause Communications lost for over 10 seconds while operating in the remote mode Are all connections secure Secure connections NO NO Send start command NO Did message clear YES Are commands being sent to the unit Did message clear VES Reset controller Return to normal See page 91 operation Did message clear Replace controller see pagelss 18 These error messages require controller chip replacement see pagel82 RAM FAILED RAM CHECK ROM FAILED Ear Message Erer Message Erer Message BAD OFFSET Ero Message This error message requires replacing the control board or controller s chip see pages 82 and 83 BAD KEYPAD Error Message These error messages require checking user software hardware Eror Message Eror Message Error Message Unit will not start no error message displayed Did display come on YES FOR voltage and or phase to IT co
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22. High Capacity Coolant Distribution Unit CDU Chiller Jaguar Platform Thermo Manual P N U00918 Rev 08 03 05 Troubleshooting FRU Replacement Thermo ELECTRON CORPORATION Table of Contents Preface Section Safety After sale Support a mare ne 3 MA 3 VA ea a a a on me 5 EMO 6 Lockout Tagout LOTO PRE RE 6 Section Il Troubleshooting Error Code Troubleshooting T VPFPF NA 21 Monitoring Fluid Loss EE 23 Section Ill FRU List r UI Lu o O Sauna a nd 25 Section IV FRU Replacement Electrical Components dm ce 42 Electrical BOX NNN 4A BG A sects q 45 1 1 TUDE PRE ER 46 EP EN e E E A E ES 47 HFE Fer Bag KiLu uu ni de a nt an 48 A A 53 Jank Level SWIlol EE washus 54 SEI z au sake 55 Temperature Control Valve Assembly 58 Temperature Control Valve Actuator 60 Water FIOW ek Elle 61 HFE Side Temperature Sensor rtd1 62 PETN EEN 63 Drip Pan Level Switch BEE 64 Pressure E E te NEE 65 Plumbing Pressure Regulator to Temperature Control Valve 67 Plumbing Facility inlet FDC vanene 68 H2O Side Temperature Sensor rtd2 EE 69 Return Pipe Assembly Process low 10 Supply Pipe Asse
23. Je lt Monitoring for Fluid Loss Each line on the Reservoir Gauge represents approximately 1 10 of a gallon On a routine basis check and record the fluid level If the fluid level is dropping ata rate faster than indicated by the specification then perform the following 1 Ensure the Tank Fill Port and the Tank Auxiliary Port Cap are properly installed and on hand tight 2 Check all sanitary gaskets to insure that they are properly installed and are on according to the Torque Specification Sheet on pagel86 3 Look for signs of a leak at all connections and solder joints 4 If none of the above yield any results use a Halogen Leak detector on each connection and joint 5 Check for leaks at the Test Equipment per your procedures Reservoir Gauge 23 This page intentionally left blank 24 Description SYS HFE 30CDU FRU CDU RETURN PIPE ASSY FRU CDU FILTER BAG FRU CDU FILTER O RING FRU CDU PUMP W GASKETS FRU CDU PUMP SUCT LINE FRU CDU INLINE DRIER FRU CDU SUPPLY PIPE ASSY FRU CDU FILL PORT SCREEN FRU CDU PRESS REGULATOR FRU CDU FLOW XDUCER FRU CDU TEFLON PASTE FRU CDU FACIL INLET PIPE FRU CDU VALVE W ACTUATOR FRU CDU VLV ACTUATOR ONLY FRU CDU INSUL TAPE FRU CDU TANK LVL SWITCH FRU CDU PRESS XDUCER FRU CDU DRIP PAN SWITCH FRU CDU RTD H20 SIDE FRU CDU DRIER TUBE FRU CDU RTD HFE SIDE FRU CDU FILL PORT CAP FRU CDU FILL PORT O RING FRU CDU PETES PLUG FRU CDU CIRCUIT BREAKER FRU CD
24. N INNON T3NVd MOY ITONIS NId t 9td omide z t du UINYOASNVYL DI 39018 TVNINGIL elt 30018 TVNINYIL aiz 39018 TVNIN2331L alc INYA AONINOIYVA 318VIMVA JAL YOLOANNOO YIMOd YOLDINNO9 YIMOd 319V1d3938 MOY TIONIS Nid t VAOS O3S AOZL YT AUVNINd O Z 807 812970 3lVld ON3 86H20 dOLS UNA 0S6FZ0 3lVld 0NA 8p6 ZO dOLS UNI 612920 LS6 Z0 0 6780 dOIS UNI OVAOPZ 00Z WES dHOL AIALOIASIY 19 ONY Z L S IYM YOS eme tea ba SI SOINS VNIHO YOW 3009 40700 AMALOIASIY L9 ONY TL SIYM 3O3 N3389 ON 038 LHM MA SI SOIN En YO4 3009 407109 e MOTIZA N3399 ONY VEL OL TONZ ONV TOME LS LOZP80 NOILVOIJIOIAS BVISIN OWYSHL HLIM JONVAYDDOV NI 39 TIM NYSOVIG 38IM G319103dS 3SIMYIHLO SSITNN TAANND 1 Z ZZD 11 71 21 L vi V1d dH S L z ama NL 3ONVYO SD LON dd A 8 6 HNId 038 NMOYS y S 9 MOTIZA yovia d n SNOLLDINNOO YOLON IVNYILNI 401 992010 qN3 qv3q ISN M0738 NMOHS JYV SNOILOANNOD YOLOW A80Z Z y OL LL WO JHM YadWAP JAON ANS OL HOLIMS did 39V1d L SALON TIANYO p1 2 29 Ft dH S SOLOW dWfd 19181 003 OY MOMS NIA OL 1 f ZUM GHONVHO a lo SLAG SISSVHI TIANYO p1 29 me vt L 8lz m8 1 1 91 AN NIVAO OT3IHS 789 NAANY9 190 TO 1803 18 190 8Lz 8 Maos LIT 119 189 91z DEES 1892 LO 1m18 189Z 81 118 1993 L M18 1892 ov
25. NEXT y Process Fluid Differential Y HFE DP XXP Pressure NEXT Main Loop 89 Engineering Loop The Engineering Loop allows you to open or close the temperature control valve Use the YES button to enter the valve condition The display will then flash between the position of the valve and the facility flow value Use the YES orthe NO buttons to open or close it in 10 increments When the desired value is displayed press ENTER and then NEXT to sequence through the displays Press NEXT to sequence the display through the cool duty cycle the coolant return pressure the coolant supply pressure the facility water temperature and the ambient air temperature Press NEXT again to return to the Main Loop Main Loop HOLD HICAPACITY e NO NEXT 90 ENTER NEXT Em SETUP NO HOLD Lei ENTER NEXT y O enenere a YES XX PCT XX SC MOD VALVE 100 PC XX XG E NEXT AA NEXT ENTER NEXT e NEXT Ate Engineering Loop Factory Reset Factory Reset returns all the controller settings to its factory preset values Main Loop HOLD HICAPACITY AM A Set YES NO YES Q NO CONFIGURE OO ENTER SILENCE Afterthe Reset a controlller calibration is required Referto Teradyne Service Documentation for proper procedure 91 30 1 j eg LINA VNIHO SMIIA 0300 14X1 Nx OC SWNIVP Le VAS 00119100309 10119913 0 7 p
26. NGO Mas 162280 66 006 09 3901313V2 JAVA ONILVINDIY 38NSSIYI NCO NYA Sein f Ly 006 09 OvVdA3X NG NYA L8zSto Tr 006 09 did LIINI A11719V4 AG Nyy 96 60 Z6 006 09 HOLIMS Nvd d 4Q NMO Ny 078280 S 006 09 2016 34H Gly Nd Aud 128480 G 006 09 9N 1d N d diva NO Nas 261 60 9 006 09 JAVA ONILVINGON Ol ONIdid NG NYI 66 C60 65 006 09 4 Lg INTI NOTIONS and nao nus reeeo 0Z 006 09 ATBNISSY INIT ATddNS NAD nuj CHGCEO f 14 006 09 BIONGSNVEL MOTA NO Naa vrst60 EECH UINV3HA LINOUID NGO Nyd egen f z 006 09 YOLOVINOD NG Nyd 9 8280 G 006 09 JAIYO AON300383 JTBVIYVA NAO Nad 8L80 92 006 09 331113 G4A NO NU 8c8 80 006 09 6 8280 6 006 09 08480 08 006 09 198 80 18 006 096 Ll srseso_ 78 006 09 0006010 DU y E CD ESS ES Po Y ew Le nj 669560 mg 64 006 09 De 6S 006 09 Z8 006 095 006 09 Se en A Se MOHS LON J9QIHLYVD 1y 006 09 JAVA 80 006 09 d A ra i 006 09 GE ZS 006 09 1 006 09 we Z 006 09 GG 006 09 006 09 7 006 09 sooner A MEE A x a ry LINN VNIHJ SMAIA 0300 143 NYA 0 YYNDVF 101101000 00213913 OU A Gu 1 NO819313 OMYI3H1 MOHS NOLLVZISOHINV N311138 INOHLIM T3NNOSU3d NON19273 Com NYH 83H10 01 NOA AB 30vm SI RMSODSIQ HIHINNA ON Int NOILIGNOO NO NOA OL Q3S01S 0 SI GNV TY31N30
27. ON ML IPW Nid 01900 9N1d YOLDINNOO E Ld I Nid t IPN ININ 198900 9N1d 40103NNOO 9H0 189 91 3 N N bo N D E er ar 1809 dl a THM 107 SEL ELCH d eer gt oorr m8 19 zel OM 22 671 ioir YJOSNIS JYNSSJYd INN AlddNS LNY1009 LEET EE zoir d38 19 LEL m6 2z 21 Ge UNIV ON V CNV ON Y LINOV MI EINOV T1NOV MI ZLNOV I ONE V DOAGL NIZadNTINd NI 18dNTINd 1NO7TTENLA LNOT LENLY 110 zadnTind 107 LadNTINd x ma zz 06 a MI Z A K n18 77 68 KS a ma zz 88 VEI 19487843TT08LNOO s BAN39 81 919 gNO8 ANNOYS Qld N a ew NId 22010 SM HOLDANNOO SISSYHI RW Nid 9 2010 OMIA HOLIANNOO TIVA del 6 9600 gns Q OMd YOLISNNOD IMALAO OQAS O z8s 80 YIONASNVYL IUNSSIYd YOSNIS IYNIVYIANIL SZSr80 YOSNIS IYNIVYIdNIL alaz gOV C11 USS C COOMNTIA 9LTYEO HOLIMS dW3L ON HOIH Svit I Od 33S 39018 TVNINYIL g z L Od 335 JANG AON300334 ITEVIYVA GAL L 9 Gd 1998 4ITIOHLNOD ZOLd S L ON90 LNONMd Lal _ ale DOAG LNOWMd TL 13A 790 LLL n18 19 601 OVA A QAYOT ovial JOH OVIEL GVOT Cut 10H7EOVINL OVOT Zil LOH TOVISL QvoT LOVISL lOH LOVIN 1HM T9 08 Lem 18 19 64 OIA 2z 81 98 L 39vd 335 ma lo LL RE Ee ee ma zz 18 ma zz LL Ma zz EL 1 302 dr ZALON 180 9L G38 81
28. Page 42 Check resistance pins 1 and Coolant RTD J102 Facility RTD P103 Level Switches Check resistance pins 1 and J1 Check resistance Pins 1 and 2 warning Pins 3 and 4 shut down Drip Pan J2 Check resistance Switch Pins 1 and2 Facility Flow Transducer Check Voltage Pins 1 and 2 Motor Valve Measure Voltage Pins 1 and 2 Pressure Transducers Measure voltage Pins 2 and 3 supply Pins 5 and 6 return 200 00 N 150 00 a E Q 100 00 O 50 00 5 10 15 20 43 100 Ohms 0 C 110 Ohms room temp 100 Ohms 0 C 110 Ohms room temp 0 Ohms closed Ohms open 0 Ohms closed Ohms open See chart below 100 open gt 9 5 VDC 0 open lt 6 0 VDC 3 5 psi per volt plus 0 5 volts example 150 psi 4 5 volts 25 30 35 Flow Rate gpm ElectricalBox Assembly 360 900 79 N Turn off and Lockout Tagout LOTO power before servicing Tools Required 2 Philips Head Screwdriver 11 32 wrench Wiring Diagram Procedure 1 Using 2 Philips Head remove the 4 screws securing the electrical box assembly to the front of the unit 2 Remove the single screw securing the base of the control box to the unit s mid frame 3 Remove the 8 connectors at the bottom of the control box 4 Atthe pump motor remove the wiring running from the base of the control box 5 Remove the 11 32 nut securing the ground wire at the rear of the unit 6 Sli
29. TO lock out power remotely Electrical LOTO can be provided by Disconnecting main power at the facility power source prior to the system controller cabinet The unit does not provide LOTO forthe facility water flow An external user supplied device is required In addition follow all local facility LOTO directives Section ll Troubleshootin Error Code Troubleshooting LEVEL WARN LED LEVEL WARN Error Message Cause Upper low level warning switch closed for at least 3 seconds Fluid Level OK Add fluid Also see Monitoring Fluid Loss on page Ps Did message clear Is YES switch wiring defective Replace Did switch wiring Message se pagd 54 clear Seet I Return to normal controller operation see pag 91 Did message clear YES Replace controller see page 83 FILTER GJ LED CHG FILTER Eror Message Cause Return pressure greater than 10 psi for I minute NOTE Normally indicates the filter in the reservoir needs changing Remove filter See page Change filter See page Did error message clear YES Reset controller See poge 91 Return to normal operation Did message clear YES LOW HFE PRES LED Eror Message Cause major leak has developed or the unit supply pressure less than 20 psi for 30 seconds after pump VFD start NOTE I If a pump shu
30. Thermo Electron reserves the right to change or improve the design of any CDU without assuming any obligation to modify any CDU previously manufactured THE FOREGOING EXPRESS WARRANTY IS IN LIEU OF ALLOTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TOWARRANTIES OR MERCHANTABILITY AND FITNESS FORA PARTICULAR PURPOSE Thermo Electron s OBLIGATION UNDER THIS WARRANTY IS STRICTLY AND EXCLUSIVELY LIMITED TO THE REPAIR OR REPLACEMENT OF DEFECTIVE COMPONENT PARTSAND Thermo Electron DOES NOT ASSUME OR AUTHORIZE ANYONE TO ASSUME FOR IT ANY OTHER OBLIGATION Thermo Electron ASSUMES NO RESPONSIBILITY FOR INCIDENTAL CONSEQUENTIAL OR OTHER DAM AGES INCLUDING BUT NOT LIMITED TO LOSS OR DAMAGE TO PROPERTY LOSS OF PROFITS OR REVENUE LOSS OF THE UNIT LOSS OF TIME OR INCONVENIENCE This warranty applies to CDUs sold in the United States Any CDUs sold elsewhere are warranted by the affiliated marketing company of Thermo Electron This warranty and all matters arising pursuant to it shall be governed by the law of the State of New Hampshire United States All legal actions brought in relation hereto shall be filed in the appropriate state or federal courts in New Hampshire unless waived by Thermo Electron
31. U CONTACTOR FRU CDU TRANSFORMER FRU CDU VAR FREQ DRIVE FRU CDU LON ADAPT BOARD FRU CDU TEMP OPTION BRD FRU CDU VFD FILTER FRU CDU EMO THERMOSTAT FRU CDU 1 5 SANIT GASKT FRU CDU 2 SANIT GASKET FRU CDU 1 5 SANIT CLMP FRU CDU 2 SANIT CLMP FRU CDU TC400 CNTRL BRD FRU CDU EPROM SOFTWARE FRU CDU PIPING TO MOD VLV FRU PRV CARTRIDGE FRU KEYPAD FRU CDU DRIP PAN PLUG FRU CDU ELECT BOX ASSY FRU VFD BOX ASSY FRU MOTOR OVERLOAD Thermo 603099991707 093354 093355 093385 093356 093542 093449 093543 093386 093359 093544 093387 093496 093497 087774 093388 087775 087782 087820 087777 093362 087821 093397 093363 093384 087835 087836 087779 087837 087786 087787 087838 087788 093380 093381 093382 093383 087790 087791 093499 015779 015781 093498 087839 087840 087841 one Section Ill FRU List Teradyne 873 612 00 360 900 00 360 900 01 360 900 02 360 900 03 360 900 70 360 900 05 360 900 711 360 900 07 360 900 08 360 900 72 360 900 10 360 900 52 360 900 53 360 900 13 360 900 14 360 900 15 360 900 16 360 900 54 360 900 18 360 900 19 360 900 55 360 900 21 360 900 22 360 900 23 360 900 74 360 900 75 360 900 26 360 900 76 360 900 28 360 900 29 360 900 77 360 900 31 360 900 32 360 900 33 360 900 34 360 900 35 360 900 38 360 900 39 360 900 59 360 900 41 360 900 42 360 900 57 360 900 79 360 900 80 360 900 81 360 900 72 Transducer Water Flow d s tarts ruse KAPP e
32. an Plug 360 900 21 Fill Port Cap 07 360 900 59 Piping to Mod Valve 360 900 05 Pump Inline Dryer 360 420 00 Programmable Chip Extractor 38 360 900 42 Keypad 30 This page intentionally left blank 40 Section IV FRU Replacement For personal safety and equipment reliability the following procedures should only be performed by a qualified technician The following steps assume the technician is knowledgable of all Swagelok initial tightening and retightening procedures Contact our Service Depart ment for assistance Contact with hazardous voltage inside the chiller can cause severe injury of death Turn off and Lockout Tagout LOTO power before servicing Have a qualified technician verify that line voltage is no longer present within the unit after performing a LOTO procedure and before working on system Performance maintenance and service procedures other than those described in this manual may result in a hazardous situation 41 Electrical Components To access any of these electrical components you must remove the control box assembly and the side panel TC 400 Controller Board Temp Option Board see page Programmable Chip seepagel81 see page 82 Circuit Breaker see page LON Adapter Board see pagel85 VFD Eilter see EMO Thermostat see page 76 Contactor see page 75 Transformer see 12845 y 90 00 Bottom View See Next
33. ap cutters Scissors Insulating Tape Procedure 1 Remove the electrical box assembly see pag 144 2 Remove the insulation covering the sensor 3 Cut the aluminum tape securing the sensor to the facility line 4 Undo the wiring from below the electrical box 5 Attach new sensor with hose clamp 6 Install new tape and insulation 7 Connect wiring 8 Ensure the LED and error message on the controller are both extinguished 9 Install insulation 69 Return Pipe Assembly Process Flow 360 900 00 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required One 1 2 wrench or adjustable wrench One 9 16 wrench or adjustable wrench One 5 8 wrench or adjustable wrench Procedure 1 Drain the HFE Refer to Teradyne Service Documentation for proper proce dure 2 Unsnap the black plastic cap on the transducer 3 Use the 5 8 wrench to disconnect the transducer 70 5 Use the 1 2 wrench to disconnect the process lines from the dryer 7 Undo the sanitary fitting at the tank 8 Reverse the procedure to install a new line Tighten all connection Referto the Swagelok Installation on page 87 Sanitary Fitting 25 Ibs U bolts Hand tighten and 3 turns 9 Once the unit is restarted check for leaks 71 Supply Pipe Assembly Process Flow 360 900 71 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required One 1 2 wrench or adjustable w
34. before servicing Tools Required 1 3 4 wrench Two 1 1 4 wrenches Copper tubing cutting tool Tywrap cutter scissors Tape Insulating Procedure For easier access to the valve remove the unit from the cabinet 1 Drain the water Refer to Teradyne Service Documentation for proper proce dure 2 Remove the insulation around the valve 3 Use a 1 3 4 wrench to disconnect the Swageloks 4 Unplug the 6 pin connector and disconnect the ground wire 5 Open the clamp securing the valve to the unit 58 6 To reinstall a new valve first connect the 1 3 4 Swageloks finger tight 7 Install the clamp 8 Tighten the two Swageloiks Refer to the Swagelok Installation on page 87 Torque clamp 50 Ibs 9 Reinstall the 6 pin connector and the ground wire Torque ground wire 24 28 Ibs 10 Once the unit is restarted check for leaks 11 Ensure the LED and error message on the controller are both extinguished 12 Install insulation 59 Temperature Control Valve Actuator 360 900 13 AN wane Turn off and Lockout Tagout LOTO power before servicing Tools Required 1 5 8 wrench Tape Insulating Procedure For easier access to the actuator remove the unit from the cabinet 1 Drain the water Refer to Teradyne Service Documentation for proper proce dure 2 Use the 1 5 8 wrench to disconnect the actuator from the valve 3 Unplug the 6 pin connector and disconnect the ground
35. bels Never operate damaged or leaking equipment Never operate the CDU without cooling fluid in the fluid reservoir Process fluid are subject to environmental regulatory restrictions Do not dispose into the environment In the United States use proper OSHA approved location for disposal Use remote lockout tag out procedures prior to servicing the CDU Make sure the CDU is off before connecting or disconnecting the power cord or other cables Always turn off the CDU and disconnect the power cord from the power source before performing any service or maintenance procedures or before moving the CDU Always empty the fluid reservoir before moving the CDU Never operate equipment with damaged power cords Refer service and repairs to a qualified technician EMO Circuit Each of the following safeties is part of the test system Emergency Off EMO circuit The tripping of either of these safeties will cause power to be dropped to the CDU by the test system The EMO circuit should not exceed 10A 24VDC High Air Temperature TSH 101 This safety opens the EMO circuit when the air temperature safety switch detects a temperature inside the CDU greater than 70 C The temperature switch is self resetting at a temperature of 54 C or below Lockout Tagout LOTO Before performing Chiller maintenance the energy sources associated with the Chiller system must be lockout and tagged out LOTO Since the CDU itself has no electrical LO
36. de the control box assembly out from the unit 7 Swap out the LON Adapter board from the replaced assembly into the new assembly see page 8 To reinstall reverse the procedure Torque Control Box to Mid Pan Bottom 14 16 Ibs Torque Control Box to Mid Pan Top 24 28 lbs Torque Control Box Assembly to Sides 24 28 Ibs 9 Rewire according to the wiring diagram 10 Return the replaced assembly to Thermo Electron 44 360 900 42 Keypad Tools Required Screwdriver 11 32 wrench Procedure 1 Remove the 4 screws securing the keypad panel to the front of the unit 2 Disconect ribbon cable from control board 3 Remove the 11 32 grounding nut 4 Peal the keypad off the panel 5 When reinstalling tighten gounding nut 14 16 Ibs 45 Drier Tube 360 900 19 When the cartridge color change feature blue to pink reaches the bottom of the top cap the dryer tube needs changing ZA Turn off and Lockout Tagout LOTO power before servicing Tools Required Tywrap cutter scissors Procedure 1 Removethe top and bottom tubes from the dryer tube nipples 2 Cut the ty wrap 3 Reverse the procedure to install a new dryer tube 4 Once the unit is restarted check for leaks 46 Fill Port Screen 360 900 07 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required None Procedure 1 Remove the fill port cap by turning counterclockwise 2
37. ess to the pump remove the unit from the cabin 1 Drain the water Refer to Teradyne Service Documentation for proper proce dure 2 Remove the electrical box assembly see page 44 3 Remove sanitary clamps from both suction and discharge lines to the plate exchanger 55 4 Using a 11 16 wrench remove the fitting from the pump s drain line 6 Remove the pump and plate from the unit CAUTION The pump weighs at least 80 pounds 7 Using a 1 2 wrench remove the nuts and washers securing the pump to the pump plate 8 When reinstalling a new pump do not tighten any of the nuts bolts or clamps until all plumbing lines are properly aligned Also use new gaskets when reinstalling the sanitary clamps 9 Reorrect pump discharge line to pump Recheck the alignment 56 10 Using a 11 16 wrench install the fitting from the pump s drain line 11 Install the sanitary clamps on the pump suction and discharge line 12 Tighten all connections Torque Pump to Pump Plate 100 110 Ibs Torque Pump Plate to Case 175 Ibs Torque Sanitary Fittings 25 Ibs 13 Reconnect all the wiring Torque Pump Motor Ground Wires 3 24 28 Ibs 14 Reinstall the electrical box assembly see pagel44 15 Once the unit is restarted check for leaks 16 Return the replaced pump to Thermo Electron 57 Temperature Control Valve Assembly 360 900 53 AN wane Turn off and Lockout Tagout LOTO power
38. g RFI Ground Wire Transformer Mounting Screws 8 32 x 1 4 Contactor Mounting Screws 10 32 x s Circuit Breaker 11 32 Mounting Nuts Circuit Breaker Wire Connections Hand tight 24 28 Ibs 24 28 lbs 14 16 Ibs 24 28 Ibs 24 28 Ibs 25 Ibs 24 28 Ibs 16 19 Ibs 14 16 Ibs 4 4 7 lbs 4 4 7 lbs 16 19 Ibs 10 12 Ibs 6 8 Ibs 8 10 Ibs 8 10 Ibs 4 4 7 lbs 14 16 Ibs 25 Ibs 24 28 Ibs 157 Ibs 22 26 Ibs 14 16 Ibs 24 28 Ibs 14 16 Ibs 20 Ibs 86 Swagelok Tube Fitting Instructions Installation 1 Insert tubing into the Swagelok tube fitting 2 Make sure that the tubing rests firmly on the shoulder of the tube fitting body and that the nut is finger tight 3 Scribe the nut at the 6 o clock position 4 While holding fitting body steady tighten the nut 11 4 turns to the 9 o clock position Note For 1 16 1 8 and 3 16 in 2 3 and 4 mm tube fittings tighten the nut 3 4 turn to the 3 o clock position Installation in High Pressure Applications and High Safety Factor Systems 1 Follow steps 1 and 2 ofthe Swagelok Tube Fitting Instructions 2 Tighten the nut until the tubing will not rotate freely by hand 3 Follow steps 3 and 4 of the Swagelok Tube Fitting Instructions Gageability On initial installation the Swagelok gap inspection gauge assures the installer or inspector that a fitting has been sufficiently tight ened Position t
39. he Swagelok gap inspection gauge next to the gap between the nut and body e If the gauge will not enter the gap the fitting is sufficiently tightened e If the gauge will enter the gap additional tightening is required 87 Reassembly Instructions You may disassemble and reassemble a Swagelok tube fitting port connector cap and plug many times 1 Insert tubing with pre swaged ferrules into the fitting body until the front ferrule seats 2 Rotate the nut with a wrench to the previously pulled up position At this point a significant increase in resistance will be encountered 3 Tighten slightly with a wrench Note Do not use the gap inspection gauge with reassembled fittings Do not mix or interchange parts with those of other manufacturers 1 Swagelok Pocket Catalog of Tube Fittings MS 13 58 88 Section V Controller Loops Main Loop An alphanumeric display presents numeric readings of various operating conditions within the chiller Display function is selected by pressing the appropriate keys to move through a menu of available information Main Loop When the controller is first powered up it goes through a short self test and then enters the Main Loop and displays the unit configuration HICAPACITY Unit Configuration A NEXT Process Fluid Supply HFE I AS AL Temperature a NEXT Facility Fluid Supply H2O I A SC Temperature NEXT H2O F XX XG Facility Water Flow Rate E
40. ll stop flashing the previous value is restored and the Program LED will turn off Or Press Enter to save a change The digit will stop flashing and the Program LED will turn off 11 Press Esc to return to the parameter list Continue to press Esc to back out of the programming menu If pressing Esc does not change the display then d001 Output Frequency is displayed Press Enter or Sel to enter the group menu Settings Display Group and Number Setting P031 208 P033 29 4 P036 2 P038 2 A051 7 A052 5 78 Pump Motor Overloads 360 900 81 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required McMaster Carr 8554A26 or equivalent torque screw driver Wiring Diagram Procedure 1 Remove all wiring to the overload 2 Remove the two screws securing the overload to the box assembly 3 When installing torque all screws to 24 28 Ibs 4 Reconnect all wiring Refer to wiring diagram 5 Check for error codes on the controller 79 Circuit Breaker 360 900 74 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required McMaster Carr 8554A26 or equivalent torque screw driver Wiring Diagram Procedure 1 Remove the electrical box assembly see page 44 2 Remove the four nuts securing the circuit breaker to the unit 3 Remove all wiring to the circuit breaker Spring 4 Press the spring on the circuit breaker to separate it from the bracket
41. mbly Process Flow 12 PSC TR roitaiaieancodd 74 VFD Filter Contactor Transformer 15 DOE 1005 EN EE ME 16 AP E E o O 77 WED SENOS E 18 Pump MOWT NNN 19 CCR RSR e E UA 80 Temp Option Board rr rrrnrsrssssisrasaa 81 Sia EEE T E A 82 TC 400 Controller EEN 83 LON Adapter Board BEE 85 Torque Specification Sheet 86 Swagelok Tube Fitting Instructions 87 Section V Controller Loops KAR EOOD uuu EEE 89 le lolo o EEE 90 Factory Reset sisi 91 Section VI Drawings FRU Exploded Views 92 GOE DE ANN EN ie 95 Electrical Diagram 96 WARRANTY Preface After sale Support Thermo Electron Corporation is committed to customer service both during and after the sale If you have questions concerning the CDU operation contact our Sales Department If your CDU fails to operate properly or if you have ques tions concerning spare parts contact our Service Department 800 258 0830 603 436 9444 Fax 603 436 8411 Before calling please obtain the following information CDU BOM number CDU serial number CDU software version voltage of power source The CDU s BOM and serial number label are located on the label on the front to
42. p ofthe CDU See Service Manual for instructions on how to display the software version Warranty CDUs have a warranty against defective parts and workmanship for 24 months from date of shipment See back pages for more details This page intentionally left blank Section I Safety Warnings Make sure you read and understand all instructions and safety precautions listed in this manual before installing or operating your CDU If you have any questions concerning the operation of your CDU orthe information in this manual contact our Sales Department for assistance DANGER indicates an imminently hazardous situation which if not avoided AN will result in serious injury or death This signal word is limited to the most extreme situations WARNING indicates a potentially hazardous situation which if not avoided could result in serious injury or death CAUTION indicates a potentially hazardous situation which if not avoided CAUTION may result in minor or moderate injury It may also be used to alert against unsafe practices Performance of installation operation or maintenance procedures other than those described in this manual may result in a hazardous situation and may void the manufacturer s warranty Transport the CDU with care Sudden jolts or drops can damage the CDU Do not attempt to defeat any of the interlock switches or safety features built into the CDU Observe and never remove all warning la
43. pan 3 Unplug the sensor from below the control box 4 Reverse procedure to install new sensor Refer to the Swagelok Installation Sheet on page 87 5 Once the unit is restarted check for leaks 62 Pressure Transducers 360 900 16 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required 5 8 wrench Tywrap cutters Scissors Procedure 1 Unsnap the black plastic cap s on the transducer s 2 Use the 5 8 wrench to disconnect the transducer s 3 Unplug the wiring 4 Reverse the procedure to install a new transducer To tighten the fittings refer to the Swagelok Installation Sheet on pages 87 5 Once the unit is restarted check for leaks 63 Drip Pan Level Switch Kit 360 900 54 N Turn off and Lockout Tagout LOTO power before servicing Tools Required 3 8 wrench Tywrap cutters Scissors Procedure 1 Remove the 3 8 nut securing the kit to its bracket 2 Undo wiring from below the electrical box 3 To reinstall reverse the procedure 64 Pressure Regulator 360 900 08 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required Two 2 1 16 wrenches or adjustable wrenches 1 8 diameter test probe Peterson Equip Co Inc 500 Gauge Adapter or equivalent Insulating Tape Procedure For easier access to the assembly remove the unit from the cabinet 1 Drain the water Refer to Teradyne Service Documentation
44. r ms vi ory verre eure 360 900 15 Tank Level Switch 26 360 900 54 Sensor Kit Drip Pan Level 360 900 18 RTD H20 Side 360 900 55 RTD HFE Side o 360 900 26 Transformer Su Q LL O LL gt N o cO e 360 900 16 Pressure Transducer 28 360 900 74 Circuit Breaker 360 900 75 Contactor 360 900 76 Var Freq Drive 360 900 80 VFD Box Assembly 360 900 81 Motor Overload NOTE The VFD box 360 900 80 consists of a VFD two motor overloads and the associated wiring O SE EE TT UE 29 360 900 28 LON Adapter Board 360 900 31 EMO Thermostat 30 360 900 79 Electrical Box Assembly 360 900 00 Return Pipe Assembly Process Flow 31 360 900 01 Filter Bag Kit 360 900 03 Pump with Gaskets 360 900 70 Pump Suction Line with Gaskets 360 900 71 Supply Pipe Assembly 32 360 900 08 Pressure Regulator 360 900 52 Facility Inlet Pipe maaa keent s 360 900 53 Valve Assembly Temperature Control 33 360 900 19 Drier Tube 360 900 32 Gasket 172 360 900 33 Gasket 2 34 360 900 2353 Petes Plug 360 900 41 Pressure Relief Valve Cartridge cr ee Pa La pa ag 35 360 900 02 O ring Filter Housing 360 900 07 Fill Port Screen 360 900 10 Teflon Paste 36 360 900 14 Tape Insulating 360 900 57 Fitting Drip P
45. rench One 9 16 wrench or adjustable wrench One 5 8 wrench or adjustable wrench Procedure 1 Drain the HFE Refer to Teradyne Service Documentation for proper proce dure 2 Unsnap the black plastic cap on the transducer 3 Use the 5 8 wrench to disconnect the transducer 4 Use the 1 2 wrench to disconnect the temperature sensor SE 6 Undo the u bolts securing the line to the unit 8 Reverse the procedure to install a new line Tighten all connection Referto the Swagelok Installation on page 87 Sanitary Fitting 25 Ibs U bolts Hand tighten and 3 turns 9 Once the unit is restarted check for leaks 2702 PRV Cartridge 360 900 41 Tools Required Adjustable wrench Two screwdrivers Procedure 1 Loosen locknut and turn adjusting screw counterclockwise to remove the spring tension 2 Remove the bonnet using the adjustable wrench 4 When installing new cartridge ensure the o rings and washers are properly installed Washer 74 VFD Filter 360 900 77 Contactor 360 900 75 Transformer 360 900 26 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required McMaster Carr 8554A26 or equivalent torque screw driver Wiring Diagram Procedure 1 Remove the electrical box assembly see pag 444 2 Remove wiring and screws from transformer and contactor to access the RFI 3 Remove wiring and screws securing RFI to the unit 4 To reinstall components
46. rrect Did display come on YES Is 1T secondary voltage correct display come on YES Return to normal operation message clear Replace controller see pagelss 20 UOHIPUO9 PSPUNOI e JOJ s e ula Jnd no 3AUP ay o BuuIM jeu1ajxe pue 10 0u ay 493YD ue YOOUD E 4 22 1 D 08 papesoxe Jou sey aunjesodwia juaiquie JU A SUN GAA AUIS JEU App JO P9x90 q 104 42840 OULIBY JOCJUOD SJSIX9 PLO JOJOW SAISS99X9 UY GA UO suol 99uuo2 Mel uol do SME IQ IIMEU P E SUI JO au jooap ay pu x3 UONBJ9U3B34 Jojow Aq pasneo aq osje ues abeJJOAIO AO sng SUOIJIDUOD uaisue JO BHEJOA aul YBIY JOJ SUI DY 24 JOHUON uol dnu Jul Jamod au JO BHEJJOA MO 104 SUI OY DUILUOOUT 3UJ JOHUON sasny jndul 280 7 uondnua ul J mod au JO BHEJJOA MO JOJ SUI OY BUIUIO9UI SY JOJUON L uo 9V SJeuluu JNAJNO AHp ay JO 2 0U uo uo Je pajoajep U99q sey puno yjuea o yjed Jua uno y onJeA p uy p d e Sp999X9 unJeJ dui YUISJESH du PEOLOAO 3luo1 58 8 EUISJU IOJOW 9 219 9992 0 9 qeun SI SAU 2N EA WNWIXEUW p p x abejjon snq oq OnJeA WNWIUIW y Mo aq at SWEJJOA SNA DO JBUILIOU JO S9 Mojaq paulewal 3bejjon sng oq uonduaseg 4 d Jine puno dwg ISAO yulsjeaH PEOUINO JOJON D IIe S JOJO 96E J0A 1810 96e J0A Jepun SSO JOMOd yney ELOY 8004 2004 9004
47. so see Monitorine OK ACO TMG Fluid Loss on pag 23 Did messoge clear YES swiich wiring defective Replace Did switch wias Message see page 54 re Return to normal controller operation see page 91 Did message clear Replace controller see pag 83 11 TEMP FAULT GJ HIGH TEMP Error Message Cause Fluid temperature higher than alarm setpoint value in controllers setup loop NOTE This is normally not a pump issue Is facility water adequate NO Adjust facility water temperature flow oressure Did message clear Adjust voltage YES voltage at valve 9 YNDO NO Refer To leradyne service YES Documentation NO Did message clear Replace valve and adjust voltage YES NO SSES NO Adjust Apress re across valve See page correct 66 YES Did message clear NO VES Return to normal operation Reset controller see page 91 Replace controller see poge 83 gt 12 TEMP FAUT LED LOW TEMP Error Message Cause Fluid temperature lower than alarm setpoint value in controller s setup loop NOTE This is normally not a pump issue Is voltage OVDC Refer to Teradyne Service Documentation NO Did Replace valve message adjust voltage clear Reset controller Return to normal operation Did
48. t down due to an overload condition than the corresponding MOL error message will also be on Otherwise measure the amperage of each pump to determine if it is running VES Repair the source of the leak s NO Did error message clear VES VES Troubleshoot VFD Return to normal 21 See page 22 operation YES Is VFD displaying an error message Did error message clear NO NO Are Is DUMP YES pressure Replace running transducers transduce functional See page i Did error message clear Is VFD Volt IN correct NO YES Return To normal operation Is VFD Volt OUT correct Did error message clear Continued on next page Continued from previous page Is VED Correct V OUT Volt OUT Refer to Teradyne correct Service Documentation YES Did error message clear VES Is wiring between VFD and pump Replace wiring correct Did error message clear YES Replace LO See page 55 Reset Return to normal controller ER operation See page 91 Did message clear Replace controller see page ec 10 LVL FAUT LED LEVEL FAIL Error Message Cause Lower low level warning switch open for at least 3 seconds NOTE he LEVEL WARN LED should also be on if not replace the level switch assembly Fluid Level Al
49. ut Tagout LOTO power before servicing Tools Required Two 2 1 16 wrenches or adjustable wrenches One 1 3 4 wrench or adjustable wrench Insulating Tape Procedure For easier access to the assembly remove the unit from the cabinet 1 Drain the water Refer to Teradyne Service Documentation for proper proce dure 2 Remove insulation around the connections 3 Undo the bottom union fitting on pressure regulator 5 To reinstall tighten union one full turn past hand tight 6 Tighten the fitting refer to the Swagelok Installation Sheet on ege 7 Once the unit is restarted check for leaks then install insulation 67 Facility Inlet Pipe 360 900 52 AN Turn off and Lockout Tagout LOTO power before servicing Tools Required Two 2 1 16 wrenches or adjustable wrenches One 1 3 4 wrench or adjustable wrench Insulating Tape Procedure For easier access to the assembly remove the unit from the cabinet 1 Drain the water Refer to Teradyne Service Documentation for proper proce dure 2 Remove insulation 3 Undo top union fitting on pressure regulator rs a 3 5 To reinstall reverse the procedure 6 Tighten u bolts until split washers on both sides are flat 7 Once the unit is restarted check for leaks then install insulation 68 H20 Side Temperature Sensor rtd2 360 900 18 AN 2 Turn off and Lockout Tagout LOTO power before servicing Tools Required Tywr
50. wire 4 Reverse the procedure to install the actuator Torque actuator to 20 25 Ibs 5 Once the unit is restarted check for leaks 6 Install insulation 60 Water Flow Transducer 360 900 72 AA wei Turn off and Lockout Tagout LOTO power before servicing Tools Required Adjustable wrenches Teflon Sealant FasSeal ATS Insulating Tape Procedure For easier access to the assembly remove the unit from the cabinet 1 Drain the water Refer to Teradyne Service Documentation for proper proce dure 2 Remove the insulation 3 Use a wrench to hold the bottom fitting in place and a second wrench to undo the top hose 4 Remove the bottom Swagelok 5 Unplug the wiring from under the electrical box 6 The new flow transducer can be installed in either direction 7 Connect both fittings hand tight NOTE Use supplied thread sealant on upper connection 8 Tighten the fittings refer to the Swagelok Installation Sheet on pagel87 9 Connect the wiring to the control box 10 Once the unit is restarted check for leaks 11 Ensure the LED and error message on the controller are both extinguished 12 Install insulation 61 HFE Temp Sensor rtd1 360 900 55 Tools Required N Turn off and Lockout Tagout LOTO power before servicing 1 2 wrench Tywrap cutters Scissors Procedure 1 Use the 1 2 wrench to disconnect the sensor 2 Slide the sensor down and through the unit s mid
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