Page 1
87-900-865-01 (B)
JULY 2006
(GB) INSTRUCTION MANUAL
Turbo-V60
Leak Detector
PCB Controller
Model 969-9840
vacuum technologies
Page 2
Turbo-V 60 Leak Detector
PCB Controller
Page 3
Page 4
Page 5
TABLE OF CONTENTS
Section Page
- Safety summary
1
I Description
1-1 General 2
1-2 Turbo-V60 controller description 2
1-3 Controller specifications 3
1-4 Controller outline 3
II Installation
2-1 General 4
2-2 Line voltage selection 4
2-3 Power interconnections 4
2-4 Input/Output interconnections 5
2-5 Turbo-V pump connection 5
III Operation
3-1 General 6
3-2 Start-up 6
3-3 Soft Start mode deselection 6
3-4 Starting the pump 6
3-5 Pump shutdown 7
3-6 Power failure 7
IV Maintenance
4-1 General 8
4-2 Controller test 8
Page 6
87-900-865-01 (B)1
SAFETY SUMMARY
Operators and service personnel must be aware of all hazards associated with this equipment. They must know how to
recognize hazardous and potentially hazardous conditions, and know how to avoid them. The consequences of
unskilled, improper, or careless operation of the equipment can be serious. This product must only be operated and
maintained by trained personnel. Every operator or service person must read and thoroughly understand
operation/maintenance manuals and any additional information provided by Varian.
All warnings and cautions should be read carefully and strictly observed. Address any safety, operation, and/or
maintenance questions to your nearest Varian office.
The following format is used in this manual to call attention to hazards:
!
Warning are used when failure to observe instructions or precautions could result in injury or death.
Cautions are used when failure to observe instructions could result in damage to equipment, whether Varian supplied or
other associated equipment.
NOTE
Infomation to aid the operator in obtaining the best performance from the equipment.
WARNING!
CAUTION!
Page 7
SECTION I - DESCRIPTION
87-900-865-01 (B)
2
1-1 General
The Turbo-V60 Leak Detector PCB controller is a
microprocessor-controlled, solid-state, frequency
converter with self-diagnostic and protection features.
The controller drives (within ten steps) the Turbo V-60
pump during the starting phase by controlling the
voltage and current respect to the speed reached by
the pump.
It incorporates all the facilities required for the
automatic operation of the Turbo-V60 pump series.
Remote start/stop and output control capability are
provided via auxiliary connectors.
1-2 Turbo-V60 controller description
The controller is a solid-state frequency converter
which is driven by a single chip microcomputer. The
package composition is:
− Power transformer with interconnection cables
− PCB including: power supply and 3-phase output,
analog and input/output section, microprocessor
and digital section
− Controller to pump interconnection cable.
The power supply and the 3-phase output converts the
single phase (50-60 Hz) AC mains supply into a 3phase, low voltage, medium frequency output which is
required to power the Turbo-V pump.
The microcomputer generates the variable output
frequency and controls the 3-phase output voltage
according to the software and the gas load condition of
the pump.
Moreover, it manages input and output signals for a
fully automatic operation.
A dedicated non-volatile RAM is used to store pump
operating parameters and the input/output programmed
information upon failure for a period of 10 years
accumulated off time.
Two adjustable trimmers are provided to set the pump
rotational speed as follows:
− P1 – High speed trimmer: 50 to 70 KRPM
− P2 – Low speed trimmer: 30 to 50 KRPM
The controller can be operated via remote signals
through input/output connector.
Page 8
SECTION I - DESCRIPTION
87-900-865-01 (B)
3
1-3 Controller specifications
Input:
Voltage
Frequency
Power
Two ranges selectables on
a three pin connector on
the transformer primary:
- 120 Vac±20%,
- 220 Vac±20%,
1-phase
47 to 63 Hz
350 VA maximum
Output:
Voltage
Frequency
Power
54 Vac nominal ±10%,
3-phase
1167 Hz, ±2%
150 W maximum
Operating temperaure 0°C to + 40 °C
Storage temperature -20°C to + 70°C
J2 optoisolator input
4 to 12 Vdc
J2 optoisolator output
ICsat 1.6 mA
VCE max 0.6 V
VCEO 70 V
Interconnecting
cables
Pump cable (5-wire,
55 cm long)
Weight 0.5 Kg (1.1 Ibs)
1-4 Controller outline
The outline dimensions for the Turbo-V60 Leak
Detector PCB controller are shown in Fig. 1-1.
.
Figure 1-1 – Controller outline
Page 9
SECTION II - INSTALLATION
87-900-865-01 (B)
4
2-1 General
Inspect the controller for any shipping damage.
!
High voltage developed in the controller can cause
severe injury or death. Before servicing the unit,
disconnect the input power cable.
NOTE
The PCB installed into the customer system must be
positioned so that cold air (forced or natural convection) can flow through the PCB components
2-2 Line voltage selection
The controller can operates with two ranges of input
voltage:
– 120 Vac ±20%
– 220 Vac ±20%
The line voltage selection is done on the three pin male
connector on the primary wires of the transformer:
− for 120 Vac connect the line wires as follows:
– 120 Vac to pin 2 (white)
– 0 V to pin 3 (bleu)
− for 220 Vac connect the line wires as follows:
– 220 Vac to pin 1 (brown)
– 0 V to pin 3 (bleu)
NOTE
The mating connector and the female pins are provided
2-3 Power interconnections
The power supply from the external transformer must
be connected to J8 connector
See Fig. 2-1 for interconnections detail.
Figure 2-1 - J8 connector interconnections
WARNING!
Page 10
SECTION II - INSTALLATION
87-900-865-01 (B)
5
2-4 Input/Output interconnections
All the input/output signals to the controller must be
connected at J15 mating connector (see Fig. 2-2).
Figure 2-2 – Input/Output connector
Pin 1-6 Input A optically isolated from the internal
circuit.
In conjunction with the Input B determines the controller
mode of operation according to the following truth table.
Pin 2-7 Input B optically isolated from the internal
circuit.
In conjunction with the Input A determines the controller
mode of operation according to the following truth table.
INPUT SIGNAL
LOGIC LEVEL
CONTROL UNIT
CONDITION
AB
LOW LOW LOW FREQUENCY
LOW HIGH HIGH FREQUENCY
HIGH LOW HIGH FREQUENCY
HIGH HIGH LOW FREQUENCY
Pin 3-8 Output Normal optically isolated from the
internal circuit.
Pin 4-9 Output Overload optically isolated from the
internal circuit.
2-5 Turbo-V pump connection
A 55 cm long cable is provided to connect the controller
to the pump.
Figure 2-3 shows the pump output connector
configuration where pins:
Pins A-F = pump temperature sensor
Pins B-C-D = 54 Vac 3-phase output to pump motor
stator
Pin E = ground.
Figure 2-3 – Turbo-V pump connector
Page 11
SECTION III - OPERATION
87-900-865-01 (B)6
3-1 General
Make all vacuum manifold and electrical connections
and refer to Turbo-V pump instruction manual prior to
operating the Turbo-V controller.
!
To avoid injury to personnel and damage to the
equipment, if the pump is laying on a table make sure it
is steady. Never operate the Turbo-V pump if the pump
inlet is not connected to the system or blanked off.
The controller operates completely automatically after
the remote start command is given.
The only user available commands are two trimmers to
set the pump rotational speed: the first one (P1) sets
the high speed, the second (P2) sets the low speed.
The two trimmers are factory preset as follows:
– P1 (high speed) to 60 KRPM
– P2 (low speed) to 33 KRPM
To select different rotational speeds, act on the
appropriate trimmer. The variation ranges are:
– P1: 50 to 70 KRPM
– P2: 30 to 50 KRPM
3-2 Startup
Plug the controller power cable into a suitable power
source.
The controller is factory preset with the Soft Start mode
enabled that allows the pump to ramp-up to Normal
speed slowly with a minimum ramp-up time of 75
seconds and a maximum of about 45 minutes.
If it is necessary to deselct this mode refer to
paragraph 3-3.
If the Soft Start mode is deselected, the ramp-up will be
done within 60 seconds.
3-3 Soft Start mode deselection
The Soft Start mode is enabled and disabled by means
of a jumper located on the controller PCB.
To deselect the Soft Start mode operate as follows:
– Disconnect the power from the controller.
– Move the red jumper from the actual position to the
other according to the label attached over the
integrated circuit near the jumper (see Fig. 3-1).
– Connect the power.
Figure 3-1- Soft Start jumper
3-4 Starting the pump
To start the pump it is necessary to set the Input A and
Input B signals on J15 connector both to low logic level,
or one to low and the other to high logic level.
In the first case the output to the pump is at low
frequency, in the other case the output is at high
frequency.
The time to change the speed from low frequency (33
KRPM) to high frequency (60 KRPM) is 12 sec.
The time to change from high frequency (60 KRPM) to
low frequency (33 KRPM) is 3 sec.
WARNING!
Page 12
SECTION III - OPERATION
87-900-865-01 (B)7
3-5 Pump shutdown
To shutdown the pump it is necessary to set the Input A
and Input B signals on J15 connector both to high logic
level.
3-6 Power failure
In the event of a power failure (momentary or long
term), the Turbo-V controller will stop the turbopump.
When power is restored, the Turbo-V controller
automatically restarts the turbopump.
Page 13
SECTION IV - MAINTENANCE
87-900-865-01 (B)8
4-1 General
Replacement controllers are available on an advance
exchange basis through Varian. If necessary,
information is provided to aid the operator in
determining malfunctions and corrective steps to be
taken.
!
Voltages developed in the unit are dangerous and may
be fatal. Service must be performed by authorized
personnel only.
4-2 Controller test
a) Equipment required
– Digital voltmeter (DVM) true RMS.
– Dummy load: 3 x 48Ω, 50W each or 3 x 78Ω, 50W
each.
– Potentiometer 50KΩ, 1/4W minimum.
b) Test set up
– Remove the power cable.
– Disconnect the Turbo-V controller.
– Set potentiometer to 30KΩ and connect it as
directed in Fig. 4-1.
Figure 4-1 – Dummy load connections
4-2.1 Power supply test
a) DC voltage test
Check the DC voltages referring to test points indicated
in Fig. 4-2. Refer also to Figg. 4-3 and 4-4. The meter
should read:
– + 5Vdc ± 5%
– ± 12 Vdc ± 5%
– Ground reference = case of Q3.
Switch on the controller and check:
– 54 Vdc ± 10% between TP3(-) a TP5(+) (Fig. 4-2).
b) AC three-phase output voltage test
On the pump connector connect the DVM in turn
between:
pins B and C, B and D, C and D.
The meter should read 44 Vac ±15%; a different value
of 0.4 Vac is tolerable between phase and phase.
4-2.2 Test with dummy load
– Connect the 48Ω or the 78Ω dummy loads to the
pump connector pins B, C, D as shown in Fig. 4-1.
– Disconnect the potentiometer, set it to 10KΩ, and
then reconnect it.
– Connect the power cable.
– Switch on the controller and check the values as
per he following table.
WARNING!
Page 14
SECTION IV - MAINTENANCE
87-900-865-01 (B)
9
During start-up
without Soft Start
mode
After start-up
With
48Ω
dummy
load
With 78Ω
dummy
load
With 48Ω
dummy
load
With
78Ω
dummy
load
Current
±10%
1.62 A 1.1 A 1 A 1 A
Power ±10%
80 W 58 W 30 W 48 W
Speed
±4KRPM
17 70 40 63
Temperature
±2°C
52° C 52° C 52° C 52° C
– Check the 3-phase ac output voltage.
After start up it should be:
36 Vac with 78Ω dummy load and
21 Vac with 48Ω du y load.
Switch off the controller and remove the power cable.
4-2.3 Pump over-temperature test
– Disconnect the potentiometer, set it to 5KΩ, and
then reconnect it.
– Disconnect the dummy loads.
– Connect the power cable.
– Switch on the controller.
– Check the 3-phase ac output voltage.
It should be zero.
– Switch off the controller and remove
power cable.
4-2.4 Functional test
Perform the functional test with the turbo-pump, taking
care to check the ramp sequence and start up time.
DISPOSAL
Meaning of the "WEEE" logo found in labels
The following symbol is applied in accordance with the
EC WEEE (Waste Electrical and Electronic Equipment)
Directive.
This symbol (valid only in countries of the European
Community) indicates that the product it applies to
must NOT be disposed of together with ordinary
domestic or industrial waste but must be sent to a
differentiated waste collection system.
The end user is therefore invited to contact the supplier
of the device, whether the Parent Company or a
retailer, to initiate the collection and disposal process
after checking the contractual terms and conditions of
sale.
Page 15
SECTION IV - MAINTENANCE
87-900-865-01 (B)10
Figure 4-1
Page 16
Request for Return
1. A Return Authorization Number (RA#) WILL NOT be issued until this Request for Return is completely filled out,
signed and returned to Varian Customer Service.
2. Return shipments shall be made in compliance with local and international Shipping Regulations (IATA, DOT, UN).
3. The customer is expected to take the following actions to ensure the
Safety
of workers at Varian: (a) Drain any oils or
other liquids, (b) Purge or flush all gasses, (c) Wipe off any excess residues in or on the equipment, (d) Package the
equipment to prevent shipping damage, (for Advance Exchanges please use packing material from replacement unit).
4. Make sure the shipping documents clearly show the RA# and then return the package to the Varian location nearest you.
North and South America
Varian Vacuum Technologies
121 Hartwell Ave
Lexington, MA 02421
Phone : +1 781 8617200
Fax: +1 781 8609252
Europe and Middle East
Varian SpA
Via Flli Varian 54
10040 Leini (TO) – ITALY
Phone: +39 011 9979111
Fax: +39 011 9979330
Asia and ROW
Varian Vacuum Technologies
Local Office
CUSTOMER INFORMATION
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Contact person: Name: ……………………………………..… Tel: ……………………….…...…………….….…....
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Europe only: VAT reg. Number: ………………..……………... USA only: Taxable Non-taxable
Customer Ship To: ………………………….……… Customer Bill To: …………………..……………...
……………..…………………... ..………………………………...
………………..………………... ..………………………………...
PRODUCT IDENTIFICATION
Product Description Varian P/N Varian S/N Purchase Reference
TYPE OF RETURN (check appropriate box)
Paid Exchange Paid Repair
Warranty Exchange
Warranty Repair
Loaner Return
Credit Shipping Error
Evaluation Return
Calibration
Other ……………….
HEALTH and SAFETY CERTIFICATION
Varian Vacuum Technologies CAN NOT ACCEPT any equipment which contains BIOLOGICAL HAZARDS or
RADIOACTIVITY. Call Varian Customer Service to discuss alternatives if this requirement presents a problem.
The equipment listed above (check one):
HAS NOT
been exposed to any toxic or hazardous materials
OR
HAS
been exposed to any toxic or hazardous materials. In case of this selection, check boxes for any materials that
equipment was exposed to, check all categories that apply:
Toxic Corrosive Reactive Flammable Explosive Biological Radioactive
List all toxic or hazardous materials. Include product name, chemical name and chemical symbol or formula.
.……………………………………………………………………………………………………………………..
Print Name: …………………………………. Customer Authorized Signature: ……………...…………………….
Print Title: …………………………………... Date: ..…../..…../……
NOTE:
If a product is received at Varian which is contaminated with a toxic or hazardous material that was not disclosed,
the customer
will be held responsible
for all costs incurred to ensure the safe handling of the product, and
is liable
for any harm or injury to Varian
employees as well as to any third party occurring as a result of exposure to toxic or hazardous materials present in the product.
Do not write below this line
Notification (RA)#: ……………………….……….. Customer ID#: ……….…………. Equipment #: ……………………..
Page 17
Request for Return
FAILURE REPORT
TURBO PUMPS and TURBOCONTROLLERS
POSITION PARAMETERS
Does not start
Noise
Vertical
Power: Rotational Speed:
Does not spin freely
Vibrations
Horizontal
Current: Inlet Pressure:
Does not reach full speed
Leak
Upside-down
Temp 1: Foreline Pressure:
Mechanical Contact
Overtemperature
Other: Temp 2: Purge flow:
Cooling defective …………………. OPERATION TIME:
TURBOCONTROLLER ERROR MESSAGE:
ION PUMPS/CONTROLLERS VALVES/COMPONENTS
Bad feedthrough
Poor vacuum
Main seal leak
Bellows leak
Vacuum leak
High voltage problem
Solenoid failure
Damaged flange
Error code on display
Other
Damaged sealing area
Other
Customer application:
Customer application:
LEAK DETECTORS INSTRUMENTS
Cannot calibrate
No zero/high backround
Gauge tube not working Display problem
Vacuum system unstable
Cannot reach test mode
Communication failure
Degas not working
Failed to start
Other
Error code on display
Other
Customer application:
Customer application:
PRIMARY PUMPS DIFFUSION PUMPS
Pump doesn’t start
Noisy pump (describe)
Heater failure
Electrical problem
Doesn’t reach vacuum
Over temperature
Doesn’t reach vacuum
Cooling coil damage
Pump seized
Other
Vacuum leak
Other
Customer application:
Customer application:
FAILURE DESCRIPTION
(Please describe in detail the nature of the malfunction to assist us in performing failure analysis):
NOTA: Su richiesta questo documento è disponibile anche in Tedesco, Italiano e Francese.
REMARQUE : Sur demande ce document est également disponible en allemand, italien et français.
HINWEIS: Auf Aufrage ist diese Unterlage auch auf Deutsch, Italienisch und Französisch erhältlich.
Page 18
Sales and Service Offices
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Varian s.a.
7 Avenue des Tropiques
Z.A. de Courtaboeuf - B.P. 12
Les Ulis cedex (Orsay) 91941
France
Tel: (33) 1 69 86 38 84
Fax: (33) 1 69 86 29 88
From Benelux Tel: (31) 118 67 15 70
From Benelux Fax: (31) 118 67 15 69
Canada
Central coordination through:
Varian Vacuum Technologies
121 Hartwell Avenue
Lexington, MA 02421
USA
Tel: (781) 861 7200
Fax: (781) 860 5437
Toll Free # 1 (800) 882 7426
China
Varian Technologies - Beijing
Rm 1648 Central Tower South Wing
Beijing Junefield Plaza
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Beijing 100052
P.R. China
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Fax: (86) 10 63100141
Toll Free: 800 820 6556
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Alsfelder Strasse 6
Postfach 11 14 35
64289 Darmstadt
Germany
Tel: (49) 6151 703 353
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1010 Competent House
7, Nangal Raya Business Centre
New Delhi 110 046
India
Tel: (91) 11 28521171
Fax: (91) 11 28521173
Italy
Varian Inc.
Vacuum Technologies
Via F.lli Varian 54
10040 Leini, (Torino)
Italy
Tel: (39) 011 997 9 111
Fax: (39) 011 997 9 350
03/06
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Lexington, MA 02421
USA
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Fax: (781) 860 5437
Other Countries
Varian Inc.
Vacuum Technologies
Via F.lli Varian 54
10040 Leini, (Torino)
Italy
Tel: (39) 011 997 9 111
Fax: (39) 011 997 9 350
Customer Support & Service:
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Toll-Free: 1 800 882 7426
vtl.technical.support@varianinc.com
Europe
Tel: 00 800 234 234 00
vtt.technical.support@varianinc.com
China
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vtc.technical.support@varianinc.com
Japan
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vtj.technical.support@varianinc.com
Korea
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