TE Technology TCA User Manual

.

Thermoelectric Cooling Assembly (TCA)

Instruction Manual

Drawing 4921-1 Rev. D, 07 July 2010

TE

1590 Keane Drive Phone: [phone]
Traverse City, MI 49696 USA Fax: [phone]
http://www.tetech.com e-mail: [email protected]

All Materials Copyright © 2007 - 2009 TE Technology, Inc.

TECHNOLOGY, INC

.

TE Technology, Inc. does not make any warranty, expressed or implied, that the
use or operation of the equipment will be functional or effective if the equipment
is not installed and used in accordance with this manual.

TE Technology, Inc. shall not be liable, and Purchaser shall defend, hold
harmless, and indemnify TE Technology, Inc. from and against, any losses,
costs, expenses (including reasonable attorneys’ fees), injuries, liabilities or
damages of any kind or nature whatsoever, arising out of or from the omission or
failure to use protective devices or comply with this manual. This provision is in
addition to any other indemnification provisions which are a part of the Purchase
Order or contract with Purchaser.

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2/22

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This Thermoelectric Cooling Assembly (TCA) Instruction Manual must

be read and followed carefully before installation and operation.

! Follow all recommendations and suggestions, heed all warnings contained in

this manual and use the product as intended. Failure to do so could result in
hazards and loss or damage to the TCA and/or secondary equipment.

! Only qualified technicians should install and configure the TCA.
! Use of the TCA is restricted to operators capable of understanding one of the

languages presented in this manual, as stated by agreement between TE
Technology, Inc. and the Purchaser.

! The TCA is intended to be operated in a light industrial environment only.
! Do not use in an explosive or potentially explosive environment.
! Do not use the TCA if damaged.
! Do not disassemble TCA. No user serviceable parts inside.
! Do not operate the TCA outside the specified operating temperature range.

Condensation could form on cooled sections of the TCA and on secondary
equipment. This condensate and any subsequent drainage onto other secondary
equipment could pose hazards and/or damage to the TCA and/or secondary
equipment. If such hazards are present, devices should be added to prevent or
remove the condensate such as dehumidifiers, dry gas purge systems,
desiccants, etcetera. Alternatively, cooled sections of the TCA and secondary
equipment should be restricted from being cooled below the dew-point
temperature.

Portions of the TCA could exceed 60 °C during normal operating

conditions resulting in a hazard. Use caution! Protect against contact with hot
surfaces.

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! When using a temperature controller, improper configuration of the

temperature controller, improper installation of a temperature sensor, or the use
of an incorrect temperature sensor can result in hazards or damage to the TCA
or secondary equipment.

! Hazards, excessive hot or cold temperatures, and damage to the TCA or

secondary equipment can occur from fault conditions or human errors such as:

1. Incorrect wiring of the TCA.

2. Failure or misuse of the TCA.

3. Failure or misuse of the control device used with the TCA.

4. Reduction in the flow of cooling air or liquid.

Special Liquid Heat Exchanger Warnings:

If the TCA has one or more liquid heat exchangers, mount the TCA in a

position so that an unexpected liquid leak will be diverted away from electrical
circuitry and sensitive equipment into a containment area where damage to the
equipment and/or hazards will not result.

Do not allow the liquid in the liquid heat exchanger to freeze or overheat, whether
in operation or in storage. Before use, purge all air from the liquid heat
exchanger for proper operation and to prevent overheating.

! The liquid heat exchangers are designed for use with filtered, distilled water.

Other fluids may be acceptable for use if and only if TE Technology has provided
express written notice that they are compatible with the liquid exchanger. Do not
use fluids which have not been approved by TE Technology. Otherwise, damage
and/or hazards could result.

! Do not exceed the specified operating maximum liquid pressure as noted on

the TCA specification sheet or 205 kPa if it is not otherwise specified.
Additional Operation Warnings:

! Proper operation of the TCA is dependant on sufficient air flow through the

fans, heat sink fins, and/or the liquid heat exchanger if so equipped.

! Do not obstruct air flow or liquid flow to the TCA or use in areas where the

heat sink is not well ventilated. The fan and cooling fins should be kept clear of
dirt and dust. Clean by directing compressed air over the fins.

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Do not operate the TCA if the heat-sink fan is not operational. This could

cause damage and create hazards from the heat sink being greater than 60 °C.
Do not operate the TCA if the heat-sink fan is operational but exhibits bearing
noise or is otherwise not operating as normally expected.

! Frost/ice should not be allowed to form on the heat sink, fan(s), or cold sink (if

so equipped) as this could obstruct air flow and decrease performance and/or
cause damage to the TCA and secondary equipment. If frost/ice contacts the
cold-sink or heat-sink fan, de-energize the TCA until the frost/ice has been
removed.

Do not operate TCA without finger guards. This could result in a hazard.

Portions of the TCA (the heat sink, for example) will become warmer

than the ambient temperature. They can become hotter than 60 °C even if
control temperatures of greater than 60 °C are not desired. The operating
temperature of the TCA depends on many factors: ambient temperature, input
power, and heat pumping. If the TCA is to be used in conditions where a portion
of the TCA could possibly exceed 60 °C (for example, if the TCA is operated in
ambient temperatures greater than 35 °C) test the surface temperatures of the
TCA under the worst-case operating conditions of maximum ambient
temperature, highest heat pumping, and maximum input power. If any portion of
the TCA exceeds 60 °C place adequate guards around the TCA to prevent
contact with hot surfaces.

See “Electrical Connections” section for proper connection from controller/power
supply.

Do not:

1. Install the TCA,

2. Attach anything to the TCA, or

3. Operate the TCA or attached equipment,

that would create a voltage potential of 50 V or more on the TCA.

Protective Devices:

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! Use protective devices to prevent hazardous conditions and/or damage to the

TCA and secondary equipment (refer to connection diagram). Protective devices
should be placed at all points on the TCA and secondary equipment where a
hazardous condition can be detected. NOTE: Unless noted in the product
specifications, protective devices are not included.

Protective devices should de-energize the TCA and, as necessary, related
secondary equipment. It is recommended that such devices require the user to
remove and correct the root cause of a fault before allowing the TCA and related
equipment to be re-energized.

! Protective devices must operate independently of the primary temperature

control circuitry.

! Some temperature controllers can detect under-temperature and over-

temperature conditions and can be configured to deenergize the TCA when such
a condition is detected. If a temperature controller is used to provide under­temperature and/or over-temperature detection, it is recommended to monitor the
heat sink and, as necessary, the cold side (cold sink, cold plate, liquid heat
exchanger) for under-temperature and over-temperature conditions. However,
hazards and/or risk of loss or damage to the TCA and/or secondary equipment
could still occur if the temperature controller and/or sensors were to malfunction.
Therefore, independent, redundant protective devices are recommended in
addition to the safeguards provided by the temperature controller. For the
purposes of this manual temperature controllers are not considered protective
devices.

! TE Technology, Inc. shall not be liable, and Purchaser shall defend, hold

harmless, and indemnify TE Technology, Inc. from and against, any losses,
costs, expenses (including reasonable attorneys’ fees), injuries, liabilities or
damages of any kind or nature whatsoever, arising out of or from the omission or
failure to use protective devices.

! Protective devices should include, but are not limited to:

• Fuses to prevent against electrical overloads,

• Over/under temperature thermostats to prevent against hazardous and/or

damaging temperatures,

• Liquid flow meters to prevent against damage due to loss of coolant flow

See “Protective Device Options” below for suggested options.

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6/22

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Protective Device Options

(+) (+)

HOT-SIDE, OVER-TEMPERATURE THERMOSTAT

FUSE

DC

POWER

SUPPLY

DC

POWER

SUPPLY

HOT-SIDE, UNDER-TEMPERATURE T HERMOSTAT

COLD-SIDE, OVER-TEMPERATURE THERMOSTAT

COLD-SIDE, UNDER-TEMPERATURE THERMOSTAT

OTHER PROTECTIVE DEVICE (AS REQUIRED)

LIQUID FLOW SENSOR (AS REQUIRED)

(-) (-)

or

FUSE

RELAY

HOT-SIDE, OVER-TEMPERATURE THERMOSTAT

HOT-SIDE, UNDER-TEMPERATURE THERMOSTAT

COLD-SIDE, OVER-TEMPERATURE THERMOSTAT

COLD-SIDE, UNDER-TEMPERATURE THERMOSTAT

OTHER PROTECTIVE DEVICE (AS REQUIRED)

(+)(+)

TCA

(AND OPTIONAL

TEMPERATURE

CONTROLLER)

TCA

(AND OPTIONAL

TEMPERATURE

CONTROLLER)

LIQUID FLOW SENSOR (AS REQUIRED)

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(-)(-)

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Terminology

TCA – Thermoelectric Cooling Assembly
AC – Air Cooler
CP – Cold Plate
LC – Liquid Cooler

Note: drawings are for illustrative purposes only; consult TCA Specifications for complete details.

AC-xxx TCA Terminology

finger
guard

terminal

block
cover

finger
guard

cold sink fan

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gasket

heat sink

cold sink

supplied hole

for mounting

temperature sensor

heat sink

fan

terminal

block

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TCA mounting hole

(threaded or through

hole), typical

supplied hole

for mounting

temperature sensor

.

CP-xxx TCA Terminology

TCA mounting
hole (threaded

or through

hole), typical

threaded hole for

mounting part to plate

(location and type vary)

terminal

block

supplied hole

for mounting

temperature sensor

TETECHNOLOGY, INC.

supplied hole

for mounting

temperature sensor

terminal

block cover

finger
guard

cold

plate

heat sink

heat sink fan

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LC-xxx TCA Terminology

TCA mounting hole

heat sink

inlet/outlet

(threaded or through

hole), typical

tube

supplied hole

for mounting

temperature sensor

liquid heat

exchanger

TETECHNOLOGY, INC.

supplied hole

for mounting

temperature sensor

finger
guard

inlet/outlet

tube

terminal

block

terminal

block cover

heat sink

fan

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10/22

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Installation

Mechanical Mounting:

! Improper mounting or installation of the TCA could result in the unit falling,

creating a hazard. Be certain that the structure supporting the TCA is of
sufficient strength for its weight and that all fasteners are properly installed.

! The cold side of the TCA may form condensation. Mount the TCA in a location

that is not affected by condensation, or use caution so that condensate does not
contact areas where damage to the TCA or secondary equipment may result.
Condensate should not be allowed to contact the TCA fan or wires or electrical
connections.

! For AC-xxx units, there is a gasket on the face of the heat sink for the purpose

of sealing against the enclosure wall. The gasket must be compressed to a level
that will ensure proper sealing. Proper compression is dependant upon the
enclosure wall stiffness, the number and location of the mounting holes, the size
of the cooler, etcetera. Generally, the gasket can be completely compressed. A
suitable sealant (one that is weather resistant and provides good adhesion
between the sealing surfaces, possibly, but not necessarily, RTV silicone rubber
sealant, for example) should be applied to ensure proper sealing.

! To maintain a NEMA or IP rating or otherwise to prevent leaks of dust or

liquids, use sealing washers on all screws and seal all openings, gasket
surfaces, and mounting hardware with a suitable sealant.

Note: if the AC-xxx unit has been removed for service, the gasket should be
inspected for its ability to maintain the seal integrity prior to re-installation. If the
gasket is damaged or has lost resiliency, the gasket should be replaced.

! If an AC-xxx or other TCA has a NEMA or IP rating, the sole purpose of the

rating is to state that when installed on an enclosure the TCA can maintain the
seal integrity of the enclosure up to the stated NEMA or IP rating. However, the
TCA must be installed and tested by a qualified technician to verify the seal
integrity as there are a number of design variables which are outside the control
of TE Technology.

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TCA Mounting Hole Dimensions

NOTE: Only AC-xxx

units have gasket for

sealing the opening.

Use sealing washers

and appropriate

sealant on gasket

surface and

mounting hardware

to achieve rated

sealing.

TETECHNOLOGY, INC .

TCA

TCA

AC-027, CP-036

AC-027, CP-036
AC-046, CP-065

AC-046, CP-065
CP-061, AC-053

CP-061, AC-053

CP-121

CP-121

AC-073,

AC-073,

CP-110, CP-127

CP-110, CP-127

CP-200, CP-200HT,

CP-200, CP-200HT,

CP-200TT, CP-200HTTT

CP-200TT, CP-200HTTT

AC-162,CP-218

AC-162,CP-218

AC-140, AC-194

AC-140, AC-194

LC-035

LC-035
LC-061

LC-061
LC-200

LC-200

* This length dimension is required to prevent interference with tubing. The heat
sink face will not completely seal against the outside surface of the opening.

SCREW AND WASHER ONLY FOR: AC-027, AC-046, AC-053, CP-036,
CP-061, CP-065, CP-121, LC-035, LC-061

BOLT, NUT, AND WASHER FOR: AC-073, AC-162, AC-140, AC-194, CP-110,
CP-127, CP-200, CP-218, LC-200

A

A

(mm)

(mm)

(mm)

(mm)

W (mm)L (mm)B

W (mm)L (mm)B

85107127104.6

85107127104.6

85132152.4104.6

85132152.4104.6

82132139.788.9

82132139.788.9

157157127172.2

157157127172.2

97157190.5114.3

97157190.5114.3

157221241.3161

157221241.3161

145221241.3161

145221241.3161

145230246.4161

145230246.4161
85167*127104.6

85167*127104.6
85192*152.4104.6

85192*152.4104.6

157281*241.3161

157281*241.3161

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12/22

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TCA Orientation

TETECHNOLOGY, I NC.

DIRECTION
OF GRAVITY

TCA can function in any orientation

Bevel opening as necessary to
allow unrestricted air flow from

cold sink

Recommended orientation

when condensat ion on TCA

cold surfaces is possible

Note:

1) When mounting LC-xxx TCA, orient and
position TCA to protect other sensitive

TETECHNOL OGY, INC.

equipment (if applicable) from unexpected
leaks.

2) If TCA cold surfaces are below the dew­point temperature, condensate should be
prevented from contac t sensitive
equipment and points of electric al contact.

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Minimum Distance between Fan and Obstruction

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AIR FLOW

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>45 mm

for best pe rformance

.

0.05 mm

recommended

Thermal Interace

Material (pad or

grease)

Attaching Part to CP-xxx TCA

Part to be

cooled

0.05 mm

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Allowable Locations for Adding Holes for Mounting

Protective Devices

Typical LC-xxx TCA

SUPPLIED HOLE FOR MOUNTING TEMPERATURE
SENSOR OR OTHER PROTECTIVE DEVICE

USER ADDED HOLES
Ø4 mm MAXIMUM, 9.7 MM DEEP MAXIMUM
DO NOT BREAK THROUGH

25 mm, MINIMUM

AS REQUIRED

SUPPLIED HOLE FOR MOUNTING TEMPERATURE

SENSOR OR OTHER PROTECTIVE DEVICE

(LOCATION MAY VARY)

Typical CP-xxx or AC-xxx TCA

TETECHNOLOGY, INC.

AS REQUIRED

USER ADDED HOLES
Ø4 mm MAXIMUM,

9.7 MM DEEP MAXIMUM

AS REQUIRED

AS REQUIRED

Notes:

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1. All dimensions in millimeters.

2. Clamp directly to base of heat sink when adding holes to heat sink; clamp directly to cold side (base of cold sink, cold
plate, or liquid heat exchanger) when adding holes to cold side. Do not apply compressive force from the heat sink to
the cold side.

3. Locations for protective devices other than those shown here may be acceptable. Contact TE Technology. for
assistance with locating a protective device elsewhere on the TCA.

16/22

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Configuration

Electrical Connections:

! Only use wires, electrical cables, and connectors that have proper electrical

insulation for the operating voltages and sufficient capacity for the electrical
current required.

! Be certain that all electrical components are in good condition. Do not pinch or

damage any wires when installing or operating the TCA. Operate only with the
terminal block cover in place to prevent accidental contact with equipment
carrying hazardous voltages.

! The electrical input to the TCA must be fused appropriately to prevent injury in

the event of an electrical malfunction.

! Use wire leads which are short in length to reduce the risk of electromagnetic

interference. Use electrical shielding and ferrite beads as necessary.

! The application of incorrect voltage to the TCA can result in a hazard or

damage to the TCA and/or secondary equipment.

! The electrical connections and wires of the TCA and secondary equipment

should be restricted from being cooled below the dew point.

! Do not exceed the specified electrical ratings of the TCA.

Temperature Controller and Power Supply Connections:

! For all electrical connection types shown below, the fans should be operated

at their nominally rated voltage. Consult TE Technology, Inc. for operating fans
above or below nominally rated voltage.

• “Single Power Supply, Constant Voltage Connection” may be used for
cooling applications only.

• “Two Power Supplies, Variable Heating/Cooling Connection” may be
used with two separate power supplies: one constant voltage power
supply for the fans and one variable or constant voltage power supply
for the thermoelectric (Peltier) modules. It may be used for heating or
cooling.

• “Temperature Controller Connection” may be used with one power
supply and one temperature controller (unless otherwise specified by
the controller manual). Power supply powers the fans directly and
supplies power to the controller, which then modulates power to the
TCA thermoelectric (Peltier) modules to maintain a set temperature. It
may be used for heating or cooling.

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TCA

COLD-SIDE FAN

(AC-XXX UNITS ONLY)

HOT-SIDE FAN

(ALL UNITS)

THERMOELECTRIC

(PELTIER)

Single Power Supply, Constant Voltage Connection

Review electrical jumper connections. Install electrical jumpers as required.

Terminal Block

Cover removed

for clarity. Re-

install before

operation.

PROTECTION

DEVICES

DC

POWER SUPPLY

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Two Power Supplies, Variable Heating/Cooling Connection

TCA

COLD-SIDE FAN

(AC-XXX UNITS ONLY)

HOT-SIDE FAN

(ALL UNITS)

THERMOELECTRIC

(PELTIER)

PROTECTION

DEVICES

Review electrical jumper c onn ections. Remove elec trical jumpers as required.

Terminal Block
Cover removed

for clarity. Re-

install before

operation.

DC CONSTANT OR
VARIABLE POWER

SUPPLY

PROTECTION

DEVICES

DC POWER SUPPLY

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Temperature Controller Connection

TCA

COLD-SIDE FAN

(AC-XXX UNITS ONLY)

HOT-SIDE FAN

(ALL UNITS)

THERMOELECTRIC

(PELTIER)

TEMPERATURE

CONTROLLER

Review electrical jumper connections. Remove electrical jumpers as required.

Terminal Block
Cover removed

for clarity. Re-

install before

operation.

PROTECTION

DEVICES

DC POWER SUPPLY

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The preceding temperature controller and power supply connections are
generally applicable to our standard products. Custom products, of course, might
not necessarily follow the same conventions or connection type. However, the
same principles generally apply. That is, if you are using a temperature controller
with the TCA, the temperature controller should be modulating power to the
thermoelectric modules only. The temperature controller should NOT be used to
modulate power directly to the fans.

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Operation

Review the TCA product specification sheet and verify that the input voltage to
the TCA is appropriate. Verify that the power supply used with the TCA can
provide sufficient current. Use direct current only; do not use alternating current
unless otherwise specified by the TCA.

Be sure to follow the instruction manuals for the power supply and any
temperature controller used with the TCA.

Check for proper electrical connections. If you notice discoloration or abnormally
high operating temperatures on the wires and/or connectors, de-energize the
TCA and rectify the fault before re-energizing the TCA.

If using a temperature controller that provides pulse-width modulated output to
the thermoelectric (Peltier) modules, the pulse-width modulation frequency
should be between 300 Hz and 3,000 Hz.

Use analog output to power the TCA fans; do not use pulse-width modulated
output unless otherwise specified by the TCA specification sheet.

The actual TCA performance may vary by +/-10% from that shown in the TCA
specification sheet. Furthermore, specifications are based on the assumption of
unrestricted airflow to the fans and from the heat sink and cold sink (as
applicable to the TCA). It is further assumed that the TCA operates in standard
air and barometric pressure (101 kPa). Consult TE Technology, Inc. if the TCA is
to operate with some known airflow restriction and/or the TCA is to operate in a
non-standard gas and/or pressure.

While in operation, look for any non-operating fans or unexpected changes in fan
speed. If non-operating fans or unexpected fan speed changes are found, de­energize the TCA and inspect for improper electrical connections, failed or failing
fans, or unexpected air restrictions. Do not re-energize the TCA until the fault has
been rectified.

If you are using a custom TCA where fan(s) are not provided as part of the
assembly, be sure that the method you have chosen for dissipating waste heat is
adequate and operating correctly.

Review the frequently asked questions (FAQ & Technical information) and other
related documents posted at http://www.tetech.com.

Consult TE Technology if additional clarifications are needed.

TE

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22/22