Home

TestEquity 1027S Operation and Service Manual

Contents

1. Refrigeration System Charging Instructions WARNING Repair of the refrigeration system must be performed only by a properly trained mechanic who is experienced in repairing cascade refrigeration systems Do NOT substitute any component Do NOT substitute refrigerants Improper repairs will void the warranty These instructions are intended as guidelines for repairing TestEquity chambers Details such as how to attach a gauge manifold are not covered These are NOT do it yourself instructions R 404A Charge TestEquity does NOT recommend 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 manifold gauge to the suction and discharge ports 3 Evacuate the system to at least 100 microns DO NOT GUESS You must use a micron gauge 4 Use a charging scale to weigh in 80 ounces 5 pounds of R 404A 5 Verify the cooling performance as outlined in How to verify the chamber performance NOTE If the Temperature Controller is cycling Cool Light cycles on off the sightglass may appear 1 2 to 2 3 full This is normal Page 8 10 TestEquity 1027S Temperature Chamber Chapter 8 Maintenanc
2. copper jumper wire instead of the fuses Connecting to the Event Board 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 The Event Board is located next to the electrical subpanel Connect to the events as follows Event Output Event Board Terminals Event 1 1 2 Event 2 3 4 Event 3 5 6 Event 4 7 8 Event 5 9 10 Event 6 11 12 Event 7 13 14 The event outputs are just switches You must provide power from an external source 5 A 1 2 inch conduit hole is provided on the left side of the lower door to route your wires through Use the appropriate wire cable management fittings TestEquity 1027S Temperature Chamber Page 4 11 Chapter 4 Temperature Controller Operations Page The Operations Page provides access to menus for control tuning PID and controller alarms TestEquity has configured the security to require a password for access to all parameters in the Operations Page You must call TestEquity at 877 512 3457 or 805 480 0638 to obtain the password ZA CAUTION The Series F4 Temperature Controller Alarm functions are NOT used in the chamber s safety system and are NOT connected TestEquity does NOT recommend using the Series F4 alarm function as the main protection device The independent EZ Zone Limit Controller functions as the main protection device CAUTION The Series F4 Temperature Controller PID values h
3. e Wait for an event or process value Event outputs 1 through 7 to turn ON or OFF For controlling the power to remote devices Time in hours minutes and seconds Temperature Set Point PID set One of five sets of heat cool PID parameters Normally just leave at PID Set 1 Guaranteed Soak Ramp Rate Step Ramp Rate changes the set point to a new value in a chosen rate of time Define the Ramp Rate step by choosing Wait for an event or process value Event outputs 1 through 7 to turn ON or OFF For controlling the power to remote devices Rate in degrees per minute Temperature Set Point PID set One of five sets of heat cool PID parameters Normally just leave at PID Set 1 Guaranteed Soak Page 4 4 TestEquity 1027S Temperature Chamber Chapter 4 Temperature Controller Soak Step Soak maintains the set point from the previous step for a chosen time in hours minutes and seconds Define the Soak step by choosing Wait for an event or process value e Event outputs 1 through 7 to turn ON or OFF For controlling the power to remote devices e Time e PID set One of five sets of heat cool PID parameters Normally just leave at PID Set 1 e Guaranteed Soak Jump Step Jump initiates another step or profile Define the Jump step by choosing e Profile to jump to e Step to jump to and e Number of Repeats NOTE If a power out condition occurs during a profile and more than 20 jump steps are stored in the
4. gt gt gt gt gt gt gt gt 00 00 01 850 1 E 5 Soak gt E gt S 00 30 00 1 Yes ea 6 Jump gt u A FS Name 2 3 7i Ramp Time gt D O ee A 00 00 01 23 0 1 8 End Hold un A Step Description 1 Establishes a recommended initialization step Goes to 23 C as quickly as possible gt 2 Goes to 20 C as quickly as possible E 3 Will hold for 30 minutes Time will not start until chamber reaches 17 C within the 3 Guaranteed Soak Band 4 Goes to 85 C as quickly as possible g 5 Will hold for 30 minutes Time will not start until chamber reaches 82 C within the 3 Guaranteed Soak Band E 6 Jumps back to step 2 Repeats this 3 times for a total of 4 cycles 7 After all cycles are completed establishes the condition to end on Goes to 23 C as quickly as possible 8 Holds at 23 C indefinitely until program is manually stopped Profile Summary 50 C to 0 C 1 C minute ramp 1 hour soak time 100 cycles Test sample turned ON OFF depending on step End with return to 23 C manual set point Step Step Date Choose Digit Out Time Chi PID Guar Jump to End Idle Number Type Day Time Wait for 1 2 3 4 5 6 7 H M S Rate SP Set Soak Profile Step Repeats Type SP 1 Ramp Time gt On gt gt gt gt gt gt 00 00 01 23 0 1 2 Ramp Rate gt On gt gt gt gt gt gt 1 0 50 0 1 3 Soak gt On gt gt gt gt gt gt 01 00 00 1 No 4 Ram
5. in temperature controller are as shipped from TestEquity If tuning PID control parameters in temperature controller are as shipped from TestEquity and only occurs in cool mode Re enter values as shipped from TestEquity Control parameters may need to be changed for your unique test conditions Control parameters may need to be changed for your unique test conditions Hot gas bypass regulator may be defective or set too high Compressors turn on and off too frequently If compressor control parameters in temperature controller were changed If compressor control parameters in temperature controller are as shipped from TestEquity Re enter values as shipped from TestEquity Control parameters may need to be changed for your unique test conditions Solenoid valve SV1 may be defective in open position Excessive noise and vibration when the compressor starts Chamber has been off for several hours or more and is not connected to source of power or main disconnect switch is off during that time Chamber has been off for several hours or more and is connected to source of power and main disconnect switch is on during that time 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 Crankcase heater defective open TestEquity 1027S Temperature Chamber Page 8 9 Chapter 8 Maintenance
6. mu Page 4 8 TestEquity 1027S Temperature Chamber Chapter 4 Temperature Controller How to Edit a Profile 1 Go to the Profiles Page Move the cursor down the Main Page to Go to Profiles then press the key Main Page gt Go to Profiles Go to Setup Go to Factory 2 Choose Edit Profile e Press the W key to choose on Edit Profile e Then press the gt gt key Main gt Profile__ Create Profile Edit Profile Delete Profile 3 Select the desired stored profile to edit Edit Profile e Press the Aor Y to scroll through the list of Profilet stored profiles gt Profile2 e Press to select the desired profile Profile3 4 Choose how to edit the step Choose to e Press the Aor Y to scroll through the list of step Insert Step edit choices gt Edit Step e Press to select your choice Delete Step Done 5 To edit a step Edit Step E e Press the Aor Y to scroll through the list of steps gt Step 1 Ramp Time you want to edit Step 2 Soak e Press to scroll through the step parameters and Step 3 Ramp Time make any desired changes 6 To insert a step e Choose Edit Profile see step 4 above e Press the Aor Y to scroll through the number of the step that the new step will precede Press to enter the new step and follow the step parameter prompts Insert Before Step 1 Ramp Time gt Step 2 Soak Step 3 Ramp Time 7 To delete a step e Choose
7. 1 4 2 J ct 100066 1 ea Solenoid Valve Sporlan E6S130 3 8 x 3 8 ODF 5 100067 2 ea Solenoid Valve Coil Sporlan MKC 1 120 50 60 SV1 2 100011 2 ea Hot Gas Bypass Regulator Sporlan ADRI 1 1 4 0 55 strgt 3 8x3 8 ODF 9 100078 1 ea Dual Pressure Control Johnson P70NA IC 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 CC 100071 1 ea Page 8 12 TestEquity 1027S Temperature Chamber Chapter 8 Maintenance General Parts Description Mfr Mfr Part No Ref Part Qty UOM Port Plug Silicone Foam 4 CUSTOM CUSTOM 300534 2 ea Viewing Window CUSTOM CUSTOM 300447 1 ea Door Gasket Inner CUSTOM CUSTOM 300636 1 ea Door Gasket Outer CUSTOM CUSTOM 300637 1 ea Fan Alum 7 D 5 16 Bore CW Revcor 0705 31 R 0 3125 DANN 300006 2 ea Door Latch Chamber Workspace Southco A2 10 501 21 300009 1 ea Caster Swivel 2 ea Caster Rigid 2 ea Shelf with 4 Clips CUSTOM CUSTOM TE 2701 1 ea Shelf Retainer Clip Kason Style 66 0066000008 300015 4 ea TestEquity 1027S Temperature Chamber Page 8 13 Chapter 8 Maintenance Series F4 Temperature Controller Setup Pa
8. 8 indicates when cooling system is ON Power The of throttle of the heat positive number or cool negative number output DigitalIn Status of the digital inputs 1 through 4 Date Real time clock date Time Real time clock time TESTEQUITY 1027S Identifies the chamber model number Go to Operations Access to Operations Page Go to Profiles Access to Profiles Page Go to Setup Access to Setup Page Not displayed if ruming a profile Go to Factory Access to Factory Page Not displayed if running a profile Static Set Point Control The Temperature Controller is in Static Mode when it is not controlling a Profile When in a Static Mode the Profile Indicator Light is off see Fig 4 1 The Upper Display shows the actual chamber workspace temperature The Static Set Point SP 1 prompt is accessed from the Main Page To enter a Static Set Point 1 Press the Aor Y key to position the Cursor next to the SP1 prompt You may already be at this prompt 2 Press the key once You will see Static Set Point1 in the lower display with the current set point indicated below 3 Press the Aor Y key to change the temperature set point value Press the key once to enter the new temperature set point You are now back to the Main Page Main Page Static Set Pointi gt SP1 85 0 C 85 0 C DigitalOut A A Power1 50 Y v Adjusts Value lt Back gt Next TestEquity 1027S Temperature Chamber Page 4 3 Chapter 4 Temperature Controlle
9. Controller can function as either a single set point controller static mode or as a programmable profile controller A four line LCD display facilitates setup and programming and presents informative messages about status error and alarm conditions Digital outputs profiles and alarms can be named for easy reference An Information Key gives you quick information about the pages menus parameters and values as well as error and alarm conditions if they occur The user interface is organized into five pages of menus CAUTION The Series F4 Alarm functions are NOT used in the chamber s safety system and are NOT connected TestEquity does NOT recommend using the Series F4 alarm function as the main protection device The independent EZ Zone Limit Controller functions as the main protection device CAUTION The Series F4 Temperature Controller has been properly configured by TestEquity to match the chamber s system requirements and to perform optimally over a wide range of operating conditions Improper modifications to these setup values can result in erratic performance and unreliable operation Do not attempt to modify the setup values unless you thoroughly understand what you are doing Setup examples in the Series F4 User s Manual are NOT applicable to this chamber If there is any doubt please call TestEquity before proceeding The correct values are documented in the Series F4 Temperature Controller Setup P
10. Delete Step see step 4 above e Press the Aor Y to scroll through the number of the step you want to delete e Press to delete the step Delete Step _ Step 1 Ramp Time gt Step 2 Soak Step 3 Ramp Time 8 Save your settings e Press successively to exit the Profiles Page e After exiting the Profiles Page choose A to save the new profile values or Y to restore the old values Save profile data or restore values v Restore A Save An End Step cannot be deleted TestEquity 1027S Temperature Chamber Inserting or deleting a step will renumber all steps that follow A Jump Step that jumps to an End Step cannot be deleted Inserting a new ramp step usually requires inserting an associated soak step Deleting a ramp step usually requires deleting the associated soak step Chapter 4 Temperature Controller Profile Examples The following are examples of two typical profiles Profile Summary 20 C to 85 C no ramps 30 minute soak time 4 cycles End with program hold at 23 C 5 2 Step Step Date Choose Digit Out Time Chi PID Guar Jump to End E Number Type Day Time Wait for 1 2 3 4 5 6 7 H M S Rate SP Set Soak Profile Step Repeats Type 3 1 Ramp Time gt gt gt gt gt gt gt gt 00 00 01 230 1 O 2 Ramp Time gt gt gt gt gt gt gt gt 00001 20 0 1 2 3 Soak gt gt gt gt gt gt gt gt 00 30 00 1 Yes E 4 Ramp Time u
11. F4 s Profile Program memory the controller will terminate the profile and turn off all outputs if Continue Hold or Terminate was selected as the Power Out action If Profile Reset or Go to Idle Set Point was selected the controller will take those actions A pop up message will warn of this when the 21st jump step is programmed End Step End terminates the profile in a chosen state All profiles must have an End step It cannot be deleted or changed to another step type Define the End by choosing Hold Control Off All Off or Idle end state NOTE TestEquity recommends having the end step type to be Hold or Idle TestEquity does NOT recommend using an end step type of Control Off or All Off This does not turn off the chamber fan The chamber temperature can reach 55 C just from heat generated by the fan and even higher if your test sample is energized Wait For step option The use of Wait For in a profile is optional Ramp Time Ramp Rate and Soak steps can be programmed to wait for a particular chamber temperature or event input condition The wait conditions must be satisfied before the time clock and the step activity proceeds Digital inputs must first be configured in the System Menu as Wait For Events with the condition to be met also specified Then to wait for this digital input you must specify On meaning the condition as configured in the Setup Page or Off meaning the opposite of that condition The digital inputs have bee
12. The system uses refrigerant R 404A High pressure liquid refrigerant is fed from the condenser through the liquid line filter drier and sight glass 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 thermostatic expansion valve controls the feed of liquid refrigerant to the evaporator and by means of an orifice reduces the pressure of the refrigerant to the evaporating or low side pressure The reduction of pressure on the liquid refrigerant causes it to boil or vaporize absorbing heat which provides a cooling effect The expansion valve regulates the flow as necessary to maintain a preset temperature difference or superheat between the evaporating refrigerant and the vapor leaving the evaporator The refrigerant vapor travels through the suction line to the compressor suction inlet The compressor takes the low pressure vapor and compresses it increasing both the pressure and the temperature The hot high pressure vapor is forced out of the compressor discharge valve and into the condenser As the high pressure vapor passes through the condenser Page 8 6 TestEquity 10278 Temperature Chamber Chapter 8 Maintenance it is cooled by a fan which blows ambient air across the finned condenser surface The vapor condenses into a liquid and the cycle is repeated The temperature contro
13. based on operation at 23 C 73 F ambient and nominal input voltage Designed for use in a normal conditioned laboratory Operation at higher ambient temperatures may result in decreased cooling performance Additional ports and shelves will also affect performance Operation above 30 C 85 F or below 16 C 60 F ambient is not recommended TestEquity 1027S Temperature Chamber Page 7 1 Chapter 7 Specifications F4 Temperature Controller Specifications Specifications as configured for the TestEquity 1027S Chamber Accuracy amp Sensor Conformity 1 55 C above 50 C 1 66 C below 50 C Stability 0 1 C C rise in ambient Digital Inputs Four Contact closure or dc voltage 10 kQ impedance Retransmit Outputs Optional Two User selectable ranges 0 to 10 VDC 0 to 5 VDC 1 to 5 VDC 0 to 20 mA 4 to 20 mA Alarm Outputs Two Electromechanical relay Form C 2 A 20 VDC or 240 VAC max Digital Outputs 7 available for customer use Open collector output OFF 42 VDC Y 10 uA max ON 0 2 VDC 50 mA sink max Internal supply 5 VDC 80 mA Communications EIA 232 and EIA 485 serial communications with Modbus RTU protocol Safety Agency Approvals UL c UL 916 listed File E185611 CE to EN61010 NEMA 4X and IP65 CE EMC to EN50082 2 CE EMC to EN55011 Displays Process 5 seven segment red LED Interface Display 4 line high definition green LCD selectable C or F Data Retention Retention upon power
14. but local codes may limit the length to 6 feet TestEquity recommends that the appropriate method for your 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 operation Note that the cooling performance will be reduced by 17 at 50 Hz Why does my chamber heat or cool slower than the published specifications Performance is significantly affected by the characteristics of your test sample Factors include size weight material shape and power dissipation 1f 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 should be used to evenly distribute the load You can determine if the chamber is operating properly by following the procedure in How to verify the chamber performance How can I modify the chamber to cool faster Unfortunately there is little you can do to improve upon the designed i
15. compartment 8 5 How to clean the condenser 8 5 How to verify the calibration 8 5 Theory of Operation 8 6 Overview 8 6 Heating System 8 6 Refrigeration System 8 6 Troubleshooting 8 8 Refrigeration System Charging Instructions 8 10 R 404A Charge 8 10 Recommended Spare Parts 8 11 Major Electrical Parts 8 12 Major Refrigeration Parts 8 12 General Parts 8 13 Series F4 Temperature Controller Setup Parameters 8 14 Series F4 Setup Parameters 8 15 Series F4 Operations Parameters 8 16 Series F4 Set Lockout Parameters 8 16 EZ Zone Limit Controller Setup Parameters 8 17 Setup Menu 8 17 Operations Menu 8 17 Chapter 9 Warranty 9 1 Chapter 10 Drawings 10 1 Chapter 1 Safety Chapter 1 Safety Instructions Introduction Follow all CAUTION notices to prevent damage to the chamber or your test sample Failure to follow all CAUTION notices may void your warranty CAUTION may also indicate a potentially hazardous situation which if not avoided may result in minor or moderate personal injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury The safety alert symbol A precedes a general CAUTION or WARNING statement The electrical hazard symbol A precedes an electric shock hazard CAUTION or WARNING statement Installation Safety Notices ZA CAUTION The minimum clearance you should allow for proper ventilation around the chamber must be at least 12 fro
16. ea Fuse 4A Bussman FNQ R 4 F1 2 200083 2 ea Heat Limiter Thermodisc G5A 01 240C HL1 2 3 200070 3 ea Heater Air CUSTOM CUSTOM HTI 200061 1 ea High Low Limit Controller Watlow PM6L1AJ AAAABAB TCR2 200301 1 ea Indicator Panel 120V Neon SoLiCo S412 2 1 N1 PL2 200025 1 ea Indicator Panel 240V Neon SoLiCo S412 2 1 N2 PL1 200026 1 ea Relay Octal DPDT 10A 120VAC Idec RR2P UCAC120 CRI 3 200292 2 ea Relay Phase Control Crouzet DWRS220A PVRI 200067 1 ea Solid State Relay 25A Siemens SSRT 240D25 SSRI 2 200021 2 ea Solid State Relay 5A Omron G3NE 210T US DC5 SSR3 200129 1 ea Switch SPST Rocker Carlingswitch LRA211 RA B 125N SWl 2 200023 2 ea Temperature Controller Watlow F4SH CKA0 01AE TCR1 200001 1 ea Chart Recorder Option Recorder 1 Pen 10 Honeywell DR4301 0000 G0100 RCD1 200094 1 ea Chart paper 90 to 210 C Honeywell 24001660 034 200095 1 ea Chart paper 130 to 410 F Alternate Honeywell 24001660 033 200096 1 ea Pen Purple Six Pack Honeywell 30735489 007 200097 1 ea Major Refrigeration Parts Description Mfr Mfr Part No Ref Part Qty UOM Compressor Copeland ZF11K4E TF5 241 1 part of 100059 1 ea Evaporator Coil CUSTOM 9X32 6R 12 96 8 100060 1 ea Expansion Valve Main Sporlan SBFSE B ZP 3 8 x 5 8 ODF 6 100300 1 ea Expansion Valve Suction Cooling Sporlan SBFJ A C 3 8 x 1 2 ODF 9 100065 1 ea Distributor Sporlan 1620 2
17. examples in the Series F4 User s Manual are NOT applicable to this chamber The correct values are documented in the Series F4 Temperature Controller Setup Parameters section of this manual RS 232C The F4 Temperature Controller has an RS 232C interface A DB 9 connector is located on the rear panel It is wired to accommodate a null modem cable To communicate with the controller from a PC you need to run software that uses the Modbus RTU protocol Each controller function has a register number which can be read or written to when applicable These registers are listed Chapter Seven of the Series F4 User s Manual RS 232C Modbus programming resources can be downloaded from http www testequity com RS232 Common Modbus Registers e The actual chamber temperature reading is Modbus register 100 Input 1 Value e The static temperature set point is Modbus register 300 Set Point 1 e The temperature set point during a profile is Modbus register 4122 Set Point 1 Current Profile Status e The decimal points are implied For example 1005 is actually 100 5 and 230 is 23 0 GPIB optional The optional GPIB interface consists of an internal board which converts the F4 controller s serial interface to GPIB Chambers with a GPIB interface have a GPIB connector in place of the RS 232C connector GPIB programming resources and LabVIEW drivers can be downloaded http www testequity com GPIB Ethernet optiona
18. failure via nonvolatile memory seven years for battery backed RAM Note Total system accuracy in the chamber includes thermocouple wire accuracy Thermocouple wire accuracy is 1 C or 0 75 of reading whichever is greater Therefore total system accuracy over the chamber s operating range can be as much as 2 66 C although the typical accuracy is often better than 1 0 C Page 7 2 TestEquity 1027S Temperature Chamber Chapter 8 Maintenance Chapter 8 Maintenance WARNING Maintenance must be performed by properly trained personnel only Preventive Maintenance Intervals Daily or As Needed e Clean chamber interior and exterior e Listen for abnormal noise or vibration Every 3 Months e Inspect the door seal e Inspect the refrigeration machinery compartment e Check the refrigeration charge e Verify the chamber performance Every 6 Months e Inspect the electrical compartment e Clean the condenser Every 12 Months e Verify the calibration TestEquity 1027S Temperature Chamber Page 8 1 Chapter 8 Maintenance Maintenance Procedures How to clean the chamber interior and exterior e Wipe or vacuum out all debris e Clean surfaces with a damp cloth mild detergent or stainless steel cleaner Avoid cleaners that are abrasive or leave a residue Do NOT use steel wool e If you clean the interior with something other than water you may want to operate the chamber at high temperature approximat
19. illuminates when it is ON Heat Light The Heat Light will illuminate when the Temperature Controller turns on the heater to maintain the workspace temperature The Heat Light will cycle on off as the workspace temperature approaches and reaches the temperature set point Cool Light The Cool Light will illuminate when the Temperature Controller turns on the cooling valve to maintain the workspace temperature The Cool Light will cycle on off as the workspace temperature approaches and reaches the temperature set point Page 3 2 TestEquity 1027S Temperature Chamber Chapter 3 Operation Loading the Chamber IN WARNING IN WARNING IN WARNING IN WARNING IN WARNING IN CAUTION IN CAUTION Do NOT put items in the chamber that could burn or explode at high temperatures This chamber uses open wire heating elements which generate surface temperatures over 1000 F This is NOT an explosion proof chamber Do NOT put items in the chamber which can emit corrosive vapors or substances This chamber is NOT a curing oven There are NO provisions for venting fumes The chamber door must remain closed while the chamber is operating If 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 This chamber operates at extreme temperatures Avoid contact with air objects and surfaces that are hot or cold to preve
20. the bracket that is mounted to the chamber has slotted holes to permit adjustment e If the seal is still loose on the hinge side adjust the door hinge The hinges have slotted holes on the door side to permit adjustment Page 8 2 TestEquity 1027S Temperature Chamber Chapter 8 Maintenance How to inspect the refrigeration machinery compartment WARNING Wear safety goggles when inspecting the machinery compartment to protect against a refrigerant line which could break Turn the Main Disconnect Switch OFF Remove the side and rear panels Inspect for signs of refrigeration tubing abrasion Inspect for oil around refrigeration valves fittings and joints This may be a sign of leaks Inspect for loose hardware and tighten as required Di OT A OS Inspect for signs of insect or rodent infestation Yes 1t does happen How to check the refrigerant charge The refrigerant charge is checked by observing the sightglass The sight glass is located behind the rear bottom panel on the right side 2 Set the Temperature Controller to a low temperature Set Point The Cool Light should be on continuously 3 After about 5 minutes of operation in this mode inspect the sightglass 4 If you see bubbles or it appears partially full then this indicates that there is probably a leak 5 When the Temperature Controller is cycling Cool Light cycles on off the sightglass may appear 1 2 to 2 3 full This is normal TestEquit
21. 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 the input line voltage should be measured while the chamber is operating in a continuous HEAT mode to ensure that the expected nominal voltage of either 208 V 5 10 or 230 V 10 is present 208 V Wire T1 to 3 230 V Wire T1 to 4 1234 Control Transformer TR1 Figure 2 1 Location of Input Configuration Terminals on the Electrical Sub Panel Page 2 2 TestEquity 1027S Temperature Chamber Chapter 2 Installation NOTE Refer to Figure 2 1 for the location of the input configuration terminals on the electrical sub panel that are described below 230 V 60 Hz Input Configuration 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 Control Transformer TR1 Wire number T1 must be connected to the 230 V terminal 4 on Control Transformer TR1 208 V 60 Hz Input Configuration 4 Turn the Main Disconnect switch to the OFF position 5 Remove the lower door retaining screw located on the right side Open the lower door 6 Locate the Control Transformer TR1 Wire number T1 must be connected to the 208 V terminal 3 on Control Transformer TR1 Connection to the Power Sour
22. two of the input lines TestEquity 1027S Temperature Chamber Page 2 3 Chapter 3 Operation Chapter 3 Operation Introduction The Front Panel Switches control power to the chamber The Front Panel Lights provide indication of heat and cool functions The Limit Controller is a protection device It turns the chamber OFF if the workspace temperature exceeds either a high temperature or low temperature limit set point The Temperature Controller controls the temperature of the chamber It can function as either a single set point controller or as a programmable profile controller The Temperature Controller automatically turns the refrigeration system on or off based on the demand for cooling CAUTION This chamber has a crankcase heater to protect the 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 1t may be safe to use the chamber immediately this procedure ensures the longest possible life for the compressor if the chamber has been removed from the power source for more than 24 hours Summary of Chamber Operation Turn the Main Disconnect Switch ON Enter the appropriate high and low temperature safety limits on the Limit Controller Enter the desired temperature set point or program on the Temperature Controller Load your test sample in the chamber Turn the Master Switch ON AA SS TestEquity 1027S Temper
23. AUTION IN CAUTION IN CAUTION IN CAUTION IN CAUTION IN CAUTION IN CAUTION Page 1 2 This chamber has a crankcase heater to protect the 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 compressor if the chamber has been removed from the power source for more than 24 hours The Series F4 User s Manual is a general manual 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 F4SH CKAO 01 as described on page A 7 of the Series F4 User s Manual are applicable Cascade Control as described on page 3 6 of the Series F4 User s Manual is not applicable in this configuration The Retransmit function is available as an option The Series F4 Alarm functions are NOT used in the chamber s safety system and are NOT connected TestEquity does NOT recommend using the Series F4 alarm function as the main protection device The independent EZ Zone Limit Controller functions as the main protection device The Series F4 Temperature Controller has been properly configured by TestEquity to match the chamber s system requirements and to perform optimally over a wide rang
24. Decimal 0 Alt 0 0 C_F Cor F Ej Alt P r Lo Range Low 31 Donot make any lower r h Range High 180 Do not make any higher Fag Output 2 Function _ P 9 Do Not Change L da Limit Sides both Alt high High only or LoW Low only L h Y Limit Hysteresis e Change not recommended ALY Alarm Type of F Do Not Change PAr_I Upper Display ACP Alt none PAr e Lower Display LSE Alt Lh s High Set Point or LL S Low Set Point Ad 5 Zone Address 1 Not functional for this application NOTE 1 The Lockout Menu sets the security clearance level as follows 1 Operations Menu read only e Operations Menu set point read write 3 Operations Menu set point read or write same as level 2 4 Operations Menu full access read write required to access Calibration Offset below S Operations Menu and Setup Menu full access required to access Setup Menu and Calibration Offset below Operations Menu Prompt Function Setting Alternate Setting Low Set Point Appropriate Low Limit Set Point High Set Point Appropriate High Limit Set Point Calibration Offset Calibration Offset as required see NOTE 2 below NOTE 2 LoC parameter in Setup Menu must be set for 4 or 5 to access the Calibration Offset parameter TestEquity 1027S Temperature Chamber Page 8 17 Chapter 9 Warrant Chapter 9 Warranty TestEquity LLC Limited Warranty TestEquity LLC TestEquity warrants Environm
25. P8 Digital Outputs P9 Power 1 P10 Digital Inputs P11 Date P12 Custom Message 1 P13 None P14 None P15 None P16 None Static Page Menu Main Page Go to Setup Static Message Message 1 TESTEQUITY 1027S TestEquity 1027S Temperature Chamber Page 8 15 Chapter 8 Maintenance Series F4 Operations Parameters PID Set Channel 1 Menu Main Page Go to Operations Edit PID PID Set Channel 11 PID Set 1 5 Proportional BandA 5 0 C 9 0 if F Reset A 0 05 min Rate A 0 00 min Dead Band A 0 0 C Proportional BandB 5 0 C 9 0 if F Reset B 0 05 min Rate B 0 00 min Dead Band B 0 0 Hysteresis 0 0 Alarm Setpoints Menu Main Page Go to Operations Alarm Setpoints Alarm1 Alarml Low SP 35 0 C 31 0 if F Alarml High SP 175 0 C 347 0 if F Main Page Go to Operations Alarm Setpoints Alarm2 Alarm2 Low SP 35 0 C 31 0 if F Alarm2 High SP 175 0 C 347 0 if F NOTE The alarm outputs of the Temperature Controller are NOT connected to the chamber s safety system TestEquity does NOT recommend using the Temperature Controller s alarm function as the main protection device Series F4 Set Lockout Parameters The Series F4 Controller has several levels of security to prevent unauthorized users from changing critical configuration parameters Only the Set Point and Profile menus have Full Access TestEquity has configured all other menus to Password and have protect
26. TESTEQUITY Model 1027S Temperature Chamber With F4 Controller and EZ Zone Limit Controller 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 Copyright O 2007 2014 TestEquity LLC Rev 1 08 6 02 2014 Table of Contents Chapter 1 Safety Instructions 1 1 Introduction 1 1 Installation Safety Notices 1 1 Operation Safety Notices 1 2 Chapter 2 Installation 2 1 Uncrating 2 1 Preparation For Use 2 1 Installation Location 2 1 Condensate Drain 2 2 Input Power Configuration 2 2 Overview 2 2 230 V 60 Hz Input Configuration 2 3 208 V 60 Hz Input Configuration 2 3 Connection to the Power Source 2 3 Power Source Connection 2 3 Phase Sequence 2 3 Chapter 3 Operation 3 1 Introduction 3 1 Summary of Chamber Operation 3 1 Front Panel Switches and Lights 3 2 Main Disconnect Switch 3 2 Master Switch 3 2 Light Switch 3 2 Heat Light 3 2 Cool Light 3 2 Loading the Chamber 3 3 Port Plugs 3 3 Performance Considerations 3 4 Avoiding Moisture 3 4 Internal Test Fixtures 3 4 Chapter 4 Temperature Controller 4 1 Introduction 4 1 Security Features 4 1 Temperature Controller Keys and Displays 4 2 Main Page 4 3 Static Set Point Control 4 3 Profile Programming 4 4 Step Types 4 4 Ho
27. Terminals H H2 H3 G TB3 Terminals 10 11 12 13 14 Al A2
28. a profile is resumed during a Ramp step the controller uses the Static Set Point from the Main Page to calculate the rate of change needed to get to the set point at the end of the step When a profile is resumed in a soak step the new set point value will be used as the soak value for the time remaining in the step How to Terminate a Running Holding Profile 1 Press the Profile key while the profile is running to enter the Resume Control menu e Then press Aor Y to make your choice for Terminate e Press to select Terminate Hold Profile _ Don t Hold Hold gt Terminate If you manually terminate a running profile the profile ends with a set point of Off This does not turn off the chamber fan The chamber temperature can reach 55 C just from heat generated by the fan and even higher if your test sample is energized See Protecting an Energized Test Sample in Chapter 5 for important information regarding energized test samples How to Delete or Re Name a Profile 1 Go to the Profiles Page Move the cursor down the Main Page to Go to Profiles then press the key Main Page gt Go to Profiles Go to Setup Go to Factory gt 2 Choose Delete or Re Name e Press Aor Y to scroll through your choice e Press to select your choice The controller will prompt you to select the profile you want to delete or re name Main gt Profile__ Edit Profile Delete Profile Re Name Profile
29. 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 Temperature Controller Set Point to 30 C The compressor should turn ON within a few seconds Then the Cool Light should be ON continuously and the Heat Light should be OFF 10 The chamber should cool down to about 25 C and begin controlling Cool Light cycles ON OFF within approximately 15 minutes 11 The chamber temperature should slowly decrease and stabilize to 30 C It should NOT undershoot beyond 30 C by more than a few tenths of a degree and the compressors should NOT need to turn OFF in order to maintain 30 C 12 After stabilization the chamber temperature should vary no more than 0 5 C or a total of 1 13 Set the Temperature Controller Set Point to 23 C The chamber should begin to heat up The compressors should turn off within approximately 1 minute 14 This concludes the chamber performance verification tests 15 Let the chamber heat up to 23 C before turning the Master Switch OFF Page 8 4 TestEquity 10278 Temperature Chamber Chapter 8 Maintenance How to inspect the electrical compartment 1 Disconnect the chamber from the power source 2 Turn the Main Disconnect Switch to the OFF position 3 Remove the lower door retaining screw located on the right side Open the lower door 4 Check for loose components loose wires burned insulation near terminals and burned or ex
30. ain Page Go to Setup Alarm Output 1 2 Name Alarm Type Source Latching Silencing Hysterisis Alarm Sides Alarm Logic Show Message No Process Input 1 Alarm Self Clears Yes 1 7 C 3 0 if F Both Open on Alarm Yes on Main Page NOTE The alarm outputs of the Temperature Controller are NOT connected to the chamber s safety system TestEquity does NOT recommend using the Temperature Controller s alarm function as the main protection device Retransmit Output Menu if retransmit option is ordered Main Page Go to Setup Retransmit Output 1 Retransmit Source Analog Range Low Scale High Scale Scale Offset Set point 1 0 5V 35 0 C 31 0 if F 175 0 C 347 0 if F 0 0 Main Page Go to Setup Retransmit Output 2 Retransmit Source Analog Range Low Scale High Scale Scale Offset Input 1 0 5V 35 0 C 31 0 if F 175 0 C 347 0 if F 0 0 Digital Output Menu Main Page Go to Setup Digital Output 1 7 Name No Function Event Output Main Page Go to Setup Digital Output 8 Function Compressor Comp On Power 2 Comp Off Power 2 Compressor Off Delay 60 sec Compressor On Delay 10 sec Communications Menu Main Page Go to Setup Communications Baud Rate 9600 Address 1 Custom Main Page Menu Main Page Go to Setup Custom Main Page Pl Current File P2 Current Step P3 Set Point 1 P4 Step Type PS Target SP1 P6 WaitFor Status P7 Time Remaining
31. ample 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 be used to remove power to your test sample ifthe Limit Controller s temperature limits are exceeded To prevent damage to your test sample and the chamber s compressors do not exceed the live load rating of the chamber Do NOT put items in the chamber that could burn or explode at high temperatures This chamber uses open wire heating elements which generate surface temperatures over 1000 F This is NOT an explosion proof chamber Do NOT put items in the chamber which can emit corrosive vapors or substances This chamber is NOT a curing oven There are NO provisions for venting fumes The chamber door must remain closed while the chamber is operating If 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 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 TestEquity 1027S Temperature Chamber Page 1 3 Chapter 2 Installation Chapter 2 Installation Uncrating Inspect the shipping container for any signs of visible damage Notify the carrier and TestEquity immediately if there are signs of shipping damage The pallet is designed wi
32. arameters section of this manual CAUTION NEVER select Full Defaults in the Series F4 Factory Test Menu This will erase all the correct values which are documented in the Series F4 Temperature Controller Setup Parameters section of this manual Security Features The Series F4 Controller has several levels of security to prevent unauthorized users from changing critical configuration parameters Only the Set Point and Profile menus have Full Access TestEquity has configured all other menus to Password and have protected them with a password TestEquity does not recommend that these security levels be changed for most applications However there will be times when entry into these menus is necessary For example you may need to gain access to Setup Page in order to change from C to F display or to change the time or date You must call TestEquity at 877 512 3457 or 805 480 0638 to obtain the password TestEquity 1027S Temperature Chamber Page 4 1 Chapter 4 Temperature Controller Temperature Controller Keys and Displays Upper Display Displays actual chamber temperature during operation Displays error information if errors occur Output Indicator Lights 1A Heat Lower Displ sand 1B Cool Displays information about the setup operation and programming of the controller Alarm Output Indicator Lights Lit during an alarm Cursor state Indicates selected Main Pag
33. art up installation or maintenance not in accordance with TestEquity s written procedures 3 Defects or damages resulting from or arising out of abuse misuse neglect intentional damage accident fire flood earthquake or any other act of God This warranty as to Equipment is LIMITED to repair or replacement of parts or Equipment in the determination of TestEquity LLC THE FORGOING LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY TestEquity LLC DISCLAIMS ANY LIABILITY FOR ANY DAMAGES RESULTING FROM DELAY OR LOSS OF USE IN SERVICE OR REPAIR OR FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE USE OR PERFORMANCE OF THE EQUIPMENT EXCEPT AS STATED IN THIS PARAGRAPH This limited warranty cannot be modified in any way except in writing by both TestEquity and Purchaser Invalidation of any one or more of the provisions of this limited warranty shall in no way affect any of the other provisions hereof which remain in full force and effect This limited warranty shall be extended only to the first Purchaser of this Equipment and is not transferable TestEquity 1027S Temperature Chamber Page 9 1 Chapter 10 Drawings Chapter 10 Drawings TestEquity 1027S Temperature Chamber Page 10 1 Electrical Subpanel Component Location FNQ R 4 FNQ R 20 LP CC 20 Control F7 Transformer TR1 Switch DSW TB2
34. ature Chamber Page 3 1 Chapter 3 Operation Front Panel Switches and Lights Main Disconnect Switch The Main Disconnect Switch controls power to the entire chamber and provides a mechanical safety interlock to the lower door In the ON position clockwise primary power is connected The Temperature Controller Limit Controller and optional Chart Recorder are always functional when the Main Disconnect Switch is ON regardless of the Master Switch position The Main Disconnect Switch should be left ON if the chamber is usually used on a daily basis In the OFF position counter clockwise primary power is disconnected The Main Disconnect Switch can be left OFF if the chamber is not used on a daily basis It can also be locked in the OFF position with a padlock The knob has a red insert that can be pushed in at the top to reveal the lock hole CAUTION This chamber has a crankcase heater to protect the 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 compressor if the chamber has been removed from the power source for more than 24 hours Master Switch The Master Switch enables all chamber functions The Master Switch illuminates when it is ON Light Switch The Light Switch controls the workspace light The Light Switch
35. ave been properly configured by TestEquity to match the chamber s system requirements and to perform optimally over a wide range of operating conditions Improper modifications to these values can result in erratic performance and unreliable operation Do not attempt to modify the PID values unless you thoroughly understand what you are doing Setup examples in the Series F4 User s Manual are NOT applicable to this chamber If there is any doubt please call TestEquity before proceeding The correct values are documented in the Series F4 Temperature Controller Setup Parameters section of this manual ZA CAUTION The Autotune PID function is not appropriate for use in this chamber Using this function will result in tuning values that will not work correctly Setup Page The Setup Page provides access to menus for configuring the controller hardware TestEquity has configured the security to require a password for access to the Setup Page However there will be times when entry into these menus is necessary For example you may need to gain access to Setup Page in order to change from C to F display or to change the time or date You must call TestEquity at 877 512 3457 or 805 480 0638 to obtain the password CAUTION The Series F4 Temperature Controller setup values have been properly configured by TestEquity to match the chamber s system requirements and to perform optimally over a wide range of operating conditions Imp
36. ce A CAUTION This chamber should be connected to the AC power source by a qualified electrician who is familiar with industrial plant wiring The Main Disconnect Switch on the front panel removes primary power to the entire chamber All branch 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 input wire through the hole on the rear of the chamber using an appropriate bushing An additional 5 feet of wire will be needed need to reach to the terminals on the electrical subpanel The wires will need to pass through the Input Access Hole This hole is located 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 tie wraps 5 Connect the Hot input wires to terminals L1 L2 and L3 on the Main Disconnect Switch Connect the Ground wire NOT A NEUTRAL to the Ground terminal Phase Sequence This chamber has a protective circuit to ensure the proper input power phase sequence If the chamber does not function with the initial wiring hookup then reverse
37. cessively pitted contacts on contactors How to clean the condenser 1 Disconnect the chamber from the power source 2 Turn the Main Discomnect Switch to the OFF position 3 Remove the lower door retaining screw located on the right side Open the lower door 4 Clean the condenser and desuperheater fins with a vacuum cleaner NOTE You may need to clean the condenser more frequently if the chamber is in a dusty environment You may be able to clean the condenser less frequently if the chamber is in a very clean environment How to verify the calibration TestEquity recommends verifying the calibration before attempting to actually perform a calibration The state of the art instrumentation used in TestEquity chambers is of the highest quality and seldom goes out of calibration If you try to calibrate the instrumentation before determining that calibration is necessary you may make it worse 1f done incorrectly Variations in temperature throughout the chamber interior is NOT a measurement of 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 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 See
38. control sensor which is located in the discharge airflow Control tolerance is a measure of how much the temperature varies after stabilization at the control sensor It is a measure of the relative variations NOT the absolute accuracy of the readout The control tolerance specification for this chamber is 0 5 C or a total of 1 C For example 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 effect the control variations In some instances the test sample will reduce these variations Uniformity Also known as Gradients This is a measure of variations in temperature at different locations throughout the chamber interior at the same time after stabilization The uniformity specification for this chamber is 1 0 C or a total of 2 C when measured at least 2 away from the chamber interior walls These specifications are for an empty chamber The addition of a test sample may affect the temperature uniformity For example an energized test sample will produce a higher temperature near the sample Controller Accuracy This is the ability of the temperature controller to accurately display a temperature measurement when compared to a standard The controller display accuracy is 1 66 C However the total measuremen
39. e Recommended Spare Parts Replacement parts are available from TestEquity Parts are generally in stock and ready for immediate shipment Next day delivery is always available If you cannot risk 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 Switches Refrigeration Parts Solenoid Valves Expansion Valves Regulator Valves TestEquity 1027S Temperature Chamber Page 8 11 Chapter 8 Maintenance Major Electrical Parts Description Mfr Mfr Part No Ref Part Qty UOM Appliance Light 40W 120V Generic Generic LTI 300096 1 ea Arc Suppressor ITW Paktron 104M06QC100 AS1 2 200115 2 ea Audible Alarm Floyd Bell MC 09 201 Q ALI 200005 1 ea Circulator Motor Kit CUSTOM CUSTOM FM3 4 100575 2 ea Contactor 3 P 304 Hartland HCC 3XT02SX Cl 2 200245 2 ea Control Transformer Hammond PH350MLI TRI 200219 1 ea Disconnect Switch 3 Pole 45A ABB OT63F3 DSW 200281 1 ea Fuse 20A Bussman FNQ R 20 F4 6 200242 3 ea Fuse 20A Bussman LP CC 20 F7 9 200206 3 ea Fuse 3A Bussman FNM 3 F3 200186 1
40. e parameter or present value in memory Moves via the four gt SP1 Digital Out_ Power1 Communications Indicator Light Lit pulsates when navigation keys 9 the controller sends or receives valid Profile Indicator Light data Lit when a ramping u profile runs When blinking the profile is on hold When not lit the controller operates as a static set point Appears when the Up or Down Keys can reveal more information in the Lower Display controller Profile Key Information Key Left and Right Keys Up and Down Keys Enters the profile menu to Provides information Move right to select the Move the cursor position in the in the Lower Display choice to the right of the Lower Display through the about the cursor cursor and proceed menus in the direction of the key selected parameter tothe next screen arrow Increase or decrease a Another press toggles Move left to exit value or change a letter in a the display back to user nameable field such as the parameter events and profile names start hold resume or terminate a profile Figure 4 1 Temperature Controller Keys and Displays To navigate through the menus 1 Use the A or Y key to move the cursor to line up with the item to be selected in a menu on the lower display Press the key to select the item Enter or change the value or make a choice with the A or Y key Press the key to enter the value or choice i E Repeat until you
41. e program by holding at 23 C so this step would be to go to 23 C The final step of every profile is End You cannot delete an End step or change it to another type but you can insert new steps before it TestEquity recommends having the end step type to be Hold or Idle TestEquity does NOT recommend using an end step type of All Off or Control Off This does not turn off the chamber fan The chamber temperature can reach 55 C just from heat generated by the fan and even higher if your test sample is energized See Protecting an Energized Test Sample in Chapter 5 for important information regarding energized test samples Profile Key The Profile key Initiates the profile mode Initiates the Hold profile state Initiates the Resume profile command Initiates the Terminate profile command The Profile Key functions only from the Main Page How to Start a Profile To initiate the profile mode press the Profile key and answer the questions that follow 1 Press the Profile key to enter the Profile Control Start a Profile menu The Profile Indicator will begin blinking Press the A key for Yes v No A Yes 2 Select the desired stored profile Start Profile Press the Aor Y to scroll through the list of Profilet stored profiles gt Profile2 i e Press to select the desired profile Profile3 v 3 Select the desired step to start on Start e Press the Aor Y to scroll through the list of
42. e SV1 may be defective in closed position R 404A pressure switch DPS1 trips Trips shortly after turn on Trips after operating for a while Ambient temperature may be too high Low charge leak Dirty condenser inadequate clearance from back of chamber to the wall R 404A hot gas bypass regulator may be defective or set too low Page 8 8 TestEquity 1027S Temperature Chamber Chapter 8 Maintenance SYMPTOM CONDITION CAUSES Sightglass has bubbles or looks not full During all running conditions Only when cool light is cycling Low charge leak No problem This is normal Cools too slow No bubbles in sightglass Chamber interior is overloaded Test sample is energized giving off heat Port plug is not in port Ambient temperature is too high Cools all the time When cool light is OFF Solenoid valve SV1 may be defective in open position Does not reach 35 C Sightglass looks full Chamber is empty Port plug is not in port Door is not sealing completely Ice on evaporator Ambient temperature is too high Tuning PID control parameters are incorrect Hot gas bypass regulator may be defective or set too high Solenoid valve SV2 may be defective in open position Temperature varies more than 0 5 C or 1 C total If tuning PID control parameters in temperature controller were changed If tuning PID control parameters
43. e name of the profile Choose to Name No gt Yes Enter Profile Name _ PROFILE1 A Y Adjusts Char Save Changes 4 Choose the step type e There are six step types each of which must be defined through different parameters See Step Types earlier in this chapter Choose Step1 Type Autostart gt Ramp time a Ramp Rate v 5 Define each step type e The Series F4 prompts you to define the parameters of each step type See Step Types earlier in this chapter Choose to wait o gt Step does not wait Step waits for Enter Ramp Time o 00 00 01 H M S A Y Adjusts Digit lt gt Save Changes Enter Chi SP _ 85 0 C A v Adjusts Value lt Back gt Next 6 Choose the end state All profiles end with an End step which is preprogrammed into the new profile See End Step earlier in this chapter Choose End State Control Off All Off gt Idle gt 7 Save your settings e Press lt to exit the Profiles Page e After exiting the Profiles Page choose A to save profile data Save profile data or restore values Y Restore A Save Page 4 6 TestEquity 1027S Temperature Chamber Chapter 4 Temperature Controller Programming Hints The first step in a program should be an initialization step of 1 second usually at a set point of 23 C The next to last step establishes a condition to end on For example you may want to end th
44. e of operating conditions Improper modifications to these setup values can result in erratic performance and unreliable operation Setup examples in the Series F4 User s Manual are NOT applicable to this chamber Do not attempt to modify the setup values unless you thoroughly understand what you are doing If there is any doubt please call TestEquity before proceeding NEVER select Full Defaults in the Series F4 Controller s Factory Test Menu This will erase all the correct values which are documented in the Series F4 Temperature Controller Setup Parameters section of this manual 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 unreliable and unsafe operation 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 Always verify that the Limit Controller s high and low limits are set to temperatures that are appropriate for your test sample TestEquity 1027S Temperature Chamber Chapter 1 Safety IN CAUTION IN CAUTION IN WARNING IN WARNING IN WARNING IN WARNING IN WARNING If your test sample is energized it may be capable of raising the workspace temperature beyond safe limits This could occur if your test s
45. ed them with a password TestEquity does not recommend that these security levels be changed for most applications However there will be times when Full Access is necessary For example you may need to gain access to Setup Page in order to change from C to F display or to change the time or date You must call TestEquity at 877 512 3457 or 805 480 0638 to obtain the password Set Lockout Menu Main Page Go to Factory Set Lockout Set Point Full Access Oper Autotune PID Password Oper Edit PID Password Oper Alarm SP Password Profile Full Access Setup Password Factory Password Page 8 16 TestEquity 1027S Temperature Chamber Chapter 8 Maintenance EZ Zone Limit Controller Setup Parameters 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 erratic performance and unreliable operation Do not attempt to modify the setup values unless you thoroughly understand what you are doing If there is any doubt please call TestEquity before proceeding Setup Menu Prompt Function Setting Alternate Setting i of Lockout Menu el See NOTE 1 below En Sensor Type C Do Not Change L im Linearization amp Do Not Change dEL
46. ely 125 C after cleaning This helps to bake out any residue Remove the port plugs to permit the residual vapors to escape e Clean the silicone door gaskets with a damp cloth or mild detergent e Clean the exterior painted surfaces with a damp cloth or mild detergent If you are using a detergent test a small inconspicuous area to make sure it does not damage the finish How to listen for abnormal noise or vibration You should become familiar with normal operating noises 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 e Circulator motor and fan noises with compressors off e Compressor start up and running noises sequential starting of compressors e Condenser fan noises e Relay and valve cycling noises when cool light is cycling How to inspect the door seal The door has two silicone gaskets to minimize thermal losses and moisture migration e Inspect the gaskets for dirt and tears e Repair minor tears with a high quality RTV silicone such as GE RTV167 e Check the integrity of the door seal by closing the door on a sheet of paper With the door closed slowly pull the paper You should feel the resistance getting lighter as the paper goes past the inner gasket Repeat this all around the door at several places e If the seal is not tight adjust the door latch The stainless steel catch on
47. ental Chambers Equipment manufactured by TestEquity and supplied under this contract to be free from defects in materials and workmanship under normal use and proper maintenance TestEquity will repair or replace any defective part for a period of THREE YEARS from the date of invoice TestEquity reserves the right to require any defective part be returned freight prepaid to TestEquity s factory or to inspect any defective part at the Purchaser s site TestEquity shall have sole discretion to determine whether any part is defective and whether any defective part will be repaired or replaced This limited warranty shall extend to any standard chamber accessory and component part which is normally sold by TestEquity Non standard accessories and component parts specified by the Purchaser shall be warranted only to the extent of the original manufacturer s warranty 1f any exists If the repair or replacement is performed in the FIRST YEAR from the date of invoice TestEquity will also pay for the labor associated with the repair at the Purchaser s site subject to TestEquity s prior approval During the SECOND and THIRD YEAR of the warranty period Purchaser will be responsible for the installation and cost of installation of replacement or repaired parts Purchaser shall notify TestEquity in writing of any alleged defect within 10 days after its discovery within the warranty period TestEquity reserves the right to satisfy the labor portion of t
48. epare it for operation Perform ALL the steps in the Preventive Maintenance Schedule before placing the chamber back into service This will ensure that nothing has been damaged and that a leak has not developed This chamber has a crankcase heater to protect the 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 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 necessary refrigerants and may not be familiar with the microprocessor based controls This chamber should only be serviced by a qualified mechanic that is familiar with low temperature cascade refrigeration systems Call TestEquity to recommend one in your area or to check if the one you would like to use is qualified Can Should I put a filter in front of the condenser air inlet No TestEquity does not recommend this Just follow the maintenance procedures and clean the condenser fins periodically How often should I charge the refrigeration syste
49. from the 208 230 VAC input line All line branch circuits are individually fused A stepdown transformer provides 115 VAC for all instrumentation and control elements Refer to the electrical and refrigeration drawings to identify the referenced items described below Heating System 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 HL1 2 3 provide failsafe protection against a catastrophic failure by opening the heater circuits 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 Master Switch the safety relay CR3 and the phase control relay PCR1 CR3 is controlled by the temperature limit controller TCR2 If either the high or low temperature safety limits are exceeded TCR2 turns off CR3 which turns off C1 PCR1 will disable CR1 if the input power phase sequence is incorrect Refrigeration System 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
50. his limited warranty either through its own service personnel or an authorized agent In order to provide expeditious service TestEquity reserves the right to satisfy its limited warranty obligation by sending replacement parts to be installed by the Purchaser if they can be installed easily without special tools or training TestEquity reserves the right to satisfy this limited warranty by requiring 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 States and Canada For all other locations Purchaser is responsible for all labor costs for repairs or parts installation and for all shipping costs associated with providing replacement parts This limited warranty does not cover 1 Defects or damages arising as the result of shipment by common carriers or private transportation unless TestEquity undertakes shipment and transportation of the Equipment to Purchaser s site or contractually assumes the risk of damage to the Equipment in shipment 2 Defects or damages arising out of or as the result of mishandling modification or improper start up installation or maintenance of the Equipment including st
51. in connection on the rear of the chamber This provides a way to remove condensate that may accumulate in the chamber during low to high temperature cycling or when the refrigeration system runs to maintain moderate temperatures Any time the ambient air is subjected to temperatures below the dew point moisture will condense out of the air The effect is ice or frost during low temperature operation When the chamber is heated above 0 C the ice or frost will turn into water The fitting accommodates a 12 inch male pipe thread The chamber drain water is not under pressure and is fed by gravity Therefore it must empty into an open floor drain Alternatively the chamber drain can empty into a condensate pump You can purchase a condensate pump from suppliers such as Grainger www grainger com Input Power Configuration 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 input voltage configuration prior to installation or to change the input voltage from one configuration to another Z CAUTION This chamber must be properly configured for either 208 V or 230 V nominal input 208 V and 230 V are NOT
52. ion or the parameter whose value appears in the Up Down Keys O rw When in a menu scrolls through available options for any given prompt In other menus can change set points upper display and modify the upper display to a higher or lower value EZ Key RESET Key Advance Key O Resets the limit after a Returns to the Home Page or Advances through the trip condition has cleared Resets the limit after a trip parameter prompts condition has cleared Figure 5 1 Limit Controller Keys and Displays How to Set the High and Low Temperature Safety Limits 1 Press the O key once to get the prompt in the lower display This is the Low Limit Set Point prompt 2 Press the Aor Y key to enter the desired Low Limit Set Point in the upper display Make sure it is lower than your actual chamber temperature set point and at least below room temperature to prevent nuisance tripping 3 Press the O key once again to get the prompt in the lower display This is the High Limit Set Point prompt 4 Press the Aor Y key to enter the desired High Limit Set Point in the upper display Make sure it is higher than your actual chamber temperature set point to prevent nuisance tripping 5 Press the RESET Key to return to the Home Page The upper display will show the actual chamber temperature while the lower display will show as long as the limits are not exceeded Resetting an Out of Limit Condition If the limit is exceeded the Limit Contro
53. ked in from the bottom and exits from the top 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 should be used to evenly distribute the load Verify that the temperature gradients are within acceptable limits by measuring the chamber temperature at strategic points using a multipoint thermocouple meter or data logger You may find that the temperature throughout the chamber is even but always different from what the temperature controller indicates 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 NOT by recalibrating the controller Avoiding Moisture Any time the ambient air is subjected to temperatures below the dew point moisture will condense out of the air The effect is ice or frost 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 before
54. l The optional Ethernet interface model TE 1055 consists of an external converter box that connects to the chamber s RS 232C interface Ethernet programming resources can be downloaded http www testequity com ETHERNET TestEquity 1027S Temperature Chamber Page 4 13 Chapter 5 Limit Controller Chapter 5 Limit Controller Introduction The EZ Zone Limit Controller is a protection device It turns the chamber OFF if the workspace temperature exceeds either a high temperature or low temperature limit You can set these limits to correspond to the maximum and minimum temperature that your test sample can safely withstand This provides protection against someone setting the F4 Controller to a temperature that is unsafe for the test sample It also provides protection in the unlikely event of a chamber system component failure The Limit Controller has its own temperature sensor thermocouple and functions completely independent of the F4 Controller This section provides a brief overview on how to operate the Limit Controller For more detailed instructions see the EZ Zone User s Manual CAUTION The EZ Zone User s Manual is a general manual 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 PM6LIAJ AAAABAA are applicable CAUTION The EZ Zone Limit Controller has been properly configu
55. ller alternately cycles the low stage liquid line solenoid valve SV1 and the hot gas solenoid valve SV2 ON OFF through cool relay CR1 to control the chamber temperature When SV1 is ON liquid refrigerant flows through the thermostatic expansion valve and evaporator to cool the chamber When SV1 is OFF the flow stops High pressure vapor feeds the hot gas regulator through SV2 which meters a precise amount into the suction line to maintain a minimum load on the system and keep it out of a vacuum The hot gas regulator is adjusted to keep the suction pressure at 2 PSIG when SV1 is OFF Pilot Light PL2 provides an indication on the front panel when SV1 is ON 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 DPS1 turns off the entire refrigeration system in the event of an out of limit condition The compressor is also protected by an internal overload device The compressor has a crankcase heater CC1 to prevent refrigerant from condensing in the oil when the compressor is off The compressor rotation is phase sensitive A phase control relay PCR1 ensures that the chamber can operate only if the i
56. ller will flash high limit or low limit in the upper display and in the lower display alternating with the actual chamber temperature in the upper display and in the lower display It will also shut down all chamber functions The Limit Controller cannot be reset until the temperature returns to within the limit set points Then you must press the RESET or EZ Key to resume normal operation Silencing the Audible Alarm Turning offthe MASTER switch on the chamber front panel lets you temporarily turn off the Audible Alarm even though the High or Low Limit condition may still exist Page 5 2 TestEquity 1027S Temperature Chamber Chapter 5 Limit Controller Protecting an Energized Test Sample If your test sample is energized 1t 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 safety contacts 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 terminal block TB3 on the electrical sub panel Connections
57. m This chamber uses a closed loop refrigeration system Just like your refrigerator at home 1t does not need periodic charging If the charge is low this means that there is a leak Leaks should be repaired before recharging What kind of Freon does the chamber use The word Freon is a DuPont registered trade name for their CFC based refrigerants and is incorrectly used as a generic term for refrigerants TestEquity chambers do not use CFC based refrigerants The refrigeration system uses R 404A which is also known as DuPont Suva HP62 TestEquity 1027S Temperature Chamber Page 6 3 Chapter 7 Specifications Chapter 7 Specifications Model 1027S Chamber Specifications Temperature Range 35 C to 175 C Control Tolerance 0 5 C 0 2 C Typical Measured at the control sensor after stabilization Uniformity 1 0 C Variations throughout the chamber after stabilization Live Load Capacity 23 C 0 C 10 C 20 C 30 C 4000 W 2800W 2300 W 1800W 1250W Cool Down Transition Time empty chamber End Temp Start Tempto gt 23 C 0 C 10 C 20 C 30 C 35 C 423 C wee 1 min 2 min 4 min 9min Ultimate 85 C 7min 7 5 min 10 min 13 min 19 min Ultimate 150 C 9 min 14 min 17 min 20 min 26 min Ultimate Cool Down Transition Time 80 Ib static aluminum load End Temp Start Tempto gt 23 C 0 C 10 C 20 C 30 C 35 C 85 C 8 min 16 min 20 min 25 min 33 min Ultimate Heat Up Transition Time em
58. m both the left and right side and 24 from the rear ZA CAUTION This chamber is designed for operation 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 available from TestEquity at no charge ZA 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 the input line voltage should be measured while the chamber is operating in the COOL mode to ensure that the expected nominal voltage of either 208 V 5 10 or 230 V 10 is present Operation below 198 V or greater than 253 V requires internal transformers which can be supplied for a nominal charge A CAUTION This chamber should be connected to the AC power source by a qualified electrician who is familiar with industrial plant wiring TestEquity 1027S Temperature Chamber Page 1 1 Chapter 1 Safety Operation Safety Notices IN C
59. n configured to Off by TestEquity so this option will not show unless reconfigured Guaranteed Soak step option The use of Guaranteed Soak in a profile is optional The Guaranteed Soak step requires the chamber temperature to be at the set point temperature within the Guaranteed Soak Band value before the time clock and the step activity proceeds The Guaranteed Soak Band is configured by TestEquity for 3 0 C and this can be changed in the System Menu TestEquity 1027S Temperature Chamber Page 4 5 Chapter 4 Temperature Controller How to Program a New Profile 1 Go to the Profiles Page Move the cursor down the Main Page to Go to Profiles then press the key Main Page gt Go to Profiles Go to Setup Go to Factory gt 2 Create a new Profile The cursor will be on Create Profile Press the gt key Main gt Profile__ gt Create Profile Edit Profile Delete Profile lt 3 Name the profile You can name your profiles for easy reference if desired Names can have up to 10 characters You can also use one of the default profile names ex Profile1 and skip this step To name a profile e Press to enter the name space and the first position e Press the Aor Y to scroll through the alphabet and stop at the letter or number desired e Press to move to the next position e Continue until the name is complete or until you move through the name space into the next screen e Press to save th
60. n performance TestEquity does NOT recommend using CO2 or LN2 in this chamber to achieve faster cooling due to reliability and safety considerations so it is NOT an available option Modifying the chamber to add CO2 or LN2 will void the warranty TestEquity 1027S Temperature Chamber Page 6 1 Chapter 6 Frequently Asked Questions Why is there water ice snow in the chamber Any time the ambient air is subjected to temperatures below the dew point moisture will condense out of the air The effect is ice or frost during low temperature operation When the chamber is heated above 0 C the ice or frost will turn into water 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 before removing your test sample My test specification requires convection heat only Can I turn the circulator motor off NO This will damage the heating and refrigeration systems and void the warranty You need a gravity convection oven for that kind of test How accurate is the chamber That s a loaded question There is no chamber accuracy specification as such The answer requires an understanding of several performance parameters Control Tolerance The Temperature Controller uses a thermocouple
61. nput power phase sequence is correct The temperature controller has internal logic to turn the compressors on if cooling is required to maintain the temperature set point TestEquity 1027S Temperature Chamber Page 8 7 Chapter 8 Maintenance Troubleshooting SYMPTOM CONDITION CAUSES Chamber completely Power is applied to chamber but Incorrect phase sequence inoperative nothing lights up Reverse two of the input lines Control fuse F3 open Likely cause is shorted solenoid coil on SV1 or SV2 Does not heat up at all If controller light 1A is ON circulator fan is ON the Heat light is OFF If controller light 1A is ON circulator fan is ON the Heat Solid State Relay SSRlor SSR2 is defective At least two Heat Limiters HL are open light is ON Heats up too slow Does not meet published Chamber interior is overloaded specifications Port plug is not in port Verify that input voltage is within tolerance One heat limiter HL or one heater winding is open Heat is on all the time If temperature controller light 1A is OFF the Heat light is ON Solid State Relay SSR1 or SSR2 is defective Heater is shorted to chassis Does not cool at all If temperature controller light 1B is ON the Cool light is OFF both compressors are OFF If temperature controller light 1B is ON the Cool light is ON both compressors are ON Pressure switch DPS1 or DPS2 is tripped Solenoid valv
62. nt severe burns or frostbite Protective gloves are recommended 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 be used to remove power to your test sample if the Limit Controller s temperature limits are exceeded 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 Model 1027S Temp 23 C 0 C 10 C 20 C 30 C Watts 4000 W 2800 W 2300 W 1800 W 1250 W Port Plugs Foam port plugs are provided with a gray silicone surface on one side The port plug must be inserted with the gray silicone surface facing the inside of the chamber Port plugs should be considered expendable and be replaced when they no longer provide a good seal TestEquity 1027S Temperature Chamber Page 3 3 Chapter 3 Operation Performance Considerations The performance of all chambers is significantly affected by the characteristics of your test sample Factors include size weight material shape and power dissipation if energized The test sample should be placed in the chamber in a manner that allows for air circulation The air plenum is located on the back wall of the chamber where air is suc
63. p Rate gt Off gt gt gt gt gt gt 1 0 0 0 1 5 Soak gt Of a A A BS 01 00 00 1 No 6 Jump gt gt gt gt gt gt gt gt Name 2 99 7 Ramp Rate gt Off gt gt gt gt gt gt 1 0 23 0 1 8 End Idle 23 0 Step Description 1 Establishes a recommended initialization step Goes to 23 C as quickly as possible Test sample is turned ON via Event 1 2 Goes to 50 C at a controlled rate of 1 C per minute Test sample is turned ON via Event 1 3 Will hold for 1 hour Test sample remains ON via Event 1 4 Goes to 0 C at a controlled rate of 1 C per minute Test sample is turned OFF via Event 1 5 Will hold for 1 hour Test sample remains OFF via Event 1 6 Jumps back to step 2 Repeats this 3 times for a total of 4 cycles 7 After all cycles are completed establishes the condition to end on Goes to 23 C at a controlled rate of 1 C per minute Test sample is turned OFF via Event 1 8 End of program Controller returns to a 23 C manual set point Test sample is remains OFF via Event 1 Notes m Guaranteed Soak Band is set at the factory for 3 0 C Can be changed in the System Menu gt Means no entry or selection is required Just scroll through this prompt to the next prompt EN Means prompt does not show for this step type Ax Chapter 4 Temperature Controller Digital Event Outputs The Temperature Controller has digital outputs which can be configured as Event Outputs to tu
64. page 6 2 of the Series F4 User s Manual for details Calibration verification should be performed with the Calibration Offset set to 0 0 zero The F4 Temperature Controller accuracy is specified 1 55 C above 50 C Total system accuracy in the chamber includes the controller plus the thermocouple wire accuracy of 1 0 C Total system accuracy over the chamber s operating range is can be as much as 2 55 C although it is typically better than 1 0 C The easiest way to verify the instrumentation accuracy is with an independent calibrated temperature sensor and display Place the sensor near the chamber s sensors which are located towards the right side of the conditioner fan grille If the readings agree within the specified limits above then no calibration adjustments are necessary If calibration of the temperature controller is necessary refer to page 9 2 of the Series F4 User s Manual and follow the instructions for Thermocouple Input Procedure TestEquity 1027S Temperature Chamber Page 8 5 Chapter 8 Maintenance Theory of Operation Overview The chamber is heated by an open element nichrome heater Cooling is accomplished by a single stage refrigeration system The air is circulated by a propeller fan The heater evaporator cooling coil and fan are located within an air plenum which is on the back wall of the chamber interior The heater compressor and circulator fan motor operate directly
65. pty chamber End Temp Start Temp to gt 23 C 50 C 85 C 125 C 150 C 175 C 423 C wee 1 5 min 7 min 14 min 20 min 25 min 0 C 1 5min 3 5 min 13 min 20 min 23 min 31 min 10 C 2 2min 4 2 min 14 min 22 min 25 min 33 min 35 C 5 5 min 10 min 16 min 23 min 29 min 34 min Note Transition times are measured after a 2 hour soak at the start temperature To calculate rate of change for a particular condition take the difference between the Start Temp and End Temp and divide by the Transition Time Cool Down Example empty From 85 C to 10 C 95 C 10 min 9 5 C min Cool Down Example 80 Ib From 85 C to 10 C 95 C 20 min 4 75 C min Heat Up Example empty From 35 C to 85 C 120 C 16 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 26 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 Workspace Dimensions 40 W x 32 H x 36 5 D 27 cubic feet Outside Dimensions 49 W x 73 25 H x 63 D nominal Door latch adds 3 to width on right side Circulator motor housing adds 6 to height Min Installed Clearance 12 from the left and right side 24 from the rear Access Ports 4 Port on left and right side two total Supplied with foam plugs Weight 1600 pounds NOTE Performance is typical and
66. r Profile Programming The Series F4 Temperature Controller can be programmed to store up to 256 steps into as many as 10 profiles You do not need a computer to enter a profile it can be easily done through the controller s front panel keys A Profile is a set of instructions programmed as a sequence of steps The controller handles the profile steps automatically in sequence As many as 40 different profiles and a total of 256 steps can be stored in non volatile memory The 256 steps are grouped by profile So one profile could have 256 steps or 39 profiles could have 6 steps and one could have 22 or 32 profiles could have eight steps each The maximum number of steps is 256 and the maximum number of profiles is 40 Step Types Use the six available step types Autostart Ramp Time Ramp Rate Soak Jump and End to create simple or complex profiles involving all inputs and outputs The Series F4 prompts you to define each step s properties Autostart Step The use of an Autostart step in a profile is optional Autostart pauses a profile until the specified date or day and time of a 24 hour clock Define the Autostart by choosing e Day of the week or Date e Time To invoke an Autostart step in a profile you must activate the profile via the Profile Key and select the Autostart step Ramp Time Step Ramp Time changes the set point to a new value in a chosen period of time Define the Ramp Time step by choosing
67. r this chamber If you select Full Defaults you must reconfigure all System and Operation Parameters as documented in the TestEquity manual NOT the Series F4 User s Manual TestEquity has configured the Temperature Controller with the parameters as documented on the following pages Page 8 14 TestEquity 1027S Temperature Chamber Chapter 8 Maintenance Series F4 Setup Parameters System Menu Main Page Go to Setup System GSB 1 Source Input 1 Guar Soak Band 1 3 0 C 5 4 if F Current Time local time Current Date local date PID Units US Reset Rate F or C C Show F or C Yes Upper Display Ch1 Autotune SP 90 Input 1 Fail 0 Open Loop Chl Off Power Out Time 10 Sec Power Out Action Continue Analog Input Menu Main Page Go to Setup Analog Input1 Sensor Thermocouple Type T Decimal 0 0 SP Low Limit SP High Limit 35 0 C 31 0 if F 175 0 C 347 0 if F Calibration Offset 0 0 Filter Time 1 0 sec Error Latch Self Clear Digital Input Menus Main Page Go to Setup Digital Input 1 4 Name No Function Off Control Output Menus Main Page Go to Setup Control Output 1A Function Heat Choose Cycle Time Fixed Time Enter Cycle Time 3 0 sec Hi Power Limit 100 Low Power Limit 0 Main Page Go to Setup Control Output 1B Function Cool Choose Cycle Time Fixed Time Enter Cycle Time 6 0 sec Hi Power Limit 100 Low Power Limit 0 Alarm Output Menus M
68. rameters IN CAUTION Al CAUTION AX CAUTION Al CAUTION The Series F4 User s Manual is a general manual 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 F4SH CKAO 01 as described on page A 7 of the Series F4 User s Manual are applicable Cascade Control as described on page 3 6 of the Series F4 User s Manual is not applicable in this configuration The Retransmit function is available as an option The Series F4 Temperature Controller has been properly configured by TestEquity to match the chamber s system requirements and to perform optimally over a wide range of operating conditions Improper modifications to these setup values can result in erratic performance and unreliable operation Setup examples in the Series F4 User s Manual are NOT applicable to this chamber Do not attempt to modify the setup values unless you thoroughly understand what you are doing If there is any doubt please call TestEquity before proceeding The alarm outputs of the Temperature Controller are NOT connected to the chamber s safety system TestEquity does NOT recommend using the Temperature Controller s alarm function as the main protection device NEVER select Full Defaults in the Factory Test Menu Full Defaults are NOT the TestEquity configuration parameters fo
69. red by TestEquity to match the chamber s system requirements Improper modifications to these setup values can result in unreliable and unsafe operation 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 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 be used to remove power to your test sample if the Limit Controller s temperature limits are exceeded TestEquity 1027S Temperature Chamber Page 5 1 Chapter 5 Limit Controller Limit Controller Keys and Displays Temperature Units Indicator Indicates whether the temperature is Upper Display displayed in Fahrenheit or Celsius Indicates the actual chamber temperature or displays the value of the parameter in the lower display EZ ZONE Output Indicator Lit when the limit setting is exceeded Only light 2 is applicable for this configuration Lower Display Indicates SAFE during normal operation or FA L Jin an out of limit condit
70. removing your test sample Internal Test Fixtures Some applications require internal fixtures to support test samples and provide a convenient method of connecting wires and sensors Fixtures must be designed to minimize their impact on chamber functionality and performance Fixtures should be designed for easy removal to permit maintenance and cleaning of the chamber The chamber liner should never be drilled or screwed into This will compromise the integrity of the liner and permit moisture migration due to condensation into the insulation which will eventually impact performance and lead to premature rusting of the outer cabinet Fixtures should be constructed of stainless steel This also applies to all screws and fasteners All welds should be passivated To prevent rust and corrosion never use iron or mild steel even if it is painted or plated Aluminum may be used However since the specific heat of aluminum is double that of steel it represents a greater load and will have more impact on the chamber performance Make sure that all connectors wiring pc boards and auxiliary components can withstand the temperature extremes that they will be subjected to In some cases these components may not be able to last after repeated tests and should be considered expendable Page 3 4 TestEquity 1027S Temperature Chamber Chapter 4 Temperature Controller Chapter 4 Temperature Controller Introduction The Series F4 Temperature
71. return to the original list The key again saves the value and proceeds to the next parameter in the series The lt key saves the value and backs out of the series and returns to the Main Page To edit a parameter proceed through the series using the key without changing values until you find the parameter you want to change After making the change with the with the A or Y key you may back using the key out or proceed using the key to the end of the series Page 4 2 TestEquity 1027S Temperature Chamber Chapter 4 Temperature Controller Main Page The Main Page displays manual operating parameters running program parameters and error messages It also provides access to the Operations Profiles Setup and Factory pages The following is a list of Main Page parameters and the description of their functions Main Page Current File Displayed if running a profile the name of the profile Current Step Displayed if running a profile the current step of the profile gt SP1 Static manual temperature set point entry If running a profile the current set point Step Type Displayed if running a profile the type of step Target SP1 Displayed if running a profile the target temperature during a ramp step WaitFor Status Displayed if running a profile the status during a WairFor step Time Remaining Displayed if running a profile the remaining time of the current step DigitalOut Status of the event outputs 1 to 8 An
72. rn remote devices on and off There are seven Event Outputs which are available for customer use Output number eight is configured to control the refrigeration compressors and is not available for customer use The Event Outputs are accessed from the Main Page To control the Event Outputs 1 Press the Aor Y key to position the Cursor next to the DigitalOut prompt 2 Press the key once You will see Choose Event Output prompt in the lower display 3 Press the Aor Y key to position the Cursor next to the EventOutput prompt which you want to change You will be able to select from EventOutput1 through EventOutput 7 4 Press the key once to select the desired EventOutput Then press the Aor Y key to select On or Off 5 Press the key once to return to the Choose Event Output prompt 6 Press the key once to return back to the Main Page Digital Output Connections See page 12 9 of the Series F4 User s Manual for details on how to connect to the Digital Outputs Event Board Option Your chamber may have been ordered with the Event Board option The event board contains solid state relays to control AC operated devices such as power to a test sample The solid state relays are rated for 24 to 240 VAC 3 0 Amps However TestEquity recommends derating the maximum current to 2 5 Amps The solid state relay mounting board is UL recognized CSA certified for 120 VAC max with the board mounted fuses 250 VAC max with a 22 solid
73. roper modifications to these values can result in erratic performance and unreliable operation Do not attempt to modify the setup values unless you thoroughly understand what you are doing Setup examples in the Series F4 User s Manual are NOT applicable to this chamber If there is any doubt please call TestEquity before proceeding The correct values are documented in the Series F4 Temperature Controller Setup Parameters section of this manual Page 4 12 TestEquity 1027S Temperature Chamber Chapter 4 Temperature Controller Factory Page The Factory Page provides access to menus for controller diagnostics and calibration TestEquity has configured the security to require a password for access to the Setup Page However there will be times when entry into these menus is necessary For example you may need to gain access to Factory Page in order to perform a calibration or to change the security password You must call TestEquity at 877 512 3457 or 805 480 0638 to obtain the password CAUTION NEVER select Full Defaults in the Factory Test Menu This will erase all the correct values which are documented in the Series F4 Temperature Controller Setup Parameters section of this manual Computer Interface CAUTION Every setting in the F4 Controller can be accessed via the computer interface Improper modifications to configuration settings can result in erratic performance and unreliable operation Setup
74. steps Step 1 Ramp Time Generally you would start on Step 1 but you can Step 2 Soak also start on any other step Press to select the desired start step and the profile will begin to run The Profile Indicator will Step 3 Ramp Time lt stay lit Main Page Profile 2 Running Step 1 SP1 85 0 C Y While running a profile the Main Page on the lower display will keep you informed about the progress of the profile Use the Aor Y key to scroll through the list of running profile parameters You cannot manually change any operating condition while the profile is running TestEquity 1027S Temperature Chamber Page 4 7 Chapter 4 Temperature Controller How to Hold Resume a Running Profile 1 To Hold a running profile press the Profile key to enter the Profile Control menu e Then press Aor Y to make your choice for Hold e Press to select Hold e The Main Page will appear with a profile status of Holding The Profile Indicator will be off Hold Profile _ Don t Hold gt Hold Terminate Main Page gt Profile 2 Holding Step 2 SP1 23 0 C Y 2 To Resume profile on hold press the Profile key to enter the Resume Profile menu e Then press Aor Y to make your choice for Resume Press to select Resume Resume Profile Continue Holding gt Resume Terminate While a profile is on Hold the current set point can be adjusted at the SP1 prompt on the Main Page When
75. t accuracy in the chamber includes the thermocouple sensor wire accuracy Thermocouple wire accuracy is 1 C or 0 75 of reading whichever is greater Therefore total system accuracy over the chamber s operating range can be as much as 2 66 C although the typical accuracy is often better than 1 0 C Can I tilt the chamber to move it You should be able to tilt the chamber 45 degrees to move it After tilting it and moving it into place perform the steps as outlined in How to inspect the refrigeration machinery compartment and How to check the refrigerant charge before placing the chamber back into service to make sure that no damage has occurred Page 6 2 TestEquity 1027S Temperature Chamber Chapter 6 Frequently Asked Questions Pm not going to use the chamber for a while Is there anything I should do to prepare it for 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 it is taken out of storage If the chamber has a problem and is still under warranty these problems should be resolved before being placed into storage since the warranty period starts from the date of shipment The chamber should be stored in a conditioned environment Do not store it outside or where it will be subjected to dirt or excessive moisture I haven t used the chamber for a while Is there anything I should do to pr
76. th ramps so the chamber can be rolled off without the need for a forklift or pallet jack Preparation For Use Inspect the chamber for signs of shipping damage Read this entire manual Select a suitable location to install the chamber Verify the input voltage configuration Connect to the power source E PS E E Perform following the procedures as described in the Preventive Maintenance section a Inspect the electrical compartment b Inspect the refrigeration machinery compartment c Check the refrigeration charge d 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 removal of the service access panels which are located on each side and the rear The chamber must be on a solid and level floor ZA CAUTION The minimum clearance you should allow for proper ventilation around the chamber must be at least 12 from both the left and right side and 24 from the rear ZA CAUTION This chamber is designed for operation in a conditioned laboratory environment Operation above 30 C 85 F or below 16 C 60 F ambient room temperature is NOT recommended TestEquity 1027S Temperature Chamber Page 2 1 Chapter 2 Installation Condensate Drain The chamber has a condensate dra
77. to the safety contacts are at terminals Al and A2 on terminal strip TB3 Figure 5 2 Location of Safety Contact Connections on the Electrical Sub Panel TestEquity 1027S Temperature Chamber Page 5 3 Chapter 6 Frequently Asked Questions Chapter 6 Frequently Asked Questions The input voltage label says 230 or 208 VAC I thought I had 220 or 240 VAC Is that ok 220 V is a misnomer there is no such standard as nominal 220 V in the United States 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 the input line voltage should be measured while the chamber is operating in a continuous HEAT mode to ensure that the expected nominal voltage of either 208 V 5 10 or 230 V 10 is present Also make sure the chamber is properly configured for either 208 V or 230 V nominal input as described in Chapter 2 Input Power Configuration If you have a 208 V line that measures under 198 V the chamber will require boost transformers If you have a 240 V line that measures over 252 V a 240 V line which is 10 high could measure up to 264 V the chamber will require bucking transformers Why doesn t the chamber come with a power cord and plug Most local electrical codes require permanent wiring for this type of equipment Ifused as a portable device a flexible wire with a plug may be acceptable
78. w to Program a New Profile 4 6 Programming Hints 4 7 Profile Key 4 7 How to Start a Profile 4 7 How to Hold Resume a Running Profile 4 8 How to Terminate a Running Holding Profile 4 8 How to Delete or Re Name a Profile 4 8 How to Edit a Profile 4 9 Profile Examples 4 10 Digital Event Outputs 4 11 Digital Output Connections 4 11 Event Board Option 4 11 Operations Page 4 12 Setup Page 4 12 Factory Page 4 13 Table of Contents Computer Interface 4 13 RS 232C 4 13 Common Modbus Registers 4 13 GPIB optional 4 13 Ethernet optional 4 13 Chapter 5 Limit Controller 5 1 Introduction 5 1 Limit Controller Keys and Displays 5 2 How to Set the High and Low Temperature Safety Limits 5 2 Resetting an Out of Limit Condition 5 2 Silencing the Audible Alarm 5 2 Protecting an Energized Test Sample 5 3 Chapter 6 Frequently Asked Questions 6 1 Chapter 7 Specifications 7 1 Model 1027S Chamber Specifications 7 1 F4 Temperature Controller Specifications 7 2 Chapter 8 Maintenance 8 1 Preventive Maintenance Intervals 8 1 Maintenance Procedures 8 2 How to clean the chamber interior and exterior 8 2 How to listen for abnormal noise or vibration 8 2 How to inspect the door seal 8 2 How to inspect the refrigeration machinery compartment 8 3 How to check the refrigerant charge 8 3 How to verify the chamber performance 8 4 How to inspect the electrical
79. y 1027S Temperature Chamber Page 8 3 Chapter 8 Maintenance How to verify the chamber performance These tests verify the performance of the heating refrigeration electrical controls temperature controller and air circulation systems The chamber should meet all published performance specifications if all of these tests are successfully passed These tests assume that the Temperature Controller s setup and tuning values have not been changed from the values as shipped from TestEquity Also the Limit Controller high limit must be set to over 85 C 88 C would be fine and the low limit set to 35 C If the chamber fails any of these tests it should be removed from service to prevent further damage until the cause of the problem is determined and resolved 1 The chamber interior should be empty and at ambient temperature approximately 23 C 2 Set the Temperature Controller Set Point to 85 C and turn the Master Switch ON 3 The Heat Light should be ON continuously and the Cool Light should be OFF 4 The chamber should heat up to about 80 C and begin controlling Heat 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 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

Download Pdf Manuals

Related Search

Related Contents

Electric bike 905 Se City  Vers à compost  Asrock 2U12L6SC-2TS6 server barebone    m-CAN J1850 – Installation and Operating Instructions For Harley  User Manual - Tokyo Dawn Records  Guide d`etude - Crime and Social Regulation    Whirlpool 8ED2GTKXRQ00 Refrigerator User Manual  INSTALLATION, OPERATING and SERVICE MANUAL  

Copyright © All rights reserved. Failed to retrieve file