TestEquity 1016S Operation And Service Manual Download

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Electrical Subpanel Component Location

Main

Disconnect

Switch

DSW

TB1

TB2

Control

Transformer

TR1

F1 F2

F7 F8

SSR2

SSR1

CR1

CR3

FNQ-R-4 FNQ-R-20 LP-CC-20

FNM-3

F4 F5 F6

PCR1

SSR4

TM1

SSR3

TB2 Terminals

H1 H2 H3 G G G

• • • • • •

TB1 Terminals

N N 1 2 3 4 5 7 8 9 10 11 12 13 14 15 A1 A2

• • • • • • • • • • • • • • • • • •

Summary of Contents for 1016S

Page 1: ...S 1027S Temperature Chamber 1016S all serial numbers 1027S serial number 70319 and above Operation and Service Manual TestEquity LLC 6100 Condor Drive Moorpark CA 93021 Support 877 512 3457 Toll Free 805 480 0638 Corporate 800 732 3457 805 498 9933 http www testequity com ...

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Page 3: ...___________________________ 3 2 HEAT Light __________________________________________________________________________ 3 2 COOL Light __________________________________________________________________________ 3 2 Loading the Chamber ____________________________________________________________3 3 Port Plugs ____________________________________________________________________________ 3 3 Performance ...

Page 4: ..._______________________________________________ 8 5 Theory of Operation______________________________________________________________8 6 Troubleshooting _________________________________________________________________8 8 Refrigeration System Charging Instructions_________________________________________8 10 R 404A Charge _______________________________________________________________________ 8 10...

Page 5: ...ve 30 C 85 F or below 16 C 60 F ambient room temperature is NOT recommended CAUTION The Input Voltage label on the back of the chamber indicates the input voltage configuration as shipped from the factory If the input voltage configuration is changed this label must be replaced to reflect the new configuration Replacement labels are available from TestEquity at no charge CAUTION This chamber must ...

Page 6: ...tion Do not attempt to modify the setup values unless you thoroughly understand what you are doing The correct values are documented in the EZ Zone Limit Controller Setup Parameters section of this manual CAUTION Always verify that the Limit Controller s high and low limits are set to temperatures that are appropriate for your test sample CAUTION If your test sample is energized it may be capable ...

Page 7: ...tenance section a Inspect the electrical compartment b Inspect the refrigeration machinery compartment c Verify the chamber performance Installation Location The chamber will produce a significant amount of heat during normal operation Locate the chamber in a room with adequate ventilation to prevent excessive heat build up Allow enough space around the chamber to permit serviceability and the rem...

Page 8: ...figuration Overview This chamber can be easily configured for operation from a 208 V 60 Hz or 230 V 60 Hz 3 Phase nominal input Other input voltages and 50 Hz operation are available as special options and are not covered in these instructions Your chamber was configured prior to shipment for the particular voltage that was specified at time of order These instructions should be used to verify the...

Page 9: ...h circuits on the load side of the Main Disconnect Switch are individually fused However your local electrical code may require a separate disconnect switch within sight of the chamber Power Source Connection 1 Turn the Disconnect Switch to the OFF position 2 Remove the lower door retaining screw located on the right side Open the lower door 3 Remove the chamber s right side panel 4 Mount the inpu...

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Page 11: ...for details on how to use the Temperature Controller CAUTION This chamber has a crankcase heater to protect the high stage compressor The chamber must be connected to the power source AND the Main Disconnect Switch must be ON for 3 hours prior to operating the chamber Although it may be safe to use the chamber immediately this procedure ensures the longest possible life for the high stage compress...

Page 12: ...s the longest possible life for the high stage compressor if the chamber has been removed from the power source for more than 24 hours CONDITIONING Switch ON Mode The CONDITIONING Switch enables all chamber functions When the CONDITIONING Switch is OFF only the Temperature Controller and Limit Controller are operational When the CONDITIONING Switch is ON the chamber s temperature conditioning syst...

Page 13: ...bjects and surfaces that are hot or cold to prevent severe burns or frostbite Protective gloves are recommended CAUTION If your test sample is energized it may be capable of raising the workspace temperature beyond safe limits This could occur if your test sample exceeds the live load rating of the chamber or if the chamber s refrigeration system fails This chamber has a set of contacts that can b...

Page 14: ...st during low temperature operation or water when maintaining over 0 C and cooling is required To avoid moisture condensation make sure the port plugs are inserted at all times Also avoid opening the chamber door while the chamber is operating at temperatures below room ambient When a low temperature test is completed warm the chamber to at least room ambient before opening the chamber door and be...

Page 15: ...ual and is written by the manufacturer Watlow for a wide variety of applications and configurations Not all features or functions are applicable Only the capabilities of a model PM6L1AJ AAAABAA are applicable CAUTION The EZ Zone Limit Controller has been properly configured by TestEquity to match the chamber s system requirements Improper modifications to these setup values can result in unreliabl...

Page 16: ...gher than your actual chamber temperature set point to prevent nuisance tripping 5 Press the RESET Key to return to the Home Page 6 The upper display will show the actual chamber temperature while the lower display will show SAFE as long as the limits are not exceeded Resetting an Out of Limit Condition If the limit is exceeded the Limit Controller will flash Li h1 high limit or Li L1 low limit in...

Page 17: ...that can be used to remove power to your test sample if the Limit Controller s temperature limits are exceeded The safety contacts are rated as follows Resistive 10 A 250 VAC or 10 A 28 VDC Inductive 7 A 250 VAC To access the safety contacts 1 Turn the Main Disconnect Switch to the OFF position 2 Remove the lower door retaining screw located on the right side Open the lower door 3 Locate the Termi...

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Page 19: ...030 Connect the hose from the Dry Air system to the fitting which is designated PURGE on the rear panel Connect a supply of compressed air to the 3 8 inch FPT shutoff valve of Dry Air system Connect the power cord from the Dry Air system to the DRY AIR POWER socket on the rear panel This plug must be twisted clockwise to lock it The Dry Air system requires 13 cfm of compressed air at 100 psig 175 ...

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Page 21: ...r installation be determined by a qualified electrician who is familiar with industrial plant wiring I need to send the chamber outside North America Will it work with their power Outside North America most countries have 50 Hz Standard three phase voltage systems in most 50 Hz countries are typically 380 V or 400 V Please call TestEquity for details on voltage reducing transformers for 50 Hz oper...

Page 22: ...le the temperature set point may be 25 0 C The actual temperature varies between 25 4 C and 24 5 C This corresponds to 0 4 C and 0 5 C or a total of 0 9 C of RELATIVE variations These specifications are for an empty chamber The addition of a test sample may affect the control variations In some instances the test sample will reduce these variations Uniformity Also known as Gradients This is a meas...

Page 23: ...ossible life for the high stage compressor if the chamber has been removed from the power source for more than 24 hours Can the person who services our air conditioning also service the chamber Probably not Most air conditioning mechanics are not familiar with low temperature cascade refrigeration systems While this chamber is relatively easy to maintain and repair most air conditioning mechanics ...

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Page 25: ...own Example empty From 85 C to 30 C 115 C 17 min 6 8 C min Heat Up Example empty From 30 C to 85 C 125 C 15 min 8 8 C min Input Power Requirements 230 V 10 60 Hz 3 PH Max Current Draw 31 A Recommended Service 40 A 208 V 5 10 60 Hz 3 PH Max Current Draw 16 A Recommended Service 35 A Input may be configured for nominal 208 V or 230 V in the field by changing jumpers Call for other voltages or 50 Hz ...

Page 26: ...mpty From 85 C to 30 C 115 C 19 min 6 0 C min Heat Up Example empty From 30 C to 85 C 115 C 15 min 7 5 C min Input Power Requirements 230 V 10 60 Hz 3 PH Max Current Draw 31 A Recommended Service 40 A 208 V 5 10 60 Hz 3 PH Max Current Draw 16 A Recommended Service 35 A Input may be configured for nominal 208 V or 230 V in the field by changing jumpers Call for other voltages or 50 Hz operation Wor...

Page 27: ...sonnel only Preventive Maintenance Intervals Daily or As Needed Clean chamber interior and exterior Listen for abnormal noise or vibration Every 3 Months Inspect the door seal Inspect the refrigeration machinery compartment Verify the chamber performance Every 6 Months Inspect the electrical compartment Clean the condenser Every 12 Months Verify the calibration ...

Page 28: ...ecognize changes from normal operating noises can be a valuable way to identify problems and prevent further damage Examples of noises to be aware of include Circulator motor and fan noises with compressors off Compressor start up and running noises sequential starting of compressors Condenser fan noises Relay and valve cycling noises when cool light is cycling How to inspect the door seal The doo...

Page 29: ...nt to protect against a refrigerant line which could break 1 Turn the Main Disconnect Switch OFF 2 Remove the side and rear panels 3 Inspect for signs of refrigeration tubing abrasion 4 Inspect for oil around refrigeration valves fittings and joints This may be a sign of leaks 5 Inspect for loose hardware and tighten as required 6 Inspect for signs of insect or rodent infestation Yes it does happe...

Page 30: ...inutes 5 The chamber temperature should slowly increase and stabilize to 85 C It should NOT overshoot beyond 85 C by more than a few tenths of a degree and the compressors should NOT need to turn ON in order to maintain 85 C 6 After stabilization the chamber temperature should vary no more than 0 5 C or a total of 1 C 7 Let the chamber stay at 85 C for two hours 8 After two hours at 85 C set the T...

Page 31: ...rior are NOT a measurement of controller accuracy These variations called gradients are a function of the physical design of the chamber and its airflow the characteristics of the test sample and how it is oriented in the chamber You cannot calibrate to improve gradients The common practice of measuring multiple points in the chamber and adjusting the temperature controller s calibration to correc...

Page 32: ...perature safety limits are exceeded TCR2 turns off CR3 which turns off C1 PCR1 will disable CR1 if the input power phase sequence is incorrect Cooling is accomplished by a single stage refrigeration system The refrigeration system provides cooling to the chamber interior through a finned evaporator coil which is located in the air plenum The system uses refrigerant R 404A High pressure liquid refr...

Page 33: ...During a high temperature pulldown or a continuous bypass condition it is possible for excessive hot gas to return to the compressor The suction line cooling thermostatic expansion valve senses the suction line temperature and injects liquid refrigerant to cool the hot gas within safe limits The receiver has an integral fusible relief which opens in the event of a fire A high low pressure switch D...

Page 34: ...ntroller light 1A is OFF 1 Solid State Relay SSR1 or SSR2 is defective Heater is shorted to chassis Does not cool at all 1 If F4T left PWR bar is 100 F4 controller light 1B is ON F4T Compressor Output F4 DigitalOut 8 is ON the Cool light on front panel is OFF both compressors are OFF 2 Setpoint is low than chamber temperature but F4T Compressor Output F4 DigitalOut 8 is not ON 3 If the Cool light ...

Page 35: ...mode 1 Re enter values as shipped from TestEquity 2 Control parameters may need to be changed for your unique test conditions 3 Control parameters may need to be changed for your unique test conditions Hot gas bypass regulator may be defective or set too high Compressor turns on and off too frequently 1 If compressor control parameters in temperature controller were changed 2 If compressor control...

Page 36: ...d charging the system by relying on a clear sight glass only Although a clear sight glass generally means the system is fully charged it can be misleading For example if the system is charged on a cool day or with an empty chamber it could be undercharged for hot days or with a heavy load The proper charging procedure is as follows 1 Repair any leaks before recharging 2 Attach a vacuum pump and ma...

Page 37: ... being out of service for even one day then you should purchase critical spare parts in advance Although most parts are standard and available from a variety of local distributors some parts are either harder to find or custom The following is a list of the kinds of parts that you may want to purchase in advance Electrical Parts Contactors Relays Fuses Heat Limiter Circulator Motor and Fan Switche...

Page 38: ...rlingswitch LRA211 RA B 125N SW1 200023 1 ea Switch ON OFF ON Carlingswitch RC911 RA B 0 N XLR1 SW2 200275 1 ea F4 Temperature Controller Watlow F4SH CKA0 01AE TCR1 200001 1 ea F4T Temperature Controller Watlow F4T1L2EAA2E1017 TCR1 222510 1 ea Heat Limiter Assembly Thermodisc G5A 01 240C with QC Terminals HL1 2 3 222253 3 ea Arc Suppressor ITW Paktron 104MACQRL150 AS1 3 200296 3 ea Contactor 3 P 3...

Page 39: ...00078 1 ea Dual Pressure Control Johnson P70NA 1C 11 DPS1 100015 1 ea Filter Drier Sporlan C 083 S 4 100070 1 ea Sight Glass Danfoss 140 0143 3 100081 1 ea Capillary Tube 0 036 x 36 J B TC 36 14 100043 2 ea Gauge 30 x 200 PSIG Compound Miljoco CUSTOM 12 100494 1 ea Gauge 0 x 400 PSIG Pressure Miljoco CUSTOM 14 100495 1 ea Crankcase Heater 40 W 120 V Copeland 018 0041 01 2 CC1 100071 1 ea General P...

Page 40: ...e L Sd Limit Sides both Alt high High only or LoW Low only L hY Limit Hysteresis 2 Change not recommended A ty Alarm Type oFF Do Not Change PAr1 Upper Display ACPu Alt none PAr2 Lower Display Lst Alt Lh s High Set Point or LL S Low Set Point ad s Zone Address 1 Not functional for this application NOTE 1 The Lockout Menu LoC sets the security clearance level as follows 1 Operations Menu read only 2...

Page 41: ...ing the Purchaser to return the Equipment to TestEquity when such return is feasible The following parts are excluded from this limited warranty and are sold as is or are considered expendable interior light bulb viewing window paint and cosmetic surface finishes and treatments port plugs and refrigerant This limited warranty shall extend in full to Equipment installed within continental United St...

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Page 43: ...Chapter 10 Drawings TestEquity 1016S and 1027S Temperature Chamber Page 10 1 Chapter 10 Drawings ...

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Page 45: ...n Disconnect Switch DSW TB1 TB2 Control Transformer TR1 F1 F2 F7 F8 C1 C2 SSR2 SSR1 CR1 CR3 FNQ R 4 FNQ R 20 LP CC 20 FNM 3 F3 F9 F4 F5 F6 PCR1 SSR4 TM1 SSR3 TB2 Terminals H1 H2 H3 G G G TB1 Terminals N N 1 2 3 4 5 7 8 9 10 11 12 13 14 15 A1 A2 ...

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