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Pfeiffer-Balzers Turbo Pump Controllers TCP-121 and 40

CABLE FOR TPC-040 TURBOPUMP DRIVER BALZERS PFEIFFER	
														
Motor	Ctrlr  Wire color                 Controller cable, wire colors	 							
Cable	Cable		Function                  a            b						
A        a5    BK thk   M4 coil               8	GN/YEL     GN thick						
B        a4    BU thk   M3 coil               7	BK thin    WH thin						
C        a3,U  BR thk   M2 coil               6	GY thin    BK thick, GN thin	 					
D        a2,T  PK thk   M1 coil               5	BK thk     YL thin						
E        a1,R  RD thk   45VDC                 4	BU thk     RD thin						
                                              3	BR/VIO thk BR thin						
F        b6    GN thin	COM                   2	PK/GY thk  PK thin						
M        a6    GY thin	thermistor            1	YL/RD thk  BU thin						
G        b5    YL thin	Hall 42mA drive	 										
H        b4    RD thin	Hall phase /P2	 										
J        b3    BR thin	Hall phase /P1           Pump conn, controller rear panel		
K        b2    PK thin	Hall phase P1         a8	case gnd        b8	n.c.			
L        b1    BU thin	Hall phase P2         a7	Rspeed          b7	Rspeed  1.47K or 3.32K
                                              a6	thermistor      b6	thermistor (gnd)	 	 	
N        a7    BK thin	Rspeed                a5	coil M4         b5	Hall 42mA drive	 	 	
P        b7    WH thin	Rspeed                a4	coil M3         b4	Hall phase /P2	 	 	
                                              a3	coil M2         b3	Hall phase /P1	 	 	
R        a1,E  YL thick   45VDC               a2	coil M1         b2	Hall phase P1	 	 	
T        a2,D  GY thick   1 coil              a1	DC 3v - 45v     b1	Hall phase P2	 			
U        a3,C  VIO thick  2 coil

V        a8    GN/YEL	EARTH	
S        b8    GN thk	n. c.											
						POWER CONN, controller rear panel	 	 						
                                 a8   case gnd              b8   Reset button (pull dn)	 	 	
                                 a7   PTC to +45VDC         b7   "A"			
                                 a6   Ext. standby sw.      b6   Rly K1 n.o., on=full spd	 	 	
                                 a5   com ps gnd            b5   Rly K1-K2 com	 		
                                 a4   interlock             b4   K2 n.o. on=not failed	 	 	
                                 a3   htr out 120V          b3   Panl sw, n.c.	 		
                                 a2   AC inp N              b2   Panl sw, AC inp L	 	 	
                                 a1   AC inp L, jmp to b1   b1   Panl sw n.o., jmp to a1

TCP-121 Turbo Controller


TYPICAL FAILURES:


F1 fuse, main 120VAC (F2 ventvalve? F3 heater?)


  • MOSFETS, blown coil-driver BUZ73 (we repl w/IRF630)


  • Blown PIC626 (4pin power transistor hybrid), may also kill SG3525 pwm chip DIP16 An older part, buy a few on eBay $7


  • Tiny gray transformer (15V boot-up supply,) internal short from old age.


  • Main capacitor dried out, 220uF 400V, also pair of 47uF 350V (high freq, runs warm)


  • Boot supply failed (usually the 100uF capacitor dries out. Or gray xfrmr dead.) The 100uF cap in the 15VDC boot supply must briefly run the two pwm chips until they can create their own 15VDC. If good turbo controller fails after power outage, probably the boot circuit was dead much earlier.


  • Bad socket pin PIC626, the silicone oil and white goo migrates into the four gold socket pins. Unscrewing the side panels moves the package wrt the gold sockets, can cause random flaky run/fails.



    SYMPTOMS:

    Fail after power outage, probably the boot circuit was dead much earlier (100uF cap dried out, or grey 15VAC xfrmr shorted turns.)


    Or, the relays repeatedly click, fan jerks, but only if a turbo pump is connected during power-up: overcurrent detected, PIC626 power transistor is probably shorted or SG3525A is dead, and is applying 45VDC directly to the non-spinning turbo (turbo coils normally start up at 1.5VDC, slowly rise to 35VDC giving 1KHz 60kRPM, or 24VDC for "standby" 700Hz.


    Fan not spinning. If fan not old/dead, the 24VDC fan is spun by the main +45VDC supply (through a series 220 resistor.) Spinning fan shows that raw 45V is working, good all the way up to the input to the PIC626 power transistor.


    PIC626 power "darlington" should show 75 ohms between pin3-pin4, yet NOT be shorted between pin1-pin4.



    NOTES:


    Power cable: some cables lack the jumper a1 to b1, which normally sends 120V through the front panel sw.


    K2 relay is the center relay of the three. Fail-reset: we remove power for 3sec.


    SG3525A pwm chips: one IC runs the +45VDC for turbo, other runs +15V for circuitry.


    PIC626 "darlington" is saturated/on when its pin3 is pulled down by ~0.7V wrt inp, pulled down by 9.3mA to start conduction. Spec sheet insists at least pulled down by a minimum of 30mA through its Base (minus the 10mA taken by 75ohm resistor,) to guarantee fully on. Stay below 8mA to turn off at 0.6V across Vbe and 75ohm. The 820ohm and 15V zener to gnd gives 36mA (on TCP-040, 1.5K to gnd gives 30mA.)


    TWO DIFFERENT DESIGNS, SCHEMATICS! One has pwm chips on a daughterboard, ICL7665 in the boot circuit, and drives the PIC626 pwr transistor-base square wave via an NPN wired for ~30mA constant current. The other type has pwm chips on the main board, the boot circuit has an SCR pulser, and the PIC626 transistor-base square wave is driven by a 15V zener in series with 820ohms.


    TURBO'S FEEDBACK: it comes in via four Hall Sensor signals, through dual comparator to create two 90deg quadrature square waves, then converted by CD4028 (bcd-to-decimal) into the 1,2,3,4 pattern of 15V pulses to four coil-drive open-drain transistors. 




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    Created and maintained by Bill Beaty.

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    University of Washington
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