Cincinnati Sub-Zero ZP Series Installation, Operation & Maintenance Manual Download Page 38

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GENERAL DESCRIPTION

SEQUENCE OF OPERATION

CASCADE UNIT - SYSTEM 1 (R-404A) DESCRIPTION

(Refer to Refrigeration Diagram in Drawing Section)

NOTE:

Pressure settings are approximate.

The compressor (item 101) will pump compressed R-404A vapor through the discharge line where the

high-pressure gauge (item 183) displays the high-pressure of the refrigerant.

System 1 – Description (2 HP – 6 HP Systems)

The high-pressure switch (item 195) senses the discharge refrigerant pressure and will open a contact in

the event that discharge pressure exceeds 400 PSIG (27.6 bar(g)). This contact opening will serve to shut

down the unit and will automatically reset when the pressure drops to 300 PSIG (20.7 bar(g)).

System 1 – Description (10 HP – 20 HP Systems)

The high-pressure switch (item 195) senses the discharge refrigerant pressure and will open a contact in

the event that discharge pressure exceeds 350 PSIG (24.1 bar(g)). This contact opening will serve to shut

down the unit and must be manually reset.

The discharge refrigerant vapor passes a tee which diverts some of the refrigerant to the bypass loop

(see bypass description) and enters the condenser.

Air Cooled Condensing Option (2 HP – 6 HP systems)

The condenser (item 105) cools the high pressure R-404A vapor and condenses it into a high pressure

liquid. The condenser fan motor (item 196) will be energized anytime the compressor (item 101) is

running.

The high pressure liquid leaves the condenser and flows through a filter drier (item 108) and sight glass

(item 109) then passes a tee which diverts some of the liquid refrigerant to the bypass loop (see bypass

description)

Water Cooled Condensing Option (3.5 HP – 20 HP systems)

The condenser (item 105) cools the high pressure R-404A vapor and condenses it into a high pressure

liquid. The pressure actuated water valve (item 107) will maintain the discharge pressure at

approximately 210 PSIG (14.5 bar(g)).

The high pressure liquid leaves the condenser and flows through a receiver (item 122), filter drier (item

108) and sight glass (item 109) then passes a tell which diverts some of the liquid refrigerant to the

bypass loop (see bypass description).

Summary of Contents for ZP Series

Page 1: ...58911 rev B 1 2021 Installation Operation Maintenance Manual ZP Series ...

Page 2: ...Note CSZ is continuously upgrading the components used in its equipment Consequently the physical appearance of certain components may vary from that shown ...

Page 3: ...is area was developed in an attempt to better define items on CSZ chambers that are SPECIFIC to a customer Please refer to this section for warranty controller PID parameters and calibration verification test data sheets Cincinnati Sub Zero Temperature Chamber MODEL NO SERIALNO DO NOT USE THIS MANUAL IN AN ATTEMPT TO OPERATE OR MAINTAIN ANY OTHER MODEL OR SERIAL NUMBER PLEASE READ THIS ENTIRE MANU...

Page 4: ...THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 5: ...ENERAL DANGER CONSULT MANUAL WEAR EYE PROTECTION ELECTRICAL SHOCK TURN OFF AND LOCK OUT SYSTEM POWER BEFORE SERVICING EXPLOSION ARC FLASH HAZARD WEAR PROTECTIVE GLOVES LOW TEMPERATURE FORKLIFT RIGHT DESIGNATES CHAMBER LIFTING POINTS HOT SURFACE FORKLIFT LEFT DESIGNATES CHAMBER LIFTING POINTS KEEP HANDS CLEAR PINCH HAZARD DO NOT OPERATE WITH PACEMAKER CONSULT OPERATORS MANUAL BEFORE OPERATING PROTE...

Page 6: ...CHAMBER LABELS AND MEANINGS ii THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 7: ...GURES AND TABLES Figure 1 1 Communication Plates 6 CHAPTER 2 GENERAL DESCRIPTION SYSTEM DESCRIPTION 7 CONTROLLER 7 CHAMBER 7 REFRIGERATION HEATING COMPONENTS 8 HUMIDITY 11 PEN RECORDERS OPTIONAL 17 REDUNDANT HIGH LOW LIMIT CONTROL OPTIONAL 17 IEEE 488 SYSTEM OPTIONAL 17 LN2 CO2 BOOST COOLING SYSTEM OPTIONAL 17 PROGRAMMABLE DOOR LOCK OPTIONAL 18 GN2 PURGE SYSTEM OPTIONAL 18 DRY AIR PURGE OPTIONAL 1...

Page 8: ...T 570S CONTROLLER 41 PUMPDOWN 42 SINGLE SET POINT OPERATION 43 MANUAL EVENT CONTROL 44 PROFILE OPERATION 44 START UP INSTRUCTION SUMMARY 45 SUMMARY FOR STEP BY STEP SET POINT OPERATION 45 WATLOW F4 CONTROLLER OUTPUTS 46 DRY AIR PURGE 48 IEEE 488 F4 CONTROLLER 49 HIGH LOW LIMIT CONTROL 50 VAISALA HMT337 HUMIDITY AND TEMPERATURE TRANSMITTER 50 PROGRAMMABLE DOOR LOCK IF EQUIPPED 51 AIR SUPPLY DAMPER ...

Page 9: ...ERS 58 REFRIGERATION SYSTEM PRESSURES 58 WATER COOLED UNITS OPTIONAL 58 SCROLL COMPRESSORS ONLY 61 HUMIDITY SYSTEM OPTIONAL 61 FIGURES AND TABLES Figure 4 1 Transporting A Chamber 56 Table 4 1 Cascade Water Usage 59 Table 4 2 Tundra Water Usage 60 Table 4 3 Single Stage Water Usage 60 Table 4 2 Water Usage Si Units 61 ...

Page 10: ...Components 78 Table 5 1 Test Equipment Required 63 Table 5 2 Inspection Schedule 64 Table 5 3 Inspection Procedures 68 Table 5 4 General Troubleshooting Procedures 69 Table 5 4 General Troubleshooting Procedures Continued 70 Table 5 5 Humidity System Troubleshooting Procedures 70 Table 5 6 Dry Air Purge Troubleshooting Procedures 71 Table 5 6 Dry Air Purge Troubleshooting Procedures Continued 72 T...

Page 11: ...IGERATION BILL OF MATERIALS IF REQUIRED HUMIDITY BILL OF MATERIALS IF REQUIRED DRY AIR PURGE BILL OF MATERIALS IF REQUIRED LN2 BOOST BILL OF MATERIALS IF REQUIRED GN2 PURGE BILL OF MATERIALS IF REQUIRED CHAPTER 9 DRAWINGS ELECTRICAL SCHEMATIC SYMBOLS REFRIGERATION SCHEMATIC SYMBOLS CABINETRY LAYOUT DRAWING IF REQUIRED ELECTRICAL SCHEMATIC IF REQUIRED REFRIGERATION FLOW DIAGRAM IF REQUIRED HUMIDITY...

Page 12: ...TABLE OF CONTENTS viii THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 13: ...lated to any specific procedures and therefore do not appear elsewhere in this manual These are recommended precautions that must be understood and applied during many phases of operation and maintenance of the equipment IMPORTANT All OSHA and other applicable local and national codes regulations and guidelines regarding lockout tagout procedures must be followed This includes a lockable disconnec...

Page 14: ...is therefore recommended that removal and installation of the hermetic compressor be performed by experienced personnel only Failure to follow these instructions may result in serious personal injury Gaseous nitrogen CO2 vent connection must be ducted to the outdoors to prevent displacement of oxygen around the unit DO NOT place items in the chamber that could burn or explode at high temperatures ...

Page 15: ... For continued protection against fire hazard qualified service personnel must replace fuses and circuit breakers with the same type and rating only The use of other fuses and circuit breakers is prohibited Disconnect chamber from electrical supply before changing fuses or resetting circuit breakers Prior to servicing the equipment the supply power should be disconnected by moving the main disconn...

Page 16: ...nd rayon or polyester apparel 3 Avoid static producing activities such as wiping feet and removing or putting on smocks while in the work area 4 Use ESD protective equipment such as grounded work benches grounded tools and test equipment conductive flooring air ionizers personnel ground straps with 1 megohm minimum resistance and protective apparel whenever possible 5 Store and transport ESD sensi...

Page 17: ...ety device removes power only from the chamber heaters when an over temperature condition exists in the chamber They DO NOT remove power from the product being tested PRODUCT HIGH LIMIT IF EQUIPPED The product high temperature limit can be used to protect the product being tested and the chamber from overheating The thermocouple hanging from the back of the chamber can be attached to the customer ...

Page 18: ...nt Consequently the physical appearance of certain components may vary from that shown Connection for event relay s Do not connect 115 volt power to these connections Customer events should only be connected to a 24VDC AC source See EZT 570S User Manual for exact specifications NOTE COMMUNICATION CONNECTIONS CONNECTION FOR EVENT RELAY ...

Page 19: ...ller a High Low limit and communications electronics Detailed operating instructions for the controller are found in the controller user s manuals on the digital media that accompanied the chamber Other optional controllers available include the Watlow F4 See Operating Instructions in Chapter 4 for more information regarding chamber controllers CHAMBER A Chamber Interior The chamber interior consi...

Page 20: ...tage system uses refrigerant R 404A The cascade system uses refrigerant R 404A in System 1 and R 508B R 23 in System 2 The Tundra System uses refrigerant R 410A The refrigeration system can either be air cooled or water cooled depending on the model of chamber Standard ZP Series chambers above 3 5 HP are air cooled Chambers with compressors which are 10 HP having nominally approx 12kW of capacity ...

Page 21: ... appearance of certain components may vary from that shown Lower Refrigeration Components Upper Refrigeration Components Water Inlet Location Steam Generator System Water Cooled Condenser Connection location Knockouts If Applicable Chamber Vent Dry Air Purge Optional Electrical Connection 1 EMT Conduit 35mm Metric Conduit Trade Size LN2 Boost Valves Optional ...

Page 22: ...ew Figure 2 3 ZPRC Chamber Top View Note CSZ is continuously upgrading the components used in its equipment Consequently the physical appearance of certain components may vary from that shown Blower Motor Adjustable Supply Air Damper Supply Air Return Air ...

Page 23: ... color A reference mark is provided on the filter to indicate when it should be changed Spare cartridges are available through the CSZ Service Department Refer to the Humidity Maintenance Section for instructions on how to change the filter C Water Fill Solenoid 1 This is a normally closed solenoid valve and is energized opened only when the float switch in the steam generator drops below the rese...

Page 24: ...GENERAL DESCRIPTION 12 Figure 2 4 Achievable Humidity Points ...

Page 25: ...is continuously upgrading the components used in its equipment Consequently the physical appearance of certain components may vary from that shown Drain Valve Pump inside base compartment Float Switch Recirculating Water System Optional with Humidity Demineralizer Filter Optional with Humidity ...

Page 26: ...ts equipment Consequently the physical appearance of certain components may vary from that shown Connection Location for Water Cooled Units Compressor System 1 Compressor System 2 Pressure Gauges Electrical Connection 1 EMT Conduit 35mm Metric Conduit Trade Size Water Inlet Location Float Switch Enclosure Steam Generator Assembly With Humidity Option ...

Page 27: ... a dehumidification coil Dehumidification of the chamber air is accomplished by condensing water from the chamber air onto the refrigerated surface D Wet Coil Pan The wet coil pan is used to collect moisture from the wet coil and dispense it through the chamber drain E Recirculating Water The Recirculating Water Reservoir Option is a fully integrated accessory that requires only minor installation...

Page 28: ...idity Sensor behind cover Air Temperature Sensor behind cover Plenum Cover Wet Coil Pan Note CSZ is continuously upgrading the components used in its equipment Consequently the physical appearance of certain components may vary from that shown Fans Chamber Light Heaters Evaporator Coil Dehumidification Coil Plenum Area ...

Page 29: ...main refrigeration system the chamber is equipped with an optional connection port for supplying boost cooling from an external source of cryogenic liquefied gas either carbon dioxide or liquid nitrogen The boost cooling gas is vented directly into the chamber by a controller under the conditions of sustained cooling demand Refer to the System Diagrams Chapter to see the schematic diagram for the ...

Page 30: ...e system reduces condensation within the test chamber and is used when low humidity is required The purge system consists of a control solenoid and flow meter GN2 has a dewpoint approaching 300 F 185 C that when introduced into the chamber workspace creates a slightly positive pressure within the chamber to minimize the migration of moist ambient air into the chamber The system requires approximat...

Page 31: ...manual found in the Accessories folder on the electronic media CHAMBER PERFORMANCE The performance of your chamber is significantly affected by the characteristics of your test sample Such characteristics include size material shape weight and power dissipation if energized The test sample should be placed in the chamber in a manner that allows proper ventilation Air flow is taken in from the bott...

Page 32: ...f rail is not a mechanical stop to prevent the shelf from being pulled all the way out WARNING Shelves pulled more than halfway out can become unstable WARNING Test samples should be placed in the chamber in a manner that allows proper ventilation WARNING Shelf Rail C Channel Shelf Rail Plenum Wall with Holes for Shelf Rail ...

Page 33: ...143 5 x 180 x 253 60 5 x 81 x 101 5 154 x 205 x 258 67 x 94 x 101 5 170 x 238 x 258 60 x 105 x 101 5 154 x 266 x 258 Workspace Dimensions cm W x D x H 24 x 24 x 24 61 x 61 x 61 30 x 30 x 30 76 x 76 x 76 38 x 38 x 38 97 x 97 x 97 44 x 38 x 46 112 x 97 x 117 48 x 48 x 48 122 x 122 x 122 48 x 60 x 48 122 x 152 x 122 48 x 72 x 48 122 x 183 x 122 Temperature Ranges Single Stage 34 C to 190 C 30 F to 37...

Page 34: ...9 ZP 32 6 6 SC WC 3000 2400 1500 65 29 ZP 32 10 10 SC WC 4500 3500 1700 45 ZP 32 15 15 SC WC 5500 4500 2500 53 ZP 44 3 5 3 5 SC AC 1700 1300 700 48 29 ZP 44 6 6 SC WC 2700 2100 1200 65 29 ZP 44 10 10 SC WC 4500 3500 2000 45 ZP 44 15 15 SC WC 5500 4500 3000 53 ZP 64 3 5 3 5 SC AC 1500 1100 500 48 29 ZP 64 6 6 SC WC 2500 2100 1000 65 29 ZP 64 10 10 SC WC 4500 3500 2000 45 ZP 64 15 15 SC WC 5500 4500...

Page 35: ...7 9 10 16 29 30 4 2 15 40 12 18 ZP 80 15 15 SC WC 5 7 8 11 19 20 6 2 12 31 10 15 ZP 96 3 5 3 5 SC AC 20 35 40 60 80 80 1 6 35 90 30 40 ZP 96 6 6 SC WC 13 21 24 35 50 50 2 5 35 90 30 40 ZP 96 10 10 SC WC 8 10 11 17 35 35 3 6 20 45 14 20 ZP 96 15 15 SC WC 5 5 7 5 8 5 11 5 29 5 30 5 4 1 12 5 31 5 10 5 15 5 High Performance Models Cooling Performance with Empty Chamber in Minutes from Cooling Rate Hea...

Page 36: ...7 23 ZPS 80 6 SCT WC 3100 1800 1300 46 21 ZPS 80 10 SCT WC 6000 3500 2300 29 ZPS 80 15 SCT WC 8000 5000 3000 35 ZP 96 3 5 SCT AC 2600 1300 800 37 23 ZP 96 6 SCT WC 3100 1800 1300 46 21 ZP 96 10 SCT WC 6000 3500 2300 29 ZP 96 15 SCT WC 8000 5000 3000 35 Performance is based on 230V 60 Hz operation and a 24 C ambient For 50 Hz operation stated performance and air flow may be approximately 17 less Sp...

Page 37: ... SCT WC 4 9 12 22 5 6 10 35 8 ZP 32 10 SCT WC 3 6 8 18 7 0 7 20 6 ZP 32 15 SCT WC 2 4 6 11 11 3 6 16 5 ZP 44 3 5 SCT AC 11 25 32 52 2 4 20 60 15 ZP 44 6 SCT WC 5 5 15 20 30 4 1 20 60 15 ZP 44 10 SCT WC 4 8 12 22 5 6 8 25 7 ZP 44 15 SCT WC 3 7 10 5 14 9 0 6 15 5 ZP 64 3 5 SCT AC 14 30 38 65 2 0 25 75 20 ZP 64 6 SCT WC 7 17 22 38 3 2 25 75 20 ZP 64 10 SCT WC 5 11 18 24 5 2 10 30 8 ZP 64 15 SCT WC 4 ...

Page 38: ...ust be manually reset The discharge refrigerant vapor passes a tee which diverts some of the refrigerant to the bypass loop see bypass description and enters the condenser Air Cooled Condensing Option 2 HP 6 HP systems The condenser item 105 cools the high pressure R 404A vapor and condenses it into a high pressure liquid The condenser fan motor item 196 will be energized anytime the compressor it...

Page 39: ...tem 119 and into the minimum thermostatic expansion valve item 120 where it also changes to a low pressure two phase refrigerant The two phase refrigerant is cold due to the flashing of refrigerant The two phase refrigerant enters the cascade condenser item 113 where the heat from System 2 boils the rest of the R 404A refrigerant into a vapor The cascade condenser serves as the evaporator for Syst...

Page 40: ...mperature due to the suction bypass solenoid item H129 where it allows the suction vapor to bypass the evaporator pressure regulator valve item H126 this allows the chamber to achieve low temperature dew points limited as previously discussed in this manual CASCADE UNIT SYSTEM 2 R 508B DESCRIPTION System 2 Description 2 HP 6 HP Systems The compressor item 201 will pump compressed R 508B R23 vapor ...

Page 41: ...ator The discharge refrigerant vapor passes a tee which diverts some of the refrigerant to the bypass loop see Bypass Loop description The residual discharge refrigerant vapor passes through the discharge desuperheater item 244 The discharge refrigerant vapor passes a tee In the event that discharge pressure exceeds a range of 270 PSIG 18 6 bar g to 300 PSIG 20 7 bar g see unit specific refrigerat...

Page 42: ...phase refrigerant In parallel with maximum valve liquid refrigerant flows through a minimum liquid line solenoid item 219 and into the minimum thermostatic expansion valve item 220 where it also changes to low pressure two phase refrigerant The two phase refrigerant is cold due to the flashing refrigerant The two phase refrigerant enters the distributor item 212 where the refrigerant is evenly dis...

Page 43: ...uid line solenoid valve item 210 The hot gas bypass regulator valve will allow hot discharge refrigerant vapor to flow directly to the suction line This is done as a means to control cooling capacity or to unload the system The liquid injection thermostatic expansion valve item 261 will sense the temperature of the suction gas and automatically open to feed liquid refrigerant into the suction line...

Page 44: ...sor off if a high discharge pressure event is reached Contact Cincinnati Sub Zero s service department if this occurs The high pressure switch will automatically reset When there is call for cooling 202 SOL 203 SOL is energized When the chamber output drops below 90 cooling the controller will deenergize the maximum liquid line solenoid 202 SOL When the chamber is near the set point the controller...

Page 45: ...igerant pressure and will open a contact in the event that discharge pressure exceeds 400 PSIG 27 6 bar g This contact opening will serve to shut down the unit and will automatically reset when the pressure drops to 300 PSIG 20 7 bar g The discharge refrigerant vapor passes a tee which diverts some of the refrigerant to the bypass loop see bypass description and enters the condenser A relief valve...

Page 46: ... where it also changes to a low pressure two phase refrigerant The two phase refrigerant is cold due to the flashing of refrigerant The two phase refrigerant enters the distributor item 112 where the refrigerant is evenly distributed to evaporator circuits The evaporator item 113 serves to boil the rest of the R 410A into a vapor This boiling action cools the chamber If dehumidification is called ...

Page 47: ...se opposite of the liquid line solenoid valve item 119 6 HP 15 HP The valve will allow hot discharge refrigerant vapor to flow directly to the suction line This is done as a means to control cooling capacity or to unload the system The liquid injection thermostatic expansion valve will sense the temperature of the suction gas and will automatically open to feed liquid refrigerant into the suction ...

Page 48: ...The high pressure switch 101 PS will turn the compressor off if a high discharge pressure event is reached Contact Cincinnati Sub Zero s service department if this occurs The high pressure switch has to be manually reset When there is call for cooling 101 SOL and 107 SOL are energized Once the chamber has reached a preset factory chamber temperature the maximum liquid line solenoid 101 SOL will de...

Page 49: ...ssure of the refrigerant The high pressure switch item 195 senses the discharge refrigerant pressure and will open a contact in the event that discharge pressure exceeds 350 PSIG 24 1 bar g This contact opening will serve to shut down the unit and will automatically reset when the pressure drops to 250 PSIG 17 2 bar g The discharge refrigerant vapor passes a tee which diverts some of the refrigera...

Page 50: ...wing description applies When dehumidification is called for some of the liquid refrigerant is diverted to the humidity loop The refrigerant passes through a solenoid valve item H131 and a Low RH thermostatic expansion valve item H130 Two phase refrigerant exits the thermostatic expansion valve and enters the evaporator item H125 The evaporator temperature is cold enough to freeze water out of the...

Page 51: ...ng on and off opposite of 101 SOL If the chamber does not call for cooling for ninety seconds the refrigeration system will turn off When there is a call for heating 101 SOL will de energize and the heaters will energize Mode Humidity In humidity mode the system starts in the same manner as above with the following differences When dehumidification is called for the wet coil solenoid valve H111 SO...

Page 52: ...GENERAL DESCRIPTION 40 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 53: ...ous readings To correct this condition it is recommended that the tip be dried out by turning the humidity system off and raising the temperature to 250 F 121 1 C high temp for 10 minutes The sensor accuracy will be restored by evaporating the water out of the porous cover over the sensing element NOTE Any changes to the CSZ configurations programmed in the temperature controller or safety limit w...

Page 54: ...mode of operation the Pumpdown button will be provided on the Alarm Monitor screen This provides a manual way to reset pumpdown mode Pumpdown will be automatically disabled if main power is off for more than 30 minutes This is due to the fact that without main power the crankcase heater will be off and cannot warm the compressor Depending on the temperature of the compressor this could allow refri...

Page 55: ... from the main View menu 2 Input the setpoint temperature Press the numeric display for the setpoint SP for temperature The setpoint adjust keypad will be shown on the screen Enter the desired setpoint value and press the Enter button 3 Turn the Chamber event on to start the chamber see manual event control ...

Page 56: ...rofiles so that they can be turned on and off at set time intervals To turn the chamber and optional events on off 1 Select Manual Operation from the main View menu 2 To turn the events on or off touch the slide switch PROFILE OPERATION To create and run programs on the EZT570S see Chapter 4 of the EZT 570S User Manual Sample profiles have been provided by CSZ pre loaded on the EZT 570S controller...

Page 57: ...e on to run the chamber a ON The PGM OFF ON switch should be set in this position when running single set points or when operating in a program mode without using events to turn on off option features b PGM The PGM OFF ON switch must be set in this position when running a program profile where events are used to turn features on and off 3 Use the arrow keys to navigate through the lower display an...

Page 58: ...ng is called for Output 1B Cooling output Cycles refrigeration valves when cooling is called for The compressors will run as long as cooling is called for before the time out period has expired If cooling is not called for within the preset time out period the compressors shut off They will turn back on when cooling is called for Output 2A Humidify output Cycles boiler heater or atomizing nozzle o...

Page 59: ...ge system Turns on GN2 and or air dryer components Event 5 Turns on Frozen Coil for low RH mode Event 6 8 User defined event Can be used to turn on test equipment initiate a test cycle etc Note CSZ is continuously upgrading the components used in its equipment Consequently the physical appearance of certain components may vary from that shown Audible Alarm Chamber Hi Limit Indicator Event 2 Event ...

Page 60: ...e is 125 F 52 C Figure 3 3 Dry Air Purge System Components Location 5SCFM Unit Note CSZ is continuously upgrading the components used in its equipment Consequently the physical appearance of certain components may vary from that shown NOTE During humidity operation the dry air purge system must be turned off NOTE Switch must be on manual mode for single set point operation NOTE CLEAN AND OIL FREE ...

Page 61: ...a strings what commands are available and how to create subroutines to generate checksums The commands and format used to communicate over the GPIB bus will be identical to those explained in the manual The only difference will be that a line feed LF terminator will have to be appended to the data string when it is sent so the GPIB converter can sense the end of the message The data will be sent t...

Page 62: ...e output relay can be re energized and the audible alarm silenced by the front panel Reset switch being depressed one time only when the limit condition no longer exists The Reset should be depressed a second time to reset the alarm The limit has three alarms that must be set up the same to energize all alarm contacts at the same conditions Alarm 1 shuts down the chamber Alarm 2 sounds the audible...

Page 63: ...he Door Lock event can also be turned on or off within specific profile steps like any other chamber event START UP INSTRUCTION SUMMARY REMOTE SENSOR ZPRC UNITS Enabling the RC Blower Event energizes the remote conditioning blower delivering conditioned air to the remote hood Temperature and optional humidity control is automatically transitioned from local in the chamber s plenum to remote at the...

Page 64: ...osen the wing nut and rotate the handle located on the top left corner of the chamber Once the handle is adjusted tighten the wing nut so your settings will hold Figure 3 5 Air Supply Damper Note CSZ is continuously upgrading the components used in its equipment Consequently the physical appearance of certain components may vary from that shown ...

Page 65: ... port 2 Pull the end of the glove over the port all the way to the port collar 3 Secure the glove with a 6 15 25 cm worm clamp Over tightening can cause clamp to cut rubber glove 4 Repeat all steps for right glove Note CSZ is continuously upgrading the components used in its equipment Consequently the physical appearance of certain components may vary from that shown ...

Page 66: ...OPERATING INSTRUCTIONS 54 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 67: ...it lifting points are designated with forklift labels f Forks should extend passed the other side of the chamber to prevent damage g When transporting the chamber it should be 2 3 off the floor h The rear of the chamber is heavier than the front due to the location of the refrigeration compressors 5 To Level Unit a Leveling feet have been provided at the front of the unit A 1 2 13 mm open end wren...

Page 68: ...INSTALLATION 56 Figure 4 1 Transporting a Chamber Drawing above is for illustration purposes only Not drawn to scale NOTE ...

Page 69: ...r CE marked equipment a suitably rated IEC60309 plug must be fitted to the cord 3 Hard Wired ZP H Units Use a liquid tight metallic or nonmetallic flexible conduit Power wires should be sized appropriately for the load rating of the chamber and rated at a minimum of 75 C The 1 4 EMT conduit 35 mm metric conduit trade size is equipped on the chamber as a conduit for power lines 4 Grounding Protecti...

Page 70: ... Check the system pressures using the refrigeration system pressure gauges If the R 508B System 2 static pressure is more than 30 PSI 2 bar g lower than that specified on the data plate contact the CSZ Service Department DO NOT START If the R 404A System 1 or Tundra pressure is less than 100 PSI 6 9 bar g contact the CSZ Service Department DO NOT START WATER COOLED UNITS OPTIONAL If water cooled p...

Page 71: ...OW RATE WATER TEMPERATURE WATER CONNECTION NPT 95 00 35 00 WATER HEATLOAD BTU hr 36 937 86 0 75 F C F C GPM LPH GPM LPH GPM LPH PSID bar 85 00 29 44 26 06 5 936 62 38 93 8 866 96 71 99 16 398 53 40 00 2 76 80 00 26 67 17 37 3 957 70 25 95 5 911 26 47 99 10 932 33 37 50 2 59 75 00 23 89 13 03 2 968 29 19 46 4 433 47 36 00 8 199 50 35 00 2 41 70 00 21 11 10 42 2 374 58 15 57 3 546 77 28 80 6 559 17 ...

Page 72: ...654 08 22 50 1 55 45 00 7 22 2 62 597 53 4 29 977 28 6 54 1 488 67 20 00 1 38 154 385 64 1 00 REQUIRED FLUID PRESSUREDIFFERENTIAL 101 350 72 1 00 WATER FLOW RATE INLET OUTLET 6 SCT WC WATER TEMPERATURE 10 SCT WC WATER FLOW RATE 15 SCT WC WATER FLOW RATE 95 00 35 00 WATER HEATLOAD BTU hr WATER CONNECTION NPT 61 968 02 0 75 F C F C GPM LPH PSID bar 85 00 29 44 6 83 1 554 84 40 00 2 76 80 00 26 67 4 ...

Page 73: ...pressure and flow rate the low boiler water alarm could be tripped during this process If so reset to continue filling If alarm continues to go off call Cincinnati Sub Zero 3 5 HP and larger scroll compressors are equipped with crank case heaters After connecting the power the unit must sit 4 hours before start up to properly heat up CAUTION Do not connect the steam generator or cooling tower wate...

Page 74: ... Connection Upper Refrigeration LN2 Vent Must be vented outdoors R 508B Compressor System 2 R 404A Compressor System 1 Pressure Gauges Float Switch Enclosure Steam Generator Assembly Pump Water Cooled Condenser Connections If Applicable Float Switch Note CSZ is continuously upgrading the components used in its equipment Consequently the physical appearance of certain components may vary from that ...

Page 75: ...ble Reference table used for calibrating temperature inputs Digital voltmeter Measures voltage Ammeter Measures current Two sets of manifold refrigeration gauges with charging hoses Monitoring refrigeration system pressures and connecting purge charge equipment to refrigeration system One tank of HFC 404A If Applicable Charging refrigeration system One tank of R 410A If Applicable Charging refrige...

Page 76: ... Exterior Cleaning X 2 Fluid Levels If Applicable X 3 Gas Monitor Optional Equipment Water Filter X 4 R 404A Charge If Applicable X 5 R 410A Charge If Applicable X 6 R 508B Stand By Pressure If Applicable X 7 R 508B Stand By Pressure If Applicable X 8 R 23 Stand By Pressure If Applicable X 9 Compressor Oil Level X 10 Humidity Demineralizer Filter Optional Equipment X 11 Air Cooled Condenser If App...

Page 77: ...efrigerant Call a qualified service technician to add refrigerant 6 System 2 R 508B Stand By Pressure If Applicable Check the pressure in the controller prior to starting the conditioning system A discharge pressure reading lower than the standby pressure on the data plate could indicate a leak in the system DO NOT START To check the stand by pressure power off the unit Let the unit stand for 24 h...

Page 78: ...Check to see that power and ground connections remain secure 12 Operating Current Check the operating current of the compressors heaters circulator and other components with an Ammeter Maximum operating values are shown on the electrical schematic 13 Check GFCI Receptacle s If Applicable Check per instructions on the receptacle Location of the receptacle s is indicated on the electrical schematic ...

Page 79: ...ondensing surface This interval may need to be shortened if the buildup is of a substantial amount 20 Chamber Controller Calibration Verification Calibrate Verify the chamber controller settings if all instruments in your facility are periodically calibrated to one device metrology or if a measurement system component fails The calibration verification procedure is located in the Controller Manual...

Page 80: ...erminal boards and parts of equipment by checking insulation Inspect wires for breakage and for improper dress Table 5 3 Inspection Procedures TROUBLESHOOTING PROCEDURES The corrective action procedures in this chapter should be performed if normal indications are not obtained Before attempting any corrective action or troubleshooting procedures always check cable connections for looseness or dama...

Page 81: ...apacitor s Defective start relay Replace start relay Refrigeration overcharge Recover and recharge High load amps Low voltage Check supply circuit Electrical malfunctions Check for proper wiring and correct compressor capacitor Check for grounds and measure winding resistance Defective start relay Check and replace Low Amps Low refrigerant Check for leaks charge system Insufficient cooling effect ...

Page 82: ...red level Applies only to units with an atomizing humidity system Heater failure Check heater and replace as required Atomizing nozzle clogged Remove and clean Replace demineralizer filter if necessary Air pump not functioning Check air pump Filter Strainer Clogged Remove and clean Water is not connected to unit Connect water Water control solenoid not energized Check coil replace if burned Disper...

Page 83: ... and when released Replace if necessary Improper cycle timer operation Check the power supply If the correct voltage is not present between L1 and both of the L2 terminals check the wiring and protective device supplying power to the dryer Dryers with DC solenoid valves should alternately have DC voltage between L2 and DC1 and between L2 and DC2 Replace the timer if voltage is present at either DC...

Page 84: ...d DC1 and between L2 and DC2 Replace the timer if voltage is present at either DC terminal continuously or not at all Timer Input 120VAC Timer Output 53 VDC Timer Input 240 VAC Timer Output 106 VDC Timers P 06521 F1 and F2 are the standard timers used on the HF200 HF300A and HF300B air driers The timers permit simultaneous switching of the solenoid valves every 30 seconds Check valve balls for pro...

Page 85: ...l material screwdriver or nail on exposed end of solenoid base to feel the magnetic effect indicating proper operation Each coil should be energized for 30 seconds Depress switch lever by hand and listen for clicking contact Switch should click when depressed and when released Replace if necessary Excessive drop in outlet pressure Solenoid coil burned out Remove cover place iron or steel material ...

Page 86: ...ce Department Display indicates and yellow LO LIMIT LED is ON Solenoid coil burned out Repair or replace the thermocouple Display error Sensor is connected improperly Check sensor locations connections and sensing element Repair or replace sensor as required Place jumper wire across thermocouple terminals Indicator is functioning properly if display indicates room temperature Display indicates 000...

Page 87: ...0 16 2 26 3 137 8 164 0 15 19 9 31 2 152 5 180 2 10 23 8 36 4 168 2 197 5 5 28 1 42 2 185 1 215 8 0 32 8 48 2 202 9 235 3 5 37 8 55 1 221 1 256 0 10 43 3 62 1 242 4 277 9 15 49 1 70 1 264 0 301 2 20 55 4 78 2 286 9 325 7 25 62 2 87 5 311 3 351 6 30 69 4 96 8 337 1 378 9 35 77 2 107 5 364 5 407 7 40 85 5 118 0 393 6 438 0 45 94 3 130 2 424 4 469 9 50 113 7 142 0 457 1 503 5 55 115 7 156 0 491 7 538...

Page 88: ... 8 5 10 3 28 9 1 2 1 8 9 4 11 3 26 1 1 4 2 2 10 5 12 5 23 3 1 7 2 5 11 5 13 7 20 6 2 0 2 9 12 7 14 9 17 8 2 3 3 3 13 9 16 3 15 0 2 7 3 8 15 3 17 8 12 2 3 1 4 3 16 7 19 3 9 4 3 5 4 8 18 2 20 9 6 7 3 9 5 4 19 7 22 7 3 9 4 4 6 0 21 4 24 5 1 1 4 9 6 7 23 2 26 5 1 7 5 4 7 4 25 1 28 5 4 4 6 0 8 2 27 1 30 7 7 2 6 6 9 0 29 2 33 1 10 0 7 3 9 9 31 4 35 6 12 8 8 0 10 8 33 8 36 7 15 6 8 7 11 8 36 3 Critical 1...

Page 89: ...nt of the equipment 2 Reduce or contain to a minimum the emission of PFC refrigerant during normal operation maintenance manufacture or installation of systems and ensure that the annual leakage from systems containing PFC refrigerants will not exceed 25 of the system charge in the previous year On July 1 1997 the maximum allowable annual leakage will be reduced to 20 If you have any questions abo...

Page 90: ...idity panel periodically for tightness REMOVING THE ATOMIZING NOZZLE FLUID CAP If Equipped with Atomizer System Option 1 Turn off the unit power 2 Disconnect the recirculating water 3 Open the humidity side pack cover 4 Locate square plate with two compression fittings 5 Remove the plate with the nozzle assembly attached 6 Remove the retainer ring at the end of the nozzle assembly 7 Gently pull th...

Page 91: ...ar It is also recommended to calibrate the sensor if it is not operating within its stated accuracy limits The filter on the end of the humidity sensor must be in place for the sensor to operate properly Operating the sensor without the filter will damage the instrument CAUTION On humidity units a water atomizing nozzle is used to create humidity With clean water the nozzle and filter should be cl...

Page 92: ...ler For optimal use of the atomizer and boiler systems inlet water pressure should not fall below 10 PSI 69 kPa for both boilers and atomizers A Water Pressure Regulator must be used Water specification 0 05 to 2 Mega OHMS in addition to 2mg L of free chlorine CAUTION Maximum water inlet pressure is 10 PSI 69kPa for an atomizer and 25 PSI 172 kPa for a boiler Exceeding this pressure may cause cata...

Page 93: ...terial shape and power dissipation if energized The test sample should be placed in the chamber in a manner that allows for air circulation You should not place the test sample directly on the chamber floor It should be placed on the shelf Multiple test samples should be distributed throughout the chamber to ensure even airflow and minimize temperature gradients If necessary additional shelves sho...

Page 94: ... elevated temperatures This is a temporary condition and is non toxic I m not going to use the chamber for a while Is there anything I should do before storage Perform ALL the steps in the Preventive Maintenance Schedule before placing the chamber into storage This will ensure that the chamber will be ready to operate when taken out of storage If the chamber has a problem and is still under warran...

Page 95: ...rigerants Cincinnati Sub Zero chambers do not use CFC based refrigerants The high stage system uses R 404A which is also known as DuPont Suva HP62 The low stage system uses R 508B which is also known as DuPont Suva 95 Tundra units use R 410A also known as Puron and Suva 9100 My static pressure is lower than the data plate specification Is this an indication of a leak in my refrigeration system Thi...

Page 96: ...MAINTENANCE WITH Q A 84 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 97: ... http www cszindustrial com Contact Service Request aspx 2 To order the replacement part please provide the following information a A purchase order number or credit card number b The complete Cincinnati Sub Zero Part number c The model number and serial number of the chamber for requiring the replacement part d The specific complaint regarding the failed part NOTE CSZ provides a list of parts for...

Page 98: ...SERVICE PARTS WARRANTY 86 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 99: ...SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC SYMBOLS Figure 9 1 Symbols Used on Electrical Scematics ...

Page 100: ...SYSTEM DIAGRAMS ELECTRICAL SCHEMATIC SYMBOLS Figure 9 1 Symbols Used on Electrical Scematics Continued ...

Page 101: ...SERVICE ACCESS VALVE PRESSURE RELIEF VALVE PRESSURE SWITCH HIGH LOW ETC REFRIGERATION SERVICE ACCESS VALVE CAPILLARY TUBE EXPANSION DEVICE SOLENOID VALVE FAN AND MOTOR ASSEMBLY DOWNSTREAMPRESSURE REGULATING VALVE HOT GAS BYPASS RECEIVER VERTICAL LIQUID REFRIGERANT UPSTREAMPRESSURE REGULATING VALVE HIGH PRESSURE DUMP VALVE EVAPORATOR PRESSURE REGULATOR CHECK VALVE OIL SEPARATOR ...

Page 102: ...LATING VALVE HIGH PRESSURE REFRIGERANT ACTUATED HEAT EXCHANGER REFRIGERANT EVAPORATOR COMPRESSOR SERVICE VALVE VIBRATION ELIMINATOR HEAT EXCHANGER REFRIGERANT EVAPORATOR WITH DISTRIBUTOR PIPING CONTINUATION ARROW BALL VALVE TEMPERATURE MONITORING THERMOCOUPLE HEATER STRAINER WATER INLET CRANKCASE HEATER RECEIVER HEATER ...

Page 103: ... used on Refrigeration Diagrams Continued HERMETIC SCROLL COMPRESSOR K4 SERIES HERMETIC RECIPROCATING COMPRESSOR SEMI HERMETIC RECIPROCATING COMPRESSOR SEMI HERMETIC RECIPROCATING COMPRESSOR 2 3 CYLINDERS 6 CYLINDERS SEMI HERMETIC RECIPROCATING COMPRESSOR 4 CYLINDERS ...

Page 104: ...SINGLE STAGE TUNDRA HEAT EXCHANGER AIR COOLED CONDENSER WITH SEPARATE DESUPERHEATER CIRCUIT FAN AND MOTOR ASSEMBLY CASCADE SYSTEMS BRAZED PLATE HEAT EXCHANGER CASCADE CONDENSER WITH INSULATION KIT BRAZED PLATE HEAT EXCHANGER WATER COOLED CONDENSER DESUPERHEATER ETC COAXIAL HEAT EXCHANGER WATER COOLED CONDENSER U TUBE HEAT EXCHANGER TUBE IN TUBE WATER COOLED DESUPERHEATER ...

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Cincinnati Sub-Zero ZP Series, Installation, Operation & Maintenance Manual

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