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Model 6010 Service Manual

1. FU 2 oll oso 1 1 1 1 T 2 5 Figure 1c Electrical Component Layout HEATERS 16 99 t Rm Oe sim Jer o B i n HUMIDITY INJECTION N fi BLOWER WHEE INTERIOR LEFT SIDE WITHOUT DIFFUSER PANEL Figure 2 Internal Component Layout 6010 Service Manual_B SVC 6010 30 HUMIDITY SENSOR NOTE SENSORS ARE RTD SENSOR MOUNTED BEHIND COVERS o o o ot o o oF RIGHT SIDE PERFORATED PANEL Figure 3 Temperature amp Humidity Sensor Location HUMIDITY INJECTION SOLENOID a ET gt gt gt gt 8 A OK
2. TEMPERTURE amp HUMIDITY CUSTOMER FOR REMOTE ALARM MONITORING OPTION lt ALM 202 1 LAST CONDUCTOR NUMBER USED 77 Figure 8 Electrical Schematic cont 6010 Service Manual_B SVC 6010 38 1 T R d T R 3 COM 19 8 7 I QO 9 8 4 1 el 0 u ie shy P 7 8 T R TH R4 COM 5 m al 7 7 T o 80 3 O0 6 1 O 04 3 6 30 O 27 ll le 67 5 13 6010 Service Manual_B SVC 6010 INST 1 CIE MPERATURE RAMPING INST 2 WATLUW RAMPING Figure 8 Electrical Schematic HUMIDITY 96AT CDDU AABD P TIUN 39
3. 23 Replace components ee 25 Humidity injection ae ears 25 Condenser fan os LL LIE 25 Solenoid valve amp Colla M ena ho uxo 26 27 Blower Mop 27 ce 28 FIGURES Figure 1a Electrical component layout compressor blower 1b Electrical component layout main fuse 1c Electrical component layout Chassis Figure 2 Internal Figure Temperature amp Humidity Sensor location Figure 4 Humidity Figure 5 Controller 44 4 4 Figure 6 Refrigeration component Figure 7 Refrigeration Figure 8 eee rite 6010 Service Manual_B SVC 6010 INTRODUCTION OVERVIEW The CARON Model 6010 Environmental Test Chamber provides multiple capabilities to create repeatable environmental conditions for numerous applications A PID controller controls
4. SLR VAL MAIN T Figure 6 Refrigeration Component Layout 6010 Service Manual_B SVC 6010 ACCESS VE 33 DEFROST ITEMS SHOWN CHECK VALVE lt OPTION s 2 EVAPORATOR SOLENOID VALVE DASHED LINES COP TION DEFROST WET COIL LIQUID SOLENOID GAENE VALVE WET COIL lt OPTION VALVE WET COIL CPV COOLING EVAPORATOR __ 9 ITEMS SHOWN CENTER LINES HUMIDITY OPTION NOTE DEFROST LINE MUST COME BEFORE CU HOT GAS BYPASS REGULATOR LIQUID INJECTION _ TEV HG Pr HOT GAS BYPASS esai REGULATOR FILTER DRIER CONDENSING SERVICE PORT UNIT lt SUCTIOND RECEIVER ACCUMULATOR 3C Loser SERVICE PORT HIGH SIDE Figure 7 Refrigeration Schematic 6010 Service Manual B SVC 6010 34 1 gt 115 VAC 16 AMP 60 Hz u 12 OND 3 4 io GREEN 5 Ems 6
5. 1 Water present in the chamber will hinder the dehumidification process A Check drains for proper draining B Verify water is not setting in bottom of chamber Ensure access tubes are sealed with permigum see figure 1a Humidity specifications are based on a 4 C dew point 20 C ambient The chart below illustrates the lowest humidity level specified for a given temperature High ambient air temperatures will affect humidity set points above 7596 Temperature C Relative Humidity 96 8 80 12 60 16 48 20 37 24 29 28 24 32 17 36 15 40 13 48 9 52 8 56 5 60 5 64 4 Determine if air is circulating properly inside the chamber Air should be drawn into the plenum located on the left side of the chamber interior and out the right side diffuser A piece of paper or plastic bag should cling to the top diffuser plate If air is not circulating A Check continuity across blower motor fuse 4 FU 5A see figure 1a B See troubleshooting blower motor 6010 Service Manual_B SVC 6010 12 7 8 Determine if humidity controller is calling for dehumidification Set humidity set point below humidity process value on controller Verify Output 2 on humidity controller lights up it may pulse see figure 5 If it does not light up see controller manual Determine if dehumidification solenoid is functioning A clicking noise should be heard when Output 2
6. see previous step on humidity controller turns on or off not while it stays on Or place a screwdriver tip near the wet coil solenoid valve figure 6 and see if it is magnetized See troubleshooting solenoid valves See troubleshooting condenser fan See troubleshooting refrigeration Problem Will not maintain humidity 1 Humidity specifications are based on a 4 C dew point 20 C ambient The chart previous page illustrates the lowest humidity level specified for a given temperature High ambient air temperatures will affect humidity set points above 7596 Clean humidity injection water filter figure 4 Unscrewing clear lid amp wash screen under hot water Replace if necessary Water present in the chamber will hinder the dehumidification process A Check drains for proper draining B Verify water not setting in bottom of chamber Close the air vent port amp access port on right side of chamber Ensure access tubes are sealed with permagum located behind service door figure 1 Ensure complete seal between the glass door amp unit Use a paper to feel around door for unsealed locations Humidity droop amp overshoot maybe caused by poor values for PID amp other settings See Controller Manual for PID dead band amp humidity offset settings The humidity sensor maybe saturated Dry out chamber with humidity off at 40 C for 6 hours Determine if air is circulating properly inside th
7. 2 HUMIDITY INJECTION PUMP HUMIDITY WATER FILTER LEFT SIDE WITHOUT SERVICE DOOR Figure 4 Humidity Component Layout 6010 Service Manual_B SVC 6010 31 Controller Layout Temperature 1 2 3 1 Output 1 indicates heating system 2 Output 2 indicates cooling system VAL 3 Output 3 indicates temperature alarm Ic good 4 Advance key 5 Infinity Home key 9 6 Up key 8 7 Down key 8 Lower display Setpoint Temperature C 9 Upper display Actual Temperature C Humidity 1 Output 1 indicates system humidification 2 Output 2 indicates system dehumidification 3 Output 3 Not used 4 Advance key 5 Infinity Home key 6 Up key 7 Down key 8 Lower display Setpoint Relative Humidity RH 9 Upper display Actual Relative Humidity RH Figure 5 Controller Layout 6010 Service Manual B SVC 6010 4 32 GAS BYPASS REG LATOR ER DRIER DISCHARGE ACCESS VALVE gt gt 6010 LEFT SIDE VIEW WITH SERVICE DOOR LIQUID I ECTION EXPANSIO VALVE STATIC QUID Q SOLEN LEN ID VALVE UID D VALVE CDI
8. leak is detected where the hose was verify service valve is backed all the way out If so replace king valve see appropriate section 5 If leak is detected around service valve tighten packing if possible If leak persists replace king valve see appropriate section 6 Evacuate refrigeration system see evacuate system 7 Charge refrigeration system see evacuate system 6010 Service Manual B SVC 6010 19 REPLACING REFRIGERATION COMPONENTS Note System should not be exposed to atmosphere for more than ten minutes If repairs cannot be made in this length of time cap all open areas of refrigeration system Replace filter drier 1 Recover refrigerant to 10 mm Hg as explained in previous section 2 Pressurize system with dry nitrogen above 10 psi see corresponding section This will avoid drawing ambient moisture into system while unit is under a vacuum 3 Open suction side manifold valve and vent nitrogen charge to atmosphere 4 Using an acetylene torch unsweat drier at solder connections and remove drier from system It may be necessary to gently pull on drier to get it loose Make sure solder is liquefied before pulling or a tearing of the copper line could occur 5 Replace filter drier back into system Use a brazing rod that is suited for copper to copper brazing 6 Visually inspect solder connection and leak check system see section 7 Evacuate refrigeration system see evacuate system 8 Charge ref
9. 1 Leak check pump fittings for leaks Condensor Fan 1 Disconnect wiring from condensor fan motor Take notice how fan motor is wired as you will have to rewire replacement motor Remove four screws from condensor fan mounting bracket and lift fan assembly up and out of system Using a wrench loosen fan blade retaining nut Take precautions not to bend fan blade as this will cause poor cooling efficiency and shorten the bearing life of new motor Remove fan blade from old motor Take notice to direction of the pitch of the fan blade as it will be attached to new motor Remove four screws attaching fan motor to fan assembly mounting bracket 6010 Service Manual_B SVC 6010 25 Attach new motor to fan assembly mounting bracket using screws removed Using the fan blade retaining nut attach fan blade onto replacement motor Using the four screws removed earlier install new condensor fan assembly Rewire fan motor Replace solenoid valves wet and cooling coil valves 1 2 3 Evacuate system and purge with nitrogen see corresponding section Remove solenoid coil Unsweat solenoid and remove Place new solenoid in place Clean both inlet line and outlet line of solenoid before reinstalling new solenoid Wrap wet cloth around new solenoid and sweat both joints Visually inspect connections Perform leak check procedure see leak check Replace solenoid valve humidity valve 1 2 3 Turn water supp
10. 10 GA BLK 34 1FU FUSE 7 20 AMP SLOW BLOW 10 WHITE 5 4 7 1 B ees Loads 71 9 B MAIN ON OFF LCR 0 5 6 6 1 N POWER RELAY 1 9 9 e 5 AU 5 e 3 1 Pe ec 5 E CUSTOMER CONNECTION 5 485 c FOR COMMUNICATIONS lt OPTION 4 5 TR COM 5 m amp 5 5 1 INST P4 OO 8 TU 5 TEMPERATURE 7 9 80 CONTROLLER 8 7 P 12 m 55 8 2ND_SET POINT a 5 go 2246 OPTION 1 DISCHARGE 21 1 RC PLENUM I O5 vu 22 QUENCHARC RI SOL 23 3 5 nn P5 0 7 ut COOLING SOLENOID 2 P 6 52 8 6 6 7 ALARM RELAY 5 5 6 CR 26 REMOTE ALARM RELAY 27 DV P OPTIONAL 48 GA BLUE 418 GA BLUE 28 O is 29 CR OPTION ru 8 50 22 30 2 AIR HEATERS 7 290 WATT EACH 31 E 580 V 5 A 115 V 3e 16 GA RED FROM ee 7 33 THIS POINT ON UNLESS EHR OTHERWISE NOTED 34 Y SLOW BLOW 650 39 DEFROST OPTION 4 FU ine 1 ER 60 Hz 37 DIRECTION END 38 Cow 5 FU REF ON OFF p 7 10A SLOW BLOW C STANDARD 39 8 y 24 CONDENSING UNIT 40 1 6 WP 15 V 60 Hz 28 RLA 1 PH 1 lt 2 41 42 NE AR 5 1 H m GA WHITE WIRE 47 1 E FROM THIS POINT ON 43 UNLESS OTHERWISE NOTED 44 2 MTR 7 45 4 CONDENSING UNIT FAN MOTOR CERITO 15 V 60 Hz 03 RLA 46 LAL 8 7 47 1 AUDIBLE ALARM 48 8 ub 1 DEVIATION HIGH LOW TEMP 49 VIS
11. 6 Take the volume recorded in previous step and subtract 24 oz This will give you the ending volume of refrigerant left in the cylinder after charging For Example The pressure in the charging cylinder is 70 psi With the pressure shroud rotated to 70 psi the volume of refrigerant is 34 5 oz We know that the charge is 24 oz Therefore we take the difference of 34 5 oz and 24 oz and come up with a difference of 10 5 oz This is the volume of refrigerant that should be left in the charging cylinder after charging the refrigeration system 17 Once the remaining volume has been calculated use a piece of tape or something similar to mark the cylinder at the point of calculated remaining volume 18 Open suction side of manifold gauge and bleed refrigerant into system Once volume of refrigerant reaches point of calculated remaining volume close suction manifold gauge 6010 Service Manual B SVC 6010 24 REPLACE COMPONENTS Disconnect power before replacing any component Replace humidity injection pump 1 2 3 8 9 Turn water supply off Disconnect both wires that connect pump to harness Disconnect inlet amp outlet tubes from pump head Remove pump mounting screws Remove old pump and replace with new pump Fasten pump to unit with mounting screws Reconnect inlet amp outlet tubing to pump head Connect both wires from pump to harness Turn on water supply 10 Set humidity control setpoint to 9896 1
12. CARON MODEL 6010 ENVIRONMENTAL TEST CHAMBER SERVICE MANUAL 6010 Service Manual_B SVC 6010 TABLE OF CONTENTS SECTION _________________________ 5 INTRODUCTION Qi ce Pme 3 Specifications Qi t 4 TROUBLESHOOTING bc 8 amp em 15 Humidity injection DUlfip s e 15 CONTE SS OM M 15 Solenoid valve amp 2 22 1 15 Medale S pL Ete EPUM espe is 15 Blower innere dep 16 Condenser fan cic ae ea Ei qae GO QUO e Cie 16 Refrigeration DN MC DUCUM 17 Gauge readings 5 56 17 Leak CHOCK ER neater 18 REPAIR REPLACE Repair refrigeration enr tei RE 19 Replace refrigeration 20 20 Solenoid valve 20 Hot gas bypass Valen eee eee 21 Thermostatic expansion valve 21 ees iste 21 Evacuate system 23 Recharge SySIBITi
13. NOID OPTIONAL WET COIL SOLENOID DE HUMIDIFY gt QUENCHARC REMOTE ALARM RELAY OPTIONAL HUMIDIFY SPRAY SOLENOID 120 V 6V 1A HUMIDIFY RELAY HUMIDITY SENSOR TRANSFORMER 24 VAC 8 15 MAX HUMIDITY INJECTION PUMP 24 VAC 8 15 MAX HUMIDITY SENSOR TRANSFORMER 36 4 SW end SET POINT LIGHT 1 TRE CYCLE TIMER DN DFF 24 HR 8 40 40 7 40 8 8 FU 42 46 2A SLOWBLOW gt P3 P5 P4 P6 6 PIN CONNECTOR PLUS GND P3 P5 P4 PI P6 7 COMPONENT CHASSIS GROUND BLU BLU YEL YEL RED OO Q WM CO 9 2 gt RED c ro no no gt 6 PIN CONNECTOR PLUS GND P3 P5 P4 PI P6 Zoe g no M COMPONENT CHASSIS GROUND BLU BLU 41 YEL YEL 51 RED RED C2 CO CO CO g Figure 8 Electrical Schematic cont 6010 Service Manual B SVC 6010 2ND SET POINT LIGHT CYCLE TIMER SYSTEM OPTIONAL REC 104 LIGHT BALLAST 120 V 60 Hz 050 OPTIONAL 2 B
14. UAL ALARM 50 51 9e 23 54 55 56 8 8 7 97 58 Figure 8 Electrical Schematic 6010 Service Manual_B SVC 6010 35 2 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 73 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 CUSTOMER CONNECTION FOR COMMUNICATIONS 2 3 COM pi al al NST 3 SW RHOWOF em 8 a 27 dim N 7 aa end SP OPTION free tg 5 5 FU ay 6 TA SLOW BLOW g 851 P 14 P4 R2 SUL afou 67 5 9 TV pag 7 p 20 67 7 GA BLUE GA BLUE XE 3 7 CR OPTION 3 4 2 SSR 27 ned 5 5 7 6 FU 5A SLOW BLOW dst oF 115 V STEP DOWN TRANSFORMER 252 VCT 20A BLIV AME GA YELLOW 30 AUN s s m 15 V 7 AAS DOWN TRANSFORMER 7 FU DAA IV VET O15 A 5A SLOW BLOW 418 GA YELLOW HUMIDITY TRANSHITTER INPUT 3 SOLID STATE OUTPUT RH SENSOR 31 DISCHARGE PLENUM Figure 8 Electrical Schematic cont 6010 Service Manual_B SVC 6010 RELATIVE HUMIDITY CONTROLLER SYSTEM OPTIONAL 2ND OPTION 1 RY AIR PURGE SOLE
15. ULB 20 W EACH FLUORESCENT OPTIONAL LIGHT BALLAST 100 V 60 2 550 OPTIONAL 2 BULB 20 W EACH FLUORESCENT OPTIONAL ND SET POINT RELAY 19 67 37 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 1 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 200 3 INST M FU 5 SLOW BLOW TEMP RH RECORDER 100 OM RTD 4 INST FROM RH SENSOR OPTIONAL PRODUCT TEMPERATURE SAVER 100 OHM 1 RTD DISCHARGE 5 __ HIGH LOW TEMP OPTIONAL LIMIT ALARM 49 SAMPLE SAVER RELAY BFU 54 SLOW BLOW INTERNAL OUTLET 8 53 53 OPTIONAL 1 CHART RECORDER OUTLET 3 5A SLOW BLOW 13 FU 73 OPTIONAL 1A SLOW BLOW 17 FU TU 3 SV REFERENCE DRIER PACKAGE OPTIONAL DEFROST CYCLE lt OPTION DEFROST TIMER SL DEFROST SOLENOID DEFROST RELAY HEA 7 DEFROST CYCLE ACTIVE LAMP 14 HEAT 15 V HUMIDITY INJECTION WATER LINES 54 5 5 CUSTOMER CONNECTION FOR SAMPLE SAVER ALARM NOTES mi INCANDESCENT LIGHT 6 CR
16. as explained in previous section 2 Pressurize system with dry nitrogen to 10 psi see corresponding section This will avoid drawing ambient moisture into system since the unit is under a vacuum 3 Open suction side manifold valve and vent nitrogen charge to atmosphere 4 Loosen both flare nuts on valve and remove bulb clamp in suction line 5 Replace with new expansion valve using pipe thread sealant for refrigeration systems 6 Evacuate refrigeration system see evacuate system 7 Charge refrigeration system see recharging Replace compressor 1 Recover refrigerant to 10 mm Hg as explained in previous section 2 Pressurize system with dry nitrogen to 10 psi see corresponding section This will avoid drawing any ambient moisture into system since the unit is under a vacuum 3 Disconnect wiring from compressor Take note as to how it was wired so that you may rewire the new compressor 6010 Service Manual B SVC 6010 21 8 9 Remove the bolts securing the condensing unit Take suction and discharge line flare nuts off of king valves Using acetylene torch unsweat hot gas line from tee and discharge line Remove condensing unit and replace with new one Bolt condensing unit down with bolts Rewire compressor 10 Braze hot gas line onto discharge line 11 Reconnect discharge to receiver and suction line to king valve using leak lock thread sealant and refrigeration oil on threads 12 Visually i
17. awn into the plenum located behind the diffuser plate in left side of the chamber interior and out the right side diffuser A piece of paper or plastic bag should cling to the left side diffuser plate If air is not circulating A Check continuity across blower motor fuse 4 FU 5A see figure 1a B See troubleshooting blower motor Determine if humidity controller is calling for humidity Set humidity set point above humidity process value on controller Verify Output 1 on humidity controller lights up it may pulse see figure 5 If it does not light up see controller manual Determine if humidity solenoid is functioning With Output 1 on see previous step place a screwdriver tip near the humidity injection solenoid coil figure 4 and see if it is magnetized A clicking noise could be the contact relay switching See troubleshooting solenoid valves Check continuity across humidity injection pump fuse 2 FU 2A see figure 1c Check continuity across humidity transformer fuse 6 FU 5A see figure 1c 6010 Service Manual B SVC 6010 1 9 Check continuity across humidity sensor fuse 7 FU 0 5A see figure 1c A Verify transformer 1 T on main electrical chassis figure 1c is working properly B Verify relay 3 CR on main electrical chassis figure 1c works properly 10 Atomizer maybe plugged amp need replaced Refer to replace atomizer 11 See troubleshooting humidity injection pump Problem Will not dehumidify
18. blower motor section Condenser fan 1 Check for obstruction of condenser fan If not obstructed replace condenser fan see replacing condenser fan 6010 Service Manual_B SVC 6010 16 Troubleshooting Refrigeration Gauge Readings Attach gauges to suction and discharge access fittings and read pressures while unit is operating Normal operating pressures depend on ambient conditions Pressures increase as ambient temperatures increase and decrease as ambient temperatures decrease Normal operating pressures at 70 F are 24 psi on the suction side and 120 to 140 psi on the discharge side with no load Pressures with load are 24 psi on suction and 135 to 160 on discharge Static pressure is 60 to 70 psi This system controls evaporator temperature by introducing hot gas into the evaporator The above pressures are based on the system operating in the liquid cycle and will differ with the introduction of hot gas Low suction pressure Low discharge pressure system Leak 1 Turn off amp leak check system see troubleshooting a leak Low suction pressure High discharge pressure flow is blocked 1 Check copper lines to see if they are pinched 2 Check both liquid line solenoid valves amp verify they are operating See troubleshooting solenoids 3 Replace filter dryer see replacing filter dryer High suction pressure Low discharge pressure bypassing too much gas 1 Adjust hot gas bypass valve counterclockwise unti
19. cessary to leak check the system with an electronic leak detector It is necessary to have a leak detector which will detect HFC s R 134a 4 Using a leak detector sniff all exposed solder and mechanical connections If a suspect area is found use bubble check to pinpoint leak It may be necessary to split insulation on the suction side in the area of solder connections If a leak is found repair refrigeration leak 5 If no leaks can be found using the static pressure of the system it may be necessary to boost the pressure of the system pressurize system with nitrogen Pressurize system with nitrogen 1 Recover the refrigerant R 134a from the system Do not combine the recovery system with refrigerants containing chlorine This would contaminate the refrigeration system This system is classified as a small appliance by the EPA and must be recovered to a level of 10 mm Hg 2 Connect yellow hose center of manifold gauges to R 134a cylinder Open cylinder valve and purge yellow hose Once hose is purged open suction side manifold blue hose and pressurize system to 40 psi Close suction side manifold close cylinder valve and remove yellow hose from cylinder Only use R 134a to leak check system Failure to do so will contaminate system with chlorine and ruin the life expectancy 3 Connect yellow hose to dry nitrogen bottle with regulator and purge yellow hose Failure to use a regulated flow of nitrogen could cause internal valv
20. chamber temperature and humidity optional On off outputs are used to drive duct heaters and cooling solenoids The refrigeration system uses a single compressor allowing independent cooling and dehumidification This prevents the compressor from rapid cycling and off which shortens compressor life A high limit thermal snap disk and thermal fuse prevent a heating run away The horizontal airflow pattern creates air uniformity and temperature control SPECIFICATIONS Temperature Range without lights Temperature Range with lights Heater Compressor Temperature Control Temperature Uniformity Relative Humidity Humidity Control Interior Dimensions Exterior Dimensions Work Space Shelves Number of shelves Shelf Spacing Shelf Size Shelf Area Materials Finishes Interior Exterior Feet Electrical Shipping Weight Optional items 5 C to 60 C 10 C to 60 C 580 Watts 115VAC 1 6hp 1400 BTU Hr 7 C Evaporator 0 1 C 0 3 7 20 to 98 RH 2 23 W x 25 8 D x 29 8 H 58 4cm x 65 5cm x 75 7cm x 35 D x 37 5 111 8cm x 88 9cm x 95 3cm 10 cu Ft 283 2 liters 4 Stainless Steel Wire Rod Standard 1 5 on center 15 positions Each Shelf 22 8 W x 25 4 D 57 9cm x 64 5cm 4 ft each 16 ft total Stainless Steel Interior Door Tempered Glass Metal with powder coated finish Adjustable leveling pads 115V 16A 60Hz 1Ph 400 Ib 181kgs RH levels limited by 4 C
21. e chamber Air should be drawn into the plenum located on the left side of the chamber interior and out the right side diffuser piece of paper or plastic bag should cling to the left side diffuser plate If air is not circulating A Check continuity across blower motor fuse 4 FU 5A see figure 1a 6010 Service Manual_B SVC 6010 13 B See troubleshooting blower motor 10 Atomizer maybe plugged and need replaced Refer to replace atomizer 11 See troubleshooting refrigeration 6010 Service Manual_B SVC 6010 14 TROUBLESHOOTING COMPONENTS Humidity Injection Pump 1 Check to see if voltage is applied to pump 16 V If voltage is not present verify that the control system is operating properly 2 Measure current flow lt 1 amp If current flow is not present replace pump Refer to replacing pump Compressor 1 Check to see if voltage is applied to compressor gt 110 V If voltage is not present verify that the control system is operating properly Check compressor fuse 5 FU 10A see figure 1a 2 Measure current flow 4 3 amp If current flow is not present The compressor s thermal overload may have tripped Be sure nothing is blocking the flow of air into the condenser Clean if necessary with compressed air or a vacuum Wait until compressor temperature is below 90 F or warm to touch If still no current flow replace compressor see replacing compressor If current flow is present A And comp
22. e damage to compressor Once hose is purged open suction manifold valve and pressurize to 100 psi Close suction manifold valve and remove hoses and leak check system 4 Use bubble check to leak check king valves If a leak is detected refer to repairing a refrigeration leak 6010 Service Manual B SVC 6010 18 REPAIR REPLACE REPAIR REFRIGERATION LEAK 1 Recover refrigerant to level as explained in previous section 10 mm Hg 2 Pressurize system with dry nitrogen to 10 psi See previous page This will avoid drawing any ambient moisture into system since the unit is under a vacuum 3 Open suction side manifold valve and vent nitrogen charge to atmosphere 4 Using an acetylene torch set repair solder connection as quickly as possible System should not be exposed to atmosphere for more than ten minutes If repair cannot be made in this length of time cap all open areas of refrigeration system 5 Visually inspect solder connection and leak check system see previous page 6 Evacuate refrigeration system see evacuate system 7 Charge refrigeration system see recharge system Note If during initial troubleshooting the suction pressure was in a vacuum the system filter drier must be replaced See replacing filter drier Repairing a king valve leak 1 Pressurize system with R 134A and dry nitrogen up to 100 psi 2 Back service valve all the way out and remove hose 3 Using bubble check leak check king valve 4 If
23. flows from right to left A Verify interior chamber holes in metal left amp right diffusers aren t covered B Verify shelves have 30 area open for airflow to chamber left side Temperature droop amp overshoot maybe caused by poor values for PID amp other settings See Controller Manual for PID dead band amp temperature offset settings 6010 Service Manual B SVC 6010 10 7 Determine if air is circulating properly inside the chamber Air should be drawn into the plenum located on the left side of the chamber interior and out the right side diffuser A piece of paper or plastic bag should cling to the left side diffuser If air is not circulating A Check for continuity across blower motor fuse 4 FU 5A see figure 1a B See troubleshooting blower motor The condenser fan should run continuously with refrigeration switch on See troubleshooting condenser fan if it is not If the temperature is set below 7 C for an extended time the evaporator may be frozen Set temperature to 20 C for 1 hour and then see if unit will maintain temperature 10 See Troubleshooting Refrigeration Problem Will not humidify T 2 Verify humidity switch is on Verify supply water is connected to unit with no restrictions Clean humidity injection water filter figure 4 Unscrewing clear lid amp wash screen under hot water Replace if necessary Determine if air is circulating properly inside the chamber Air should be dr
24. harge refrigeration system see recharging system RECHARGE SYSTEM 1 Connect hose from cylinder of R 134a to lower access fitting of charging cylinder 2 Turn R 134a cylinder upside down and open valve 3 Loosen hose fitting on charging cylinder and purge gas in charging hose 4 Open hand valve located on bottom of charging cylinder 6010 Service Manual B SVC 6010 5 Always fill graduated charging cylinder with at least 4 more than required charge Required charge for this system is 24 2 Hand valve on top charging cylinder will need to be open slightly while filling 6 Once cylinder reaches required level shut hand valve 7 Close valve on R 134a cylinder 8 Remove hose from charging cylinder and R 134a cylinder 9 Connect yellow hose from refrigeration system to be charged to graduated charging cylinders lower valve 10 Making sure manifold valves on equipment are closed open lower valve on graduated charging cylinder 11 Purge yellow charging hose by loosening hose fitting at manifold gauge set 12 Once hose is purged check pressure on gauge at the top of charging cylinder 13 If pressure is less than 70 psi plug in heater and heat until pressure reaches at least 70 psi 14 If pressure is higher than 70 psi rotate plastic shroud to match corresponding pressure of refrigerant in the cylinder 15 Once the shroud matches the refrigerant pressure record the volume of refrigerant in the charging cylinder 1
25. ious step on temperature controller turns on or off not while it stays on Or place a screwdriver tip near the main liquid solenoid valve figure 3 and see if itis magnetized See also troubleshooting solenoid valves 4 Determine if air is circulating properly inside the chamber Air should be drawn into the plenum located on the left side of the chamber interior and out the right side diffuser A piece of paper or plastic bag should cling to the left diffuser plate If air is not circulating A Check for continuity across blower motor fuse 4 FU 5A see figure 1a Replace if necessary B See troubleshooting blower motor 5 Check for continuity across compressor fuse 5 FU 10A see figure 1a Replace if necessary 6 The condenser fan should run continuously with refrigeration switch on See troubleshooting condenser fan if it is not 7 The compressor should run continuously with refrigeration switch on See troubleshooting compressor if it is not 8 See Troubleshooting Refrigeration 6010 Service Manual B SVC 6010 9 Problem Will not heat 1 Determine if temperature controller is calling for heating Set temperature set point above temperature process value on controller Verify Output 1 on temperature controller lights up see figure 5 If it does not light up see controller manual Determine if air is circulating properly inside the chamber Air should be drawn into the plenum located on the left side of the cha
26. it is in the defrost mode the temperature may drift up a couple degrees To adjust timer settings remove top cover of unit Timer located in front right hand corner of unit HOUR SET SCREWS HOUR TIMER MIDNIGHT DEFROST CYCLE TIMER FACTORY SETTINGS EVERY 6 HOURS FOR 16 MIN CYCLE 6010 Service Mz TROUBLESHOOTING GENERAL To access the electrical refrigeration and control panel components 1 Remove two 2 screws located at the top of the service door 2 Pull the service door towards you to access the electronics and refrigeration components SCREWS 2X SERVICE DOOR AIR FILTER 6010 CONDENSING UNIT FINS LOCATED BEHIND SERVICE DOOR BACK VIEW MODEL 6010 6010 Service Manual_B SVC 6010 Problem Will not turn on 1 Verify supply power is connected amp energized 115 VAC 60 Hz 2 Check for continuity across main internal fuse 1FU 20A see figure 1b Replace if necessary Problem Will not cool 1 Verify refrigeration switch is on 2 Determine if temperature controller is calling for cooling Set temperature set point below temperature process value on controller Verify Output 2 on temperature controller lights up it may pulse see figure 5 If it does not light up see controller manual 3 Determine if cooling solenoid is functioning A clicking noise should be heard when Output 2 see prev
27. l pressures become acceptable 2 If it won t adjust replace hot gas bypass valve see replacing bypass valve High suction pressure High discharge pressure condenser not cooling 1 Assure that the condenser fan is operational see troubleshooting condenser fan 2 Assure that system has proper air clearance on all sides for adequate airflow 3 Assure that ambient conditions are not excessively high Suction and discharge pressures are balanced compressor not running 1 Assure ambient temperature less than 90 F thermal overload may trip 2 Check compressor startup capacitor 3 Make sure the compressor is operational see troubleshooting compressor 4 Check compressor fuse 5 FU 10A see figure 1a 6010 Service Manual_B SVC 6010 17 Troubleshooting Refrigeration Leak Leak check refrigeration system 1 Remove chamber service door so refrigeration parts are visible refer to figure 6 for component layout System must not be running while leak checking 2 Visually inspect all solder and mechanical refrigeration connections use retractable mirror if necessary Look for pinholes in solder joints and other connection imperfections joint still has flux on it remove flux deposit Traces of oil around a connection may indicate a leak If a suspect area is found use a bubble check solution to pinpoint leak If a leak is detected repair refrigeration leak If no leaks be detected visually it will be ne
28. ly off Disconnect both wires that connect solenoid to harness Remove the inlet nut and tube and unscrew the solenoid Remove valve and replace with new valve Thread the new solenoid onto the pipe nipple reconnect the inlet nut and tube Reconnect both wires to harness Turn water supply on Set humidity set point to 95 on the humidity controller Verify there are no leaks in the system see leak check 6010 Service Manual_B SVC 6010 26 Solenoid Valve Coils 1 2 3 4 5 Disconnect three wires that attach coil to harness Remove nut on top of coil Pull up on solenoid coil to remove and replace with new coil Replace nut and information plate on top of coil and tighten Reconnect both coil wires back to harness Replace heaters 1 2 3 Turn power off and unplug unit Remove all screws from ceiling and remove left side diffuser see figure 2 Remove wires amp screws securing bad heater Replace with new heater Make sure ring lugs do not ground to support bracket Reinstall left side diffuser and install screws into ceiling Replace Blower motor 1 2 Disconnect power from chamber Remove all screws from ceiling false floor and remove left side diffuser see figure 2 Using an Allen wrench loosen set screw on blower wheel Slide blower wheel off of shaft Located behind the service door remove screws that hold the blower motor plate see figure 1a Discon
29. mber interior and out the right diffuser A piece of paper or plastic bag should cling to the left diffuser plate If air 15 not circulating A Check for continuity across blower motor fuse 4 FU 5A see figure 1a Replace if necessary B See troubleshooting blower motor Check amperage draw through conductor 9 between solid state relay 1 SSR amp heater fuse 3 FU see figure 1c The amperage draw should be around 5 Amps If there is no current check for continuity across A Heater fuse 3 FU 5A see figure 1c Replace if necessary B Replace Solid State Relay C Thermal fuse 16 FU 90 C see figure 2 accessible through interior left side only Replace if necessary D Thermal snap disk 1 TST 65 C see figure 2 accessible through interior left side ceiling only Replace if necessary See troubleshooting heaters Problem Will not maintain temperature 1 2 Close air vent port 8 access port on right side of chamber Ensure complete seal between the glass door amp unit Use a paper to feel around door for unsealed locations Check temperature sensor RTD located inside the chamber figure 3 and make sure it is away from the chamber wall lights and other sources of heat Note If the optional chart recorder is installed there will be two RTDs Verify glass door is out of direct sunlight amp other sources of radiant heat and exterior door is closed Air pattern throughout chamber
30. minimum dewpoint Specifications were established at 20 C with 5096 RH ambient conditions 6010 Service Manual B SVC 6010 OPTIONS This 6010 Environmental chamber maybe equipped with one or more of the following options Humidity Control A bi modal humidification system allows for independent humidification and dehumidification The humidity injection system utilizes atomizers to inject moisture into the chamber An evaporator coil accomplishes dehumidification TEMPERATURE CONTROL WATLOW 96 10203040 1o 20 0 20 0 8 ALARM HUMIDITY CONTROL WATLOW 96 HUMIDITY 10203040 1o OU 50 REFRIGERATIO PDWER e Lights and Timer The Diurnal Lighting System dual setpoint light cycle timer allows the operator to simulate day and night testing The timer light switch enables all light banks on amp off simultaneously as well as operate the two setpoint temperature humidity system 24 HOUR TIMER TIMER LIGHTS DUAL SETPUINT LIGHT CYCLE TIMER PANEL MODEL 6010 6010 Service Manual_B SVC 6010 Chart Recorder The Honeywell Circular Chart Recorder graphs temperature and or humidity over time The humidity input is 0 5 volt wired from the humidity controller A separate RTD inside the chamber monitors temperat
31. nect wires from harness to blower motor Remove motor from mounting plate and replace with new motor Reinstall motor assembly into side panel Slide blower wheel back onto shaft and tighten blower wheel set screw Reconnect wires from motor to harness Reinstall left side diffuser false floor and install screws into ceiling 6010 Service Manual B SVC 6010 27 Replace atomizers 1 2 Turn power off and unplug unit Remove all screws from ceiling false floor and remove left side diffuser see figure 2 Unscrew atomizer head Apply teflon tape to threads and install new atomizer Reinstall left side diffuser false floor and install screws into ceiling 6010 Service Manual_B SVC 6010 28 Figures ELECTRICAL CHASSIS 4 FU FUSE 5 FU 10 FUSE 000000000 ze BLOWER MOTOR 6010 LEFT SIDE VIEW WITHOUT SERVICE DOOR Figure 1a Electrical Component Layout 1 FU 20 A FUSE INSIDE SERVICE DOOR e d AREA BACK WALL Figure 10 Figure 1b Electrical Component Layout 6010 Service Manual_B SVC 6010 29 TB elelelelelelele elelelelelele 7 7834331817313957387 8 2726205 35166 o7 FU slsisislsisis
32. nspect solder connection and leak check system see leak check 13 Evacuate refrigeration system see evacuate system 14 Charge refrigeration system see recharging system 6010 Service Manual_B SVC 6010 22 EVACUATE SYSTEM Note Vacuum pump must be dedicated for the use of R 134a only Failure to do so can contaminate system with chlorine and ruin the life expectancy of the refrigeration system We recommend 6 CFM model such as the Robinair 15600 Once the leak or refrigeration component has been replaced it is necessary to evacuate and recharge the refrigeration system Leak checking gas must be vented before hooking up to pump 1 Attach manifold gauge set to refrigeration Blue hose goes on the suction access fitting and the red hose on discharge access fitting 2 Attach yellow hose to intake port of vacuum pump If your vacuum pump has an isolation valve make sure the valve is open 4 Turn power on to vacuum pump 5 With vacuum pump running open suction amp discharge side manifold gauges We recommend an evacuation of at least 6 hours 6 Vacuum level before turning pump off should be at least 29 9 mm Hg 7 Close suction and discharge side manifold gauges 8 Turn power off on vacuum pump 9 Disconnect yellow hose from intake port of vacuum pump 10 Allow system to sit for a minimum of 1 hour after evacuation to see vacuum holds If it does not leak check system see leak check and re evacuate 11 C
33. ressor is hot to the touch replace start up capacitor B And is in excess of rated load amps 4 7 amps refer to refrigeration troubleshooting Solenoid valves 1 Check to see if voltage is applied to coil 2 110V figure 6 If voltage is not present verify that the control system is operating properly 2 Measure current flow 0 1 amp A If current flow is not present replace solenoid valve coil B If current flow is present and valves do not operate replace solenoid valve Refer to replacing solenoid valve Heaters 1 Check to see if voltage is applied to heaters 2 110V If voltage is not present verify that the control system is operating properly 2 Measure current flow A If current flow is present 4 9 Amps then heaters are good B If current is below the above range replace heaters see replacing heaters 6010 Service Manual B SVC 6010 15 Blower Motor 1 Check to see if voltage is applied to blower motor 2 110V see figure 1a If voltage is not present verify that the control system is operating properly 2 Measure current flow 4 FU 5A see figure 1a A If current flow is present check for obstruction of blower wheel If not obstructed replace blower motor Refer to replacing blower motor B If current is not present let motor cool down until it is touchable the thermal overload may have tripped If motor still doesn t draw current replace blower motor Refer to replacing
34. rigeration system see recharge system Replace solenoid valve 1 Recover refrigerant to 10 mm Hg as explained in previous section 2 Pressurize system with dry nitrogen above 10 psi see corresponding section This will avoid drawing ambient moisture into system while unit is under a vacuum 3 Open suction side manifold valve and vent nitrogen charge to atmosphere 4 Remove coil from liquid line solenoid and place out of way 5 Visually inspect solder connection and leak check system see leak check 6 Evacuate refrigeration system see evacuate system 7 Charge refrigeration system see recharge system 6010 Service Manual B SVC 6010 20 Replace hot gas bypass valve 1 Recover refrigerant to 10 mm Hg as explained in previous section 2 Pressurize system with dry nitrogen to 10 psi See corresponding section This will avoid drawing ambient moisture into system since the unit is under a vacuum 3 Open suction side manifold valve and vent nitrogen charge to atmosphere 4 Unsweat connection between discharge bypass entrance and hot gas line 5 Replace discharge bypass valve back into system Use a brazing rod that is suited for copper to copper brazing 6 Visually inspect solder connection and leak check system see leak check 7 Evacuate refrigeration system see evacuate system 8 Charge refrigeration system see recharge system Replace thermostatic expansion valve 1 Recover refrigerant to 10 mm Hg
35. ure Refer to the Chart Recorder User s Manual for operation instructions Condensate Recirculating System The Condensate Recirculating System is used in facilities where a floor drain or water source is not available The system collects and recycles the condensate from the chamber and provides continuous filtered water to the chamber s humidity injection system 6010 Service Manual_B SVC 6010 5 Dryer Package Heatless Dryer Packages extend the chamber s operational limits to a minimum humidity control point of 10 RH and improve the dehumidification rate This uses 90 100 psi compressed air to purge moist air from the chamber 6010 Service Manual_B SVC 6010 Contact Closure System The Contact Closure System uses a 24 hour timer to switch between two setpoints Remote Alarm Contact Remote Alarm Contacts are contacts located on the back of the chambers for connection to an external alarm or dialing system Both normally open amp normally closed contacts are provided to signal a deviation from control safety settings Defrost Timer The optional defrost timer allows the chamber to operate at low temperatures down to 0 C When operating the chamber with this option it is recommended to utilize the defrost system to prevent ice build up on the condensing coil The defrost time is pre set to provide four defrost cycles every 24 hours once every 6 hours with the defrost duration at 16 minutes While the un

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