D U N I W A Y S T O C K R O O M C O R P.
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Instruction Manual
Instruction Manual
Thermocouple Gauge
Control Units
Models TCG-531 & TCG-531/2
Models TCG-06M & TCG-06M/2
Copyright © 1998 by Duniway Stockroom Corp.
rev083010sr
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Table of Contents
I Technical Specifications page 4
II Principle of Operation page 5
III Installation page 7
IV Operation/Calibration page 8
A. Operation
B. Calibration
V Accessing Analog Voltage/Pressure Signal page 9
VI Maintenance page 10
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List of Illustrations
Figure 1: Diagram of Thermocouple Tube and Control Unit page 5
Figure 2: TCG-531 Figure 3: TCG-06M/2 with Box page 6
Figure 2: TCG-531 Figure 3: TCG-06M/2 with Box page 6
Figure 4: Photograph of Control Unit - Side and Front page 7
Figure 5: Rear View of Meter, Showing Output Terminals page 9
page 9
Figure 6: Dis-assembled Unit page 10
Table 2: Cross Reference/Equivalent List page 11
Figure 7: Panel Mounting Holes for TCG Meter page 11
Figure 8: Thermocouple Control Unit Schematic Diagram page 12
Table 3: Component Values for Figure 7, Schematic page 12
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I Technical Specifications
Input Voltage: 110 VAC, 50/60 Hz
(for other power requirements consult Duniway Stockroom Corp.)
Weight: 1 lb (0.5 kg)
Range: 1 millitorr to 2000 millitorr
Environmental limits: 32-120oF (0-49oC)
10%-90% Relative Humidity, Non-Condensing
-1000 feet (-333 meters) to +10,000 feet (+3333 meters) altitude
Dimensions: 3.5 inches high (8.9 cm)
4.1 inches wide (10.4 cm)
3.1 inches deep (7.9 cm)
Power Cable Length: 6 feet (183 cm)
Thermocouple Cable Length: 10 feet (305 cm)
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II Principle of Operation
Thermocouple gauges belong to the class of vacuum gauges which rely on the thermal trans-
port qualities of gases. The thermocouple gauge uses the thermal conductivity property of gases, by
incorporating a wire filament which is heated by a constant source of power. Attached to this fila-
ment is a thermocouple, which measures the temperature of the wire. At high pressures, the large
number of gas molecules striking the heated wire carries energy away and cools the wire. At low
pressures, the smaller number of gas molecules striking the wire causes less cooling, and thus a
higher temperature. The thermocouple output voltage responds to these temperature changes to give
an indication of pressure: low gas pressure gives high filament temperature which gives high ther-
mocouple output voltage; high gas pressure gives low filament temperature which gives low ther-
mocouple output voltage. The meter measuring the thermocouple voltage is calibrated in pressure
units to give a direct indication of pressure.
At pressures below about 10-3 torr, the heat loss from the filament is primarily through radi-
ation since the density of gas molecules is so low. Since the heat loss due to radiation is constant,
the resulting temperature corresponds to the “zero” reading on the meter.
The thermocouple gauge is a simple, rugged device which is very useful at rough vacuum
pressures. The meter covers the pressure range of 1 to 2000 millitorr.
Figure 1: Diagram of Thermocouple Tube and Control Unit
Two different basic models are available to support either the Varian Type 531 tube or the
Hastings type DV-6M tube. For the TCG-531, a thermistor temperature compensation device is
built into the thermocouple connector for added stability. Each type is also available in a version
to support two thermocouple tubes.
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Shown below are photographs of two examples, Figure 2 shows a TCG-531 and Figure 3
shows a model TCG-06M/2 mounted in a box. See the table under Section V “Maintenance” for a
cross reference list for compatibility of various manufacturer’s tubes and Duniway Stockroom
Corp. control units.
Figure 2: TCG-531 Figure 3: TCG-06M/2 with Box
NOTE: Thermocouple Gauges should not be operated in conditions
where significant amounts of flammable gases are present; for example:
Methane, ethane, acetylene, etc.
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III Installation
The basic thermocouple controller is a self-contained meter/control/cable package. The unit
assembly consists of a meter, power unit, 6 foot power cable and 10 foot thermocouple cable. It can
be operated as a free-standing unit, or can be panel mounted. An optional box is available separate-
ly for mounting the unit.
Installation involves
1. Mounting of the unit, if required.
2. Attach the thermocouple cable to the thermocouple tube.
3. Adjust mechanical zero, if required. The mechanical zero adjust is located on the lower
front of the meter face.
4. Plug in the power cable.
Figure 4: Photograph of Control Unit - Side and Front
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IV Operation/Calibration
A. Operation
Operation of the thermocouple gauge and control is generally very simple and trouble free.
Occasional mechanical zero adjustment and calibration may be required. See “Maintenance” for
additional information.
B. Calibration
Introduction Initial matching of a tube to a control unit and long term changes to the sensing
elements require the performance of the calibration steps described below. New units ordered with
a sensor tube from Duniway Stockroom are calibrated at the factory.
1. With the line power disconnected, adjust the mechanical meter zero until the needle
indicates “OFF” (Full scale).
2. Connect the thermocouple tube, matched to the control unit, to a vacuum system capable of
reaching and maintaining a pressure of less than 1.0 micron (1 millitorr).
3. Pump down the system until the pressure is below 1.0 micron (1 millitorr).
4. Connect the thermocouple cable of the Duniway Stockroom Corp. control unit to the
thermocouple gauge tube.
5. Plug the line cord into a 115 VAC 50/60 Hertz outlet.
6. Locate the calibration control adjustment screw on the back of the control unit and adjust it
until the meter reads zero millitorr.
7. Allow the system to stabilize for approximately 15 minutes, and readjust the zero if
necessary.
NOTE
If more accurate calibration is required, the gauge can be calibrated against
an absolute pressure gauge, such as a McLeod gauge.
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V Accessing Analog Voltage/Pressure Signal
The TCG-531 and TCG-06M are equipped with terminals which provide access to an analog
voltage output signal related to the indicated pressure. Figure 5, below, shows a rear view of the
meter with the analog voltage output terminals indicated by + and -.
For the TCG-531with BOX and the TCG-06M with BOX, access to the analog voltage output
signal can be accomplished by following the dis-assembly instruction sin Section VI - Maintenance
Figure 5: Rear View of Meter, Showing Output Terminals
The relationship between pressure and analog voltage is shown below in Table 1.
TCG-531 TCG-06M
Pre s s ure M e te r Output Pre s s ure M e te r Output
Scale Re ading Voltage Scale Re ading Voltage
millitorr millivolts millitorr millivolts
OFF 0.0 DOT 0.00
2000 1.8 ATM 0.22
500 3.2 1000 0.56
200 5.2 500 1.02
100 7.1 200 2.25
30 8.4 100 3.80
0 11.0 50 5.55
10 8.56
0 10.00
Table 1: Analog Output Voltage vs. Pressure
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VI Maintenance
Aging and/or contamination can change the calibration of the thermocouple gauge, thus re-
calibration may be necessary from time to time.
The sensitivity of thermocouple gauges varies significantly from one gas species to another
and with pressure for a specific gas. For example, the sensitivity of a thermocouple gauge for he-
lium is higher than for air at intermediate pressures, but lower at high pressures.
If disassembly of the gauge control should become necessary, the following procedure should
be followed.
1. Unplug the line power cord.
2. Unplug the thermocouple gauge tube.
3. Remove the two nuts from the back of the unit.
4. Remove the white plastic cover from the unit.
5. Remove the printed circuit board from the meter
(See the photo below and schematic diagram)
Figure 6: Dis-assembled Unit
Warranty:
These thermocouple control/display products are warranted against defects in material and
workmanship for 90 days from date of delivery.
If you need to return a unit for repair, please call one of the numbers at the bottom of this page
to request a Returned Material Authorization (RMA) number.
rev531059sr
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Duniway Hastings Hastings Veeco CVC Varian Part # GP
Part # Part # Base Color Part # Part # Part #
DST-01M DV-3M BLACK DV-1M - - -
DST-04D DV-4D PURPLE DV-4M - - -
DST-06M DV-6M YELLOW - - - 270-006
DST-023 DV-23 ORANGE - - - -
DST-004 - - - GTC-004 - -
DST-036 - - - GTC-036 - -
DST-531 - - - - 0531-F0472-301 -
DST-531S - - - - 0531-F0472-303 -
DST-1518 (MDC TGT-1518 & HML TCT-1518)
Table 2: Cross Reference/Equivalent List
Figure 7: Panel Mounting Holes for TCG Meter
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Figure 8: Thermocouple Control Unit Schematic Diagram
Unit C1 R1 R2 D1 D2 RED WHT BLK A B
Type
-531 2 33 150 6.8 6.8 #7 #2 #3 #5 #1
micro ohm ohm volt volt
f. 2W 2W 5W 5W
200v
-06M 2 33 350 7.5 7.5 #5 #7 #3 NA NA
micro ohm ohm volt volt
f. 2W 2W 5W 5W
200v
Table 3: Component Values for Figure 7, Schematic
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