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Chapter 7 – Maintenance

Page 7-10

TestEquity 1016H-2 Temperature/Humidity Chamber

Theory of Operation

Overview

Refer to the electrical and refrigeration drawings to identify the referenced items described

below. The electrical items are referenced with a letter(s) and number. The refrigeration items

are referenced with a number only or number followed by a single letter.

Air Heating and Safety Systems

The chamber is heated by an open-element nichrome heater (HT1). The heater is located in the

air plenum. The temperature controller provides a time-proportioned output to the solid state

relays (SSR1, 2). This turns the heater on/off as required to maintain the temperature set point.

Pilot light PL1 provides an indication on the front panel when the heater is on. Fusible heat

limiters (HL) provide failsafe protection against a catastrophic failure by opening the heater

circuit at +240°C. The master heat contactor C1 provides a power interlock for the heaters,

circulator fan motor, and the control system. C1 is controlled by both the Conditioning Switch,

the safety relay (CR1). CR1 is controlled by the temperature limit controller (TCR2). If either the

high or low temperature safety limits are exceeded, TCR2 turns off CR1, which disables all

temperature conditioning functions.

Humidity System

Water is heated by an immersion-type heater (HT2) to generate vapor. The heater is located in

the humidifier tank. The F4T/F4 Controller provides a time-proportioned output to a solid state

relay (SSR2). This turns the heater on/off as required to maintain the humidity set point. Pilot

light PL4 provides an indication on the front panel when the humidifier heater is on.

Water level in the humidifier is maintained by a float valve assembly which is external to the

humidifier tank.

The immersion heater has an embedded thermocouple which is connected the F4T/F4 Controller

to control an alarm output. This provides failsafe protection against a heater failure in the event

of a low water condition by opening the humidifier heater contactor C4 if the heater reaches

+125°C. The alarm will self-reset when the heater r100°C.

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Содержание 1016H-2

Страница 1: ... 1016H 2 Temperature Humidity Chamber With 2x2 HP Compressors Operation and Service Manual TestEquity LLC 6100 Condor Drive Moorpark CA 93021 Technical Support 877 512 3457 Toll Free 805 480 0638 Corporate 800 732 3457 Toll Free 805 498 9933 http www testequity com ...

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Страница 3: ...__________________________ 3 2 HEAT Light __________________________________________________________________________ 3 2 COOL Light __________________________________________________________________________ 3 2 Loading the Chamber ____________________________________________________________3 4 Performance Considerations ______________________________________________________________ 3 4 Port Plugs ...

Страница 4: ...ration __________________________________________________ 7 8 How to Verify the Humidity Calibration ____________________________________________________ 7 9 Humidity Sensor Calibration and Maintenance _______________________________________________ 7 9 Theory of Operation_____________________________________________________________7 10 Overview_____________________________________________________...

Страница 5: ...ration in a conditioned laboratory environment Operation above 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 avail...

Страница 6: ...p 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 of raising the workspace temperature b...

Страница 7: ... you need to open the door while the chamber is operating wear safety goggles to prevent the high velocity airflow from blowing particles or objects into your eyes WARNING This chamber operates at extreme temperatures Avoid contact with air objects and surfaces that are hot or cold to prevent severe burns or frostbite Protective gloves are recommended ...

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Страница 9: ...ation machinery compartment c Check the low stage refrigeration charge e 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 The chamber generates a heat load of up to 17 485 BTUH during a continuous cool down from a high temperatu...

Страница 10: ... input voltage from one configuration to another CAUTION This chamber must be properly configured for either 208 V or 230 V nominal input 208 V and 230 V are NOT the same Do NOT guess Do NOT assume you have 220 V You must verify the exact type of electrical service you have If there is any doubt you must consult with a qualified electrician who is familiar with industrial plant wiring In addition ...

Страница 11: ... number TA must be connected to the 208 V terminal 3 on Control Transformer TR1 Single Phase Configuration 1 Locate the Power Distribution Terminal Block There must be a jumper between terminal C and A right side of terminal block Wire D must connect to terminal B left side of terminal block 2 The input power wires will be connected to L1 and L2 on the top of the Disconnect Switch Connect earth gr...

Страница 12: ...eed to pass through the Input Access Hole This hole is in the corner of the partition which separates the compressor compartment from the electrical compartment Three tie points are provided on the side of the chamber to secure the input wiring with provided tie wraps Three Phase Input 1 Locate the Disconnect Switch 2 Connect the Hot input wires to terminals L1 L2 and L3 on the Main Disconnect Swi...

Страница 13: ...idity system using ordinary tap water Condensate from the chamber is returned back to the water tank The water pump runs continuously when the humidity system is enabled keeping the supply line pressurized at all times Detailed assembly pictures are shown on the next page 1 Attach filter cartridge Use clamp provided on each end of filter to prevent leaking Do not overtighten 2 Position the recircu...

Страница 14: ...eptacle on the back of the chamber The drain tube from the chamber must not be submerged in the water Use the supplied clamp on each end of filter and the water inlet fitting to prevent leaking Do not over tighten the clamp screws Bottom of Filter Top of Filter Clamp Clamp Reservoir drain Drain water when it appears dirty Replace filter when this portion turns brown Clamp NOTE The rear panel of yo...

Страница 15: ...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 compressor if the chamber has been removed from the power source for more than 24 hours Summary of Chamber Operation 1 Turn the Main Disconnect Switch ON 2 Enter the appropriate high and low temperatu...

Страница 16: ...cedure ensures 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 cond...

Страница 17: ...on mode If the Humidity mode is disabled the chamber will cool in cascade refrigeration mode and there will be no humidity control HUMIDITY Light The HUMIDITY Light will illuminate when the F4T F4 Controller turns on the humidifier heater to maintain the workspace humidity The HUMIDITY Light will cycle on off as the workspace humidity approaches and reaches the humidity set point Note that the HUM...

Страница 18: ...f the chamber s refrigeration system fails This chamber has a set of contacts that can be used to remove power to your test sample if the Limit Controller s temperature limits are exceeded CAUTION To prevent damage to your test sample and the chamber s compressors do not exceed the live load rating of the chamber Live Load Capacity for 1016H 2 uncontrolled humidity mode only Temp 23 C 0 C 40 C 55 ...

Страница 19: ...se the humidity system to control moisture at low temperatures The humidity system is disabled below 7 C However if you have a source of GN2 gaseous nitrogen or Dry Air you can use the optional Purge system to eliminate moisture condensation at low temperatures Internal Test Fixtures Some applications require internal fixtures to support test samples and provide a convenient method of connecting w...

Страница 20: ... clean dry chamber For extended low humidity range below 6 C a dew point condition see Purge Option which follows The F4T F4 will automatically disable the humidity system below 7 C and above 90 C to protect the chamber Figure 3 2 Achievable Range of Temperature Humidity Conditions Humidity Mode Considerations The chamber workspace must be between 7 C and 90 C If the chamber is outside this temper...

Страница 21: ...ssed 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 psig max Purge Operation The Purge mode is enabled through the Purge button on the F4T Controller or Event 3 Digital Output 3 on t...

Страница 22: ...016H 2 Temperature Humidity Chamber Relief Vent Excess pressure in the chamber workspace is vented through a pressure relief check valve which is located on the top of the chamber behind the fan shroud There is no need to vent this externally ...

Страница 23: ...anual 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 unrelia...

Страница 24: ...r 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 th...

Страница 25: ...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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Страница 27: ...ur 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 ope...

Страница 28: ...mple 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 me...

Страница 29: ... 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 do not have the nece...

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Страница 31: ... instantaneous step change in Set Point without a controlled ramp rate Does not include the effect of proportional band when approaching setpoint Performance is reduced by 17 with 50Hz input power Input Power Requirements Current Minimum Phase Draw Service 230 V 10 60 Hz 1 PH 36 A 45 A 3 PH 24 A 30 A 208 V 5 10 60 Hz 1 PH 33 A 45 A 3 PH 22 A 30 A Input may be configured for 1 or 3 Phase in the fie...

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Страница 33: ...interior and exterior Listen for abnormal noise or vibration Inspect the demineralizer cartridge if provided Every 3 Months Inspect the door seal Inspect the refrigeration machinery compartment Check the low stage refrigeration charge Verify the chamber performance Drain the water recirculation system reservoir Every 6 Months Inspect the electrical compartment Clean the condenser Drain the humidif...

Страница 34: ...oises Being able to recognize 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 ...

Страница 35: ...he two low stage gauges marked R 508B on the left side of the rear of the chamber 3 The two gauges have different scales However they should read the same value of pressure This indicates that the system is equalized and an accurate reading can be taken 4 Both R 508B gauges should read approximately 125 PSIG 5 If the pressure is low this indicates that there is probably a leak 6 If one gauge is lo...

Страница 36: ...y 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 to maintain 85 C 5 After stabilization the chamber temperature should vary no more than 0 5 C or a total of 1 C 6 Let the chamber stay at 85 C for two hours 7 After two hours at 85 C set the F4T F4 Controller temperature set point to 65 C 8 The h...

Страница 37: ...Light cycles ON OFF within 7 minutes 5 The chamber temperature should slowly increase and stabilize to 85 C It should NOT overshoot beyond 85 C by more than 1 0 C and the compressor should NOT need to turn ON at this point to maintain 85 C 6 The chamber humidity should begin to increase within approximately 5 10 minutes after the Humidity Light turns on Then the humidity should increase to approxi...

Страница 38: ... may be able to clean the condenser less frequently if the chamber is in a very clean environment How to Drain the W100 Water Recirculation System Reservoir 1 This procedure drains the water in the recirculation system only not the vapor generator 2 If the chamber is running a humidity test turn it off Otherwise this task can be done while the chamber is operational 3 Place a basin capable of cont...

Страница 39: ... the chamber from the power source 4 Remove the lower rear panel 5 Open the Drain Valve by turning its handle 90 degrees counter clockwise Water will come out of the Drain fitting on the back of the chamber 6 After the system is drained close the Drain Valve by turning its handle 90 degrees clockwise Figure 7 2 Humidifier Drain Valve circled shown in the closed or normal operating position Humidif...

Страница 40: ...s in the chamber and adjusting the temperature controller s calibration to correct for these errors is incorrect The correct way to adjust what the temperature controller displays compared to what is measured at some point other than the controller s sensor is with the Calibration Offset parameter The F4T or F4 Temperature Humidity Controller User s Manual for details Calibration verification shou...

Страница 41: ...or calibration at all humidity conditions that the chamber is capable of achieving For the F4T Controller If calibration of the controller is necessary refer to the F4T Touch Screen Controller User s Guide For the F4 Controller If calibration of the controller is necessary refer to the F4 Temperature Humidity Controller User s Manual Humidity Sensor Calibration and Maintenance TestEquity recommend...

Страница 42: ...rs circulator fan motor and the control system C1 is controlled by both the Conditioning Switch the safety relay CR1 CR1 is controlled by the temperature limit controller TCR2 If either the high or low temperature safety limits are exceeded TCR2 turns off CR1 which disables all temperature conditioning functions Humidity System Water is heated by an immersion type heater HT2 to generate vapor The ...

Страница 43: ... circuit of the cascade condenser through the filter drier and liquid line solenoid valve to the thermostatic expansion valve The thermostatic expansion valve feeds the finned evaporator coil which is located in the air plenum where heat is absorbed to provide a cooling effect within the chamber The refrigerant vapor travels through the suction line to the compressor suction inlet The compressor t...

Страница 44: ...tage system is disabled The Humidity mode is enabled through Event 2 Digital Output 2 in the F4T F4 Controller Also the chamber workspace must be between 7 C and 90 C If the chamber is outside this temperature range the F4T F4 Controller s Alarm2 light will turn ON there is no indication on the F4T s main display but it functions similarly and the chamber will operate as though the Humidity Enable...

Страница 45: ...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 is ON compressors are ON 1 Pressure switch PS1 or PS2 is tripped 2 Controller is mis configured Re enter values as documented in the contro...

Страница 46: ...ve Compressors turn on and off too frequently 1 If compressor control parameters in F4T F4 Controller were changed 2 If compressor control parameters in F4T F4 Controller are as shipped from TestEquity 1 Re enter values as shipped from TestEquity 2 Solenoid valve SV1 or SV4 if in Humidity mode may be defective in the open position Excessive noise and vibration when the compressor starts 1 Chamber ...

Страница 47: ...d in How to verify the chamber performance NOTE If the F4 Controller is cycling Cool Light cycles on off the sightglass may appear 1 2 to 2 3 full This is normal R 508B Low Stage Charge 1 Repair any leaks before recharging 2 Attach a vacuum pump and manifold gauge to the suction discharge and expansion tank ports Attaching to the expansion tank is very important because it is otherwise very diffic...

Страница 48: ... 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...

Страница 49: ... Neon SoLiCo S412 2 1 N2 PL1 2 200026 2 ea Indicator Panel 120V Neon SoLiCo S412 2 1 N1 PL3 4 200025 2 ea Pump Receptacle Qualtek 738W CX2 01 RCP1 222303 1 ea Resistor 1 kohm 25W Vishay Dale RH0251K000FE02 R1 200295 1 ea Humidity Sensor Vaisala HMM100 RHS 200320 1 ea Solid State Relay 25A 4 32VDC in Idec RSSDN 25A SSR1 3 200021 3 ea Solid State Relay 10A 5VDC in Omron G3NE 210T US DC5 SSR4 6 8 200...

Страница 50: ...ion Cool HS Sporlan SBFJ AA C 25 100077 1 ea Expansion Valve Suction Cool LS Sporlan SBFS AA ZP 26 100526 1 ea Filter Drier Sporlan C 083 S 36 100070 1 ea Filter Drier Sporlan C 084 S 4 100631 1 ea Gauge 0 x 400 PSIG Pressure Miljoco CUSTOM 13A B 100495 2 ea Gauge 30 x 200 PSIG Compound Miljoco CUSTOM 12A B 100494 2 ea Hot Gas Bypass Regulator HS Sporlan ADRI 1 1 4 0 55 10 100078 1 ea Hot Gas Bypa...

Страница 51: ...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...

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Страница 53: ... for labor if they initiate service on their own without prior approval from TestEquity Replacement parts must be supplied by TestEquity for in warranty claims Purchaser will not be reimbursed for parts they buy on their own without prior approval from TestEquity The following parts are excluded from this limited warranty and are sold as is or are considered expendable interior light bulb viewing ...

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Страница 55: ...Chapter 9 Drawings TestEquity 1016H 2 Temperature Humidity Chamber Page 9 1 Chapter 9 Drawings ...

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