ES2000 Reach-In Chamber

Transcription

1 ES2000 Reach-In Chamber User Manual Version 4.00 Rev For Standard ES2000 Models Featuring CCS-3000 Control System Luwa Environmental Specialties, LLC

2 UTABLE OF CONTENTS U1. INTRODUCTION U2. INSTALLATION U3. OPERATION TU1.1 PRODUCT SUMMARYUT...3 TU1.2 FACTORY TESTINGUT...4 TU1.3 SAFETYUT...5T U1.4 ENVIRONMENTAL CONDITIONSU...6 U2.1 RECEIVING & INSPECTINGU...8 U2.2 SHIPPING PALLET REMOVALU...8 U2.3 CHAMBER ASSEMBLYU...8 U2.4 SITE LOCATINGU...8 U2.5 LEVELINGU...9 U2.6 DRAIN ASSEMBLY INSTALLATIONU...10 U2.7 HOOKING UP UTILITIESU...10 U2.8 INSTALLING SHELVESU REMOTE ALARM CONNECTIONS...12 U3.1 USING THE CONTROL PANELU...13 U3.2 CHANGING SETPOINTS & ALARM SETTINGSU...15 U3.3 USING PROFILING CAPABILITYU...17 U3.4 TYPICAL START UP PROCEDURESU...19 U3.5 TYPICAL SHUT DOWN PROCEDURESU CONFIGURATION 4.1 AIRFLOW SYSTEM HEAT CONDITIONING SYSTEM COOLING SYSTEMS DEFROST CONTROL SYSTEM HUMIDITY CONDITIONING SYSTEM DEHUMIDIFICATION CONDITIONING SYSTEMS OPTIONS & ACCESSORIES 5.1 DESIGN OPTIONS ACCESSORIES MAINTENANCE 6.1 PREVENTIVE MAINTENANCE CLEANING TROUBLESHOOTING SPARE PARTS & CONSUMABLES REPORTING PROBLEMS CHAMBER WARRANTY COMPANY INFORMATION SPECIFICATIONS ES C.F. BENCHTOP...38 ES C.F. UPRIGHT...39 ES C.F. DOUBLEWIDE...40 ES C.F. TRIPLEWIDE...41 ES C.F. UPRIGHT LOW TEMP OPTION...42 ES C.F. DOUBLEWIDE LOW TEMP OPTION...43 ES C.F. TRIPLEWIDE LOW TEMP OPTION APPENDICES APPENDIX A ES2000 M MODELS - HUMIDITY PERFORMANCE CURVES...46 APPENDIX B ES2000 A / AM MODELS - DAMPER ADJUSTMENT DETAIL...47 APPENDIX C ES2000 CDMD MODEL - DRIER OPERATING RANGE...47 APPENDIX D ES2000 UPRIGHT MODELS CONTROL PANEL DETAIL...49 APPENDIX E ES2000 BENCHTOP MODELS CONTROL PANEL DETAIL...50 APPENDIX F ES2000 M MODELS STEAM GENERATOR DETAIL...51 APPENDIX G ES2000 MODELS (ALL) SHIPPING PALLET REMOVAL DETAIL...52 APPENDIX H ES2000 D.W. & T.W. MODELS- CHAMBER ASSEMBLY DETAIL...53 APPENDIX I ES2000 UPRIGHT MODELS DRAIN ASSEMBLY INSTALLATION DETAIL...54 APPENDIX J ES2000 BENCHTOP MODELS DRAIN ASSEMBLY INSTALLATION DETAIL...55 APPENDIX K ES2000..MD MODELS DESICCANT DRIER DETAIL...56 APPENDIX L ES2000 -AT MODELS DRY AIR TOWER DETAIL...57 APPENDIX M ES2000 UPRIGHT MODEL GENERAL CHAMBER DETAIL / CUTSHEET...58 APPENDIX N ES2000 BENCHTOP MODEL- GENERAL CHAMBER DETAIL / CUTSHEET...59 APPENDIX O ES2000 DOUBLEWIDE MODEL GENERAL CHAMBER DETAIL / CUTSHEET...60 APPENDIX P ES2000 TRIPLEWIDE MODEL- GENERAL CHAMBER DETAIL / CUTSHEET...61 APPENDIX Q CCS-3000 RAMP / SOAK PROFILE PROGRAMMING TEMPLATE...62

3 CHAPTER 1. INTRODUCTION Forward This User Manual presents information exclusive to the standard product line, standard operational options, and standard accessories, defined within. As required, refer to the contents of the ES2000 OPERATION & MAINTENANCE MANUAL for special performance options and / or accessories that are not described within this Operation Manual. The technical contents of this manual, while accurate as of publication, are subject to change without notice. No responsibility is assumed for its use. Luwa Environmental Specialties Copyright Product Summary Product Overview The ES2000, a product of Luwa Environmental Specialties (LES), is a reach in environmental chamber designed for high demand testing, processing or conditioning. Five standard models cover temperature ranges from 2 C (36 F) to +70 C (158 F), with controlled humidification and special operational options available on select models. Four standard sizes of 12, 33, 74, and 114 cu. ft. (usable internal volume) are available. General features include: High performance electronic and mechanical systems User friendly microprocessor controls with touch screen in a single panel Industrial grade construction for continuous use Heavy duty refrigeration system with reserve BTU removal capability Modular component design with upgrade flexibility Temperature control to within ± 0.20 C (0.40 F) and uniformity of ± 0.3 C (0.5 F) (± 1.0 C (1.8 F) for 74, 114 cu.ft. models) Relative humidity control to within ± 3% (± 5% for 74, 114 cu.ft. models) Automatic alarm mode deactivation when parameter returns to normal Standard Ethernet connectivity for remote monitoring Optional EIA RS 485 or 4 to 20 ma dc output for remote monitoring Model Designations There are five standard models within the ES2000 product line: ES2000 A: Ambient air cooled, temperature control only ES2000 USER MANUAL VER

4 ES2000 AM: Ambient air cooled, with humidification, temperature and humidity control ES2000 C: Refrigerant cooled, temperature control only ES2000 CDM: Refrigerant cooled, with humidification and refrigerant based dehumidification, temperature and humidity control ES2000 CDMD: Refrigerant cooled, with humidification and desiccant based dehumidification, temperature and humidity control There are four standard sizes within the ES2000 product line, indicated with suffixes: No suffix: 33 cu.ft. upright BT: 12 cu.ft. benchtop DW: 74 cu.ft. doublewide TW: 114 cu.ft. triplewide For general chamber details / cutsheets, refer to APPENDICES M P at the end of this manual. There are four standard operational options within the ES2000 product line, indicated with suffixes (Note: There are various other special operational options provided upon request. These are specified with the S suffix) LT: Low temperature capability, 25 C. or lower (NOT applicable to 12 cu.ft. models) R: Ramping / profiling control system AT: Compressed air tower desiccant drier EX: Explosion safe interior design (exterior is NOT designed for explosion safe standards) For more technical information, refer to section 5 and the SPECIFICATIONS section at the end of this manual. 1.2 Factory Testing Preshipment safety and performance testing is performed on all control and mechanical systems. Each chamber undergoes extensive quality control procedures to verify high and low operational conditions, and verify proper alarm operations. Calibration of the process control instrumentation is performed and documented, and copies provided separately within the ES2000 OPERATION & MAINTENANCE MANUAL. All equipment, safety and performance testing is also documented in the manual. All reference standards utilized in calibration are traceable to the National Institute of Standards and Technology (NIST) Electrical Testing The following testing is performed: ES2000 USER MANUAL VER

5 A dielectric safety test is performed on every chamber wiring harness to check for electrical leaks to ground volts DC is applied to each power line to ground for 1 second with a pass / fail detector. Ground continuity safety testing is performed to all chambers ordered with the factory installed NEMA cord option. The resistivity between the door handle and the chamber ground must be 0.1 ohm or less. The amp draw of all major electrical components is checked for conformance to specification prior to performance testing Mechanical Testing C Models Only Leak testing of the self contained refrigeration system is performed prior to final assembly. The procedure is as follows: When the refrigeration system piping is completed, a pressure test is performed to ensure no leaks are present. An electronic leak detector, with trace refrigerant, is used. The system is then evacuated and charged with refrigerant. A secondary leak check is also performed Operational and Performance Testing Each chamber is configured per written procedures where all electrical and mechanical components are pre checked for operation prior to the performance testing. All settings, serial numbers and documentation is recorded for each chamber and archived for future reference. All alarm functions, indications and time delays are tested for high and low conditions. All chambers are fully performance tested from the lowest operational range to the highest in sequential order. A chamber is not accepted for compliance unless each test point is passed sequentially without failure. After performance testing, the mechanical system is checked using a leak detection system once more to ensure no leaks have developed during the start up and testing process. Temperature uniformity is tested to match specifications per chamber. All chamber setpoints, alarm setpoints, and systems enables are then pre set prior to shipment. 1.3 Safety The lightning flash with arrow symbol, within an equilateral triangle, is intended to alert the user to the presence of dangerous voltage inside electrical enclosure. With the electrical enclosure open there is the presence of non insulated voltage of significant magnitude to cause electrical shock. Only qualified individuals should enter electrical enclosure only after main power is removed. ES2000 USER MANUAL VER

6 Warnings are posted throughout this manual designated by an exclamation point inside an equilateral triangle. These important warnings must be read and followed prior to installing and operating your chamber. Permanent damage to the chamber, property damage, or personal injury or death may result if warnings are not observed. These warnings also appear on the equipment and require operator to consult manual for details. The ES2000 is very heavy, especially when fully loaded with product. Also, when empty, it has a high center of gravity and requires a solid, level surface on which to stand. Only qualified electrical personnel should perform chamber electrical hook up. Qualified mechanical personnel are recommended for hook up of the humidifier water and drain. The unit construction provides extra protection against the risk of electrical shock by grounding appropriate metal parts. The extra protection may not function unless the power cord is connected to a properly grounded outlet. It is the user s responsibility to assure a proper ground connection is provided. Prior to operating chamber, verify that all appropriate utilities are turned on and are of the proper voltage, correct water purity, pressure, etc. Refer to the SPECIFICATIONS section at the end of this manual for more information. DO NOT plug in, turn on or attempt to operate a unit, which is damaged. If the chamber remains off for an extended period of time (two weeks or longer), care must be taken to prevent damage to the mechanical systems. This includes the refrigeration, humidification, de humidification systems, and the electrical system. Purified water is mandatory for proper performance of the steam generator. ES will not warranty steam generator components in the event that purified water is not supplied. The customer should consider any local code ventilation requirements prior to operating a gas control chamber. 1.4 Environmental Conditions The chamber will safely operate under the following conditions: Indoor use. Altitude up to 2000 meters. Ambient temperature range of 5 C to 40 C. (refer to section 2.4) ES2000 USER MANUAL VER

7 Ambient humidity of 80 %RH maximum for temperatures up to 40 C decreasing linearly to 50%RH at 40 C. (refer to section 2.4) Main supply voltage fluctuations of 5 % and + 10 % of the nominal voltage. Transient overvoltages according to Insulation Category (Overvoltage category) II. Insulation co ordination is for Pollution Degree 2. ES2000 USER MANUAL VER

8 CHAPTER 2. INSTALLATION 2.1 Receiving & Inspecting Unless specifically noted otherwise, your chamber is shipped FOB Raleigh, NC. As such, it is your responsibility to inspect the chamber for visible exterior damage, and if any, describe such damage on the freight bill and file any claims necessary with the carrier. In addition to the inspection for external damage, inspect for concealed loss or damage. If any damage is found, retain all shipping materials and arrange for an official inspection by the carrier. If you need to return the chamber for any reason, contact your LES Service Representative for authorization. The chamber is designed on a modular basis and it may be more appropriate to ship only a portion of the chamber. Have all of the nameplate data available for the service representative when you call (i.e.: model, serial #, etc. located on the upper right hand side of the door). 2.2 Shipping Pallet Removal The ES2000 is shipped on a pallet which will require a forklift, or equivalent, to remove. A wrench or socket set will be required to remove bolts. For detailed information, see APPENDIX G at the end of this manual. 2.3 Chamber Assembly - 74 and 114 cu.ft. Models Only The ES2000 doublewide and triplewide chambers require assembly on site, as they are shipped in multiple sections for ease of mobility. The chamber sections cam lock together with the supplied tool. For detailed information, see APPENDIX H at the end of this manual. 2.4 Site Locating The ES2000 models are designed with overall depth dimensions to allow the chamber to pass through a standard 36ʺ doorway, but the height of the upright models is greater than most doorways. The 33 cu. ft. unit may require tilting, in which case the mover should tilt towards the right hand side as seen from the front, or toward the back. After tilting of the unit, please allow no less than 4 hours prior to start up of the chamber. The 74 and 114 cu. ft. chambers (if pre assembled) may not be easily tilted and overall depth and height should be carefully considered when selecting a location. All ES2000 models are equipped with casters and may be transported on these casters. ES2000 USER MANUAL VER

9 When selecting a location for the chamber, consider all conditions that might affect its performance. The chamber should be located in a clean environment where ambient temperatures are between 18 C (65 F) and 25 C (77 F). Ambient relative humidity should be maintained between 45 and 55%. Be sure to avoid close sources of extreme heat such as steam radiators, ovens, autoclaves, etc. See the SPECIFICATIONS tables at the end of this manual to account for chamber heat of rejection. Be sure that the room has enough cooling capacity to hold room temperature with the chamber(s) running. Ambient room temperatures above 32 C (90 F) may cause compressor cycling that will cause erratic temperature control. Contact your LES Service Representative to further discuss chamber heat of rejection. Be sure to allow adequate room in front and to the side of the chamber for the door swing. All models require approximately 102 cm (40 in) of door swing radius, as measured from the flat surface of the front door. To ensure adequate airflow around the chamber, provide a minimum of 46 cm (18 in) between the chamber and rear wall. This spacing is important for the AM series chambers considering that moist air is exhausted from the rear of the chamber and may condense against the back wall of the room. Allow no less than 15 cm (6 in) between units or any side wall. For the most consistent chamber operation, locate the chamber within m (5 10 ft) of a constant flow return air duct. This will pull away warm air rejected from the condensing unit (or damper), blower motor, and steam generator (if applicable). Failure to pull such warm air away or circulate cooler air into the mechanical section may cause periodic trip outs of the compressor, or cause over temperature conditions on the A model chambers. Note that on the A model chambers, the temperature at the mechanical compartment of the chamber (which would be a function of cool ambient) should be at least 10 C (18 F) cooler than the chamber setpoint for proper temperature control. Most importantly, locate the chamber in a site where leveling of the chamber is possible and where power, water, and condensation drain hook ups are available. The drain hook up should gravity feed to a floor drain, heated condensate pan, or condensate pump (if the feed point is higher than the bottom of the chamber). The power and water requirements are listed at the end of this manual in the SPECIFICATIONS section. 2.5 Leveling The ES2000 is very heavy, especially when fully loaded with product. Also, when empty, it has a high center of gravity and requires a solid, level surface on which to stand. Leveling feet and casters are supplied with each unit (leveling feet only on 12 cu. ft. benchtop) and should be installed completely before setting in its final location. Level the chamber by individually adjusting the feet. If the chamber must be moved, turn the leveling screws in as far as possible to minimize the possibility of damage to the leveling feet and flooring. ES2000 USER MANUAL VER

10 2.6 Drain Assembly Installation The ES2000 features an external drain assembly that requires on site installation. The system collects condensate from the evaporator / plenum area, as well as condensate / product spillage from the door area and floor of the chamber. The assembly terminates at a ½ OD stainless tube connection at the rear of the chamber (or each section on 74 and 114 cu.ft. models). For detailed information, see APPENDIX I or APPENDIX J at the end of this manual. 2.7 Hooking Up Utilities Refer to the detail below for a typical rear view of chamber: Figure A Only qualified electrical personnel should perform chamber electrical hook up. Qualified mechanical personnel are recommended for hook up of the humidifier water and drain Electrical Hook Up Refer to the unit serial tag located inside electrical enclosure for information regarding electrical power requirements. The SPECIFICATIONS section at the end of this manual also provides power requirements, but electrical service should always be provided based on serial tag information, which may include options not considered in the SPECIFICATIONS table. Building electrical service equipment must be sized according to specific chamber power requirements per all national and local electrical codes. A switch or circuit breaker provided by others must be installed as part of electrical installation. The device must be in close proximity to the chamber and must be marked as the disconnecting device for the chamber. Electrical power must be connected to the power block located inside the electrical enclosure. A proper ground connection must be made to the protective earth (ground lug) located next to power block. The unit construction provides extra protection against the risk of electrical shock by grounding appropriate metal parts. The extra protection may not function unless the ES2000 USER MANUAL VER

11 power cord is connected to a properly grounded outlet. It is the user s responsibility to assure a proper ground connection is provided. This product is intended to be installed by one of the following methods: Standard: This is a hard wire connection with 6 minimum leads (see Figure A). Connection is made in a 4 x 4 junction box located behind the control panel in the equipment area. Optional: This is a receptacle connection. A 12 foot, 10 gauge, 4 conductor cord with a NEMA plug is provided. The mating receptacle is also provided with unit for installation by others. Contact your LES Service Representative if you have questions about electrical hook ups. Note: The optional NEMA 14 cord with plug and matching receptacle set are offered through Service Parts Sales if required after receipt of chamber(s) Drain Hook Up A ½ OD stainless tube connection is provided for drainage of condensate. Figure B This should be routed to a nearby floor drain in accordance with national and local plumbing codes. Should a floor drain not be available at time of receipt, contact LES Service Parts Sales for options including a condensate pump or heated condensate pan. Note: The ES2000 A model does not require a condensate drain system; the system may be installed only as desired for accidental product spillage to the center floor drain(s) Purified Water Hook Up M Models Only A ¼ʺ OD tube compression connection is provided for the supply of purified water to the chamber humidifier (see Figure A). Plastic, brass, copper, or stainless is acceptable. This supply should be run according to all plumbing codes. Refer to the SPECIFICATIONS section at the end of this manual, or the label affixed to the rear of the chamber, for important information on water supply quality and pressure limits Compressed Air Hook Up -AT Models Only A 3/8ʺ OD tube compression connection is provided for the supply of compressed air to the chamber air tower drier system. Brass, copper, or stainless is acceptable. The tubing must be rated for no less than 150 PSIG. The compressed air requirements are: Nominal 7 SCFM in the range of 60 to 120 PSIG; instrument grade quality. Note that chamber performance is based ES2000 USER MANUAL VER

12 upon 100 PSIG supply pressure; lower pressures will result in slower, or possibly inadequate, drying and humidity recovery times. 2.8 Installing Shelves The chamber shelving is packaged separately and shipped inside the chamber. Unwrap the shelves, remove the protective paper wrap, and install each shelf by sliding shelf brackets into the opposing receiving slots on each side of the chamber; then slide the shelf into the brackets. Because of the horizontal airflow pattern in the chamber, the stainless steel shelves can be slid into the receiving slots in any spacing desired. Stainless steel shelves are provided standard with each chamber: (4) for 33 cu. ft., (2) for 12 cu. ft., (8) for 74 cu. ft., and (12) for 114 cu.ft. models. Each shelf is designed to hold up to 58 kg (130 lb) of well distributed load. Shelves may be easily removed to accommodate alternate inventory systems, racks, card or other load distribution requirements. Point loads or concentrated center loads may cause shelf deformation, or possible shelf and bracket failure. Contact your LES Service Representative for special load requirements. Additional shelves may be ordered optionally. Maximum shelf capacities are as follows: (39) for 33 cu. ft., (14) for 12 c.f., (78) for 74 c.f., and (117) for 114 cu.ft., with clearance between shelves of 7.6 cm (1.5 in) at full capacity. Note that this clearance does restrict airflow, thus having an effect on uniformity of temperature and humidity. LES recommends maximum shelving count to be ½ of the quantities listed above, at a clearance of 15.2 cm (3.0 in). 2.9 Remote Alarm Connections Alarm connections are provided, as standard, for connection to a remote alarm monitoring system provided by others. This is a set of dry contacts that are pre wired for a single, common alarm contact closure in the event of any chamber control system alarm condition including high or low temperature or humidity alarm conditions, sensor errors, etc. This connection is located on the back of the control panel and is adjacent to the power connection. The power limitation for this connection is Class 2. ES2000 USER MANUAL VER

13 CHAPTER 3. OPERATION 3.1 Using the Control Panel The controls are mounted in an integral panel at the top of the ES2000. The control panel serves to house and protect controls, recorder and alarms, as well as efficiently distribute power to the chamber interior and exterior mechanical section. The control panel is compliant to the appropriate UL standards. All control and switch functions are clearly labeled with non fading polycarbonate labels. Figure C. Refer to APPENDIX D or APPENDIX E at the end of this manual for additional full views of the control panel. Also refer to the CCS 3000 USER MANUAL for more specific control system information Chamber Power Switch The chamber power rocker switch, located on the far left, controls the power to the chamber control circuit. It must be switched to the ON position (red rocker indication) before the chamber will operate. Chamber operation is indicated by a lit touch screen Touch Screen Overview The touch screen is used for all user input and parameter displays. The Control Monitor view is the main default view which displays all important chamber information. Actual values for both Temperature and Humidity are displayed, as well as the Setpoints for each of these variables. Information for chamber output operations are displayed, as is system redundancy information (if equipped on the chamber system). The normal screen background color is blue, ES2000 USER MANUAL VER

14 and during an Alarm condition, the screen background will turn red to indicate that an alarm exists in the system. Refer to the CCS 3000 USER MANUAL for more specific touch screen information Control Monitor Setpoint Indicators Figure D. SET (green for temperature): Displays the current temperature setpoint to one tenth of a degree resolution. To change the value, press the field and a separate numeric screen will appear. Enter the new value and press DONE. The new value will appear back in the setpoint field. SET (red for humidity): Displays the current relative humidity setpoint to one tenth of a percent resolution. To change the value, press the field and a separate numeric screen will appear. Enter the new value and press DONE. The new value will appear back in the setpoint field Control Monitor Output Indicators Controller output values (below the Setpoint indicators): The values indicate percent controller output of heat (H) and cool (C) (for temperature) below the temperature setpoint field, and percent controller output of humidification (H) and de humidification (D) (for humidity) below the humidity setpoint field. Refrig: Displays that power is enabled to the refrigeration system outputs (Solenoids, Fan Contactor, and SSR Heater Output). These outputs are enabled if the chamber is not in High or Low Temperature Alarm. Defrost: Displays that a defrost cycle is currently running. Defrost is not enabled if the chamber is in High or Low Temperature Alarm. The Defrost box turns yellow when a defrost cycle is active. Humidity: Displays that power is enabled to the steam generation equipment. Humidity generating outputs are not enabled when the chamber is in High Temp ES2000 USER MANUAL VER

15 Alarm, Low Temp Alarm, High Humidity Alarm, or Defrost. Refrigeration must be enabled. DeHumidify: Displays that power is enabled to the dehumidification equipment. Dehumidification is not enabled when the chamber is in High Temperature Alarm, Low Temp Alarm, Low Humidity Alarm, or Defrost. Refrigeration must be enabled. Liquid Sol: Displays the status of the Liquid Solenoid valve. Status is energized (green) or de energized (gray). Hot Gas Sol: Displays the status of the Hot Gas Solenoid valve. Status is energized (green) or de energized (gray). Fans: Displays the status of the main Fans. Status is energized (green) or de energized (gray). Heaters: Displays the status of the air Heaters. Status is energized (green) or deenergized (gray). Exh Fans: Displays the status of the Exhaust Fans. Status is energized (green) or deenergized (gray). Note: This is not applicable to the ES2000 series Audible Alarm & Alarm Silence Switch The audible alarm is activated by an alarm condition. The audible portion of the alarm is deenergized by touching on the Silence pushbutton in the Alarm Monitor screen or by the ALARM SILENCE switch (see Figure C). The audible alarm features a 0 to 30 minute adjustable ringback feature. Refer to the CCS 3000 USER MANUAL for more specific alarm information USB Interface Port The USB interface port allows connection of an I Stick memory stick for data storage or transfer, or connection of a printer for trend printouts. The port is located to the right of the ALARM SILENCE switch, and is labeled PRINTER / MEMORY (see Figures C and E). Figure E. Refer to the CCS 3000 USER MANUAL for more specific interface information. ES2000 USER MANUAL VER

16 3.2 Changing Setpoints & Alarm Settings Temperature & Humidity Process Value Setpoints To change either the temperature or relative humidity setpoint, press the SET field, and a separate numeric screen will appear. Enter the new value, and press DONE. The new value will appear back in the setpoint field. Figure F Temperature & Humidity Alarm Settings Alarm setpoints settings are accessible via the Setup and System Settings menu selection. To change any of the temperature or relative humidity values, press the field, and a separate numeric screen will appear. Enter the new value, and press DONE. The new value will appear back in the appropriate field. Figure G. The Alarm Setpoints screen allows an operator to set high/low alarm setpoints for both temperature and humidity. Delay time in minutes for each alarm is also adjustable from 0 to 60 minutes. The alarm delay feature is useful in allowing the alarm limits to be set closer to the operating setpoint without having the associated nuisance alarms caused by extended chamber door openings and defrost cycles. The delay time begins as soon as the process value exceeds the alarm threshold and is automatically reset when the process value no longer exceeds the alarm threshold. Alarm settings are safe sided, meaning the alarm will energize at the alarm setpoint and de energize when the temperature falls outside the alarm setpoint + deadband setting (the deadband setting is configured at the LES factory). The user can press the desired field to make a change to the setpoint/delay value from the popup numeric keypad. The Ringback feature re energizes the audible alarm output if an alarm still exists after it is silenced and the Ringback time has expired. The Ringback function will continue to operate as long as the alarm is active. The Ringback time is reset each time the alarm silence is pressed from the main alarm monitor screen or from the remote alarm silence pushbutton (if equipped on the ES2000 USER MANUAL VER

17 chamber). To disable the Ringback function, enter a value of 0 into the Alarm Ringback field. Refer to the CCS 3000 USER MANUAL for more detailed information on alarm setup. Note: As a rule for the alarm delay, initially set the delay at 15 minutes. In the case of a coldroom low temperature alarm where freezing could damage a product or water service in the chamber, reduce the alarm delay to alert the operator to potentially freezing conditions. 3.3 Using Profiling Capability The CCS 3000 features the option of profiling capability. This option provides automatic ramping of temperature and humidity setpoints and turning on and off various event outputs such as lights. Figure H below shows an example of a profile step edit screen. Figure I below shows an example of a profile with varying temperature and humidity. Figure H. Figure I. The Profile menu from the Main menu structure provides access to the automated profile section of the CCS Select Profile Edit/Run to enter the profile entry section of the CCS. This menu item will only be available if the profile option is equipped on the chamber. ES2000 USER MANUAL VER

18 Refer to the CCS 3000 USER MANUAL, Section 3. for more detailed information on profiling capability Profile Screens The Profile Screens menu provides the following functions: Control Monitor: Returns user to Main chamber view. Profile Status View: Displays Profile Status view screen. Profile Entry: Displays Profile Entry screen. Guar Soak Limits: Displays Guaranteed Soak Limits settings. Plot Profile: Displays Profile plot. Profile Auto Start: Displays Profile Auto Start entry view. Refer to the CCS 3000 USER MANUAL, Section 3. for more detailed information on profiling screens and setup Profile Edit The Profile Edit menu provides the following functions: New Profile: Clears all entries for new Profile generation. Insert Step: Inserts a step into current Profile. ES2000 USER MANUAL VER

19 Delete Step: Deletes the current step from Profile. Copy Step: Copies current step data. Paste Step: Pastes current step data. Select Profile: Opens Profile from compact flash. Save Profile: Saves Profile to compact flash. Save Profile As: Saves Profile as a different name. Delete Profile: Deletes current profile. Refer to the CCS 3000 USER MANUAL, Section 3. for more detailed information on profiling screens and setup Profile Run The Profile Run menu provides the following functions: Run Profile: Starts currently loaded Profile. Hold Profile: Holds Profile that is running. Stop Profile: Stops Profile that is running. Advance Next Stage: Advances to next stage in running Profile (only when in hold). Advance Prev Stage: Advances to previous stage in running Profile (only when in hold). Refer to the CCS 3000 USER MANUAL for more detailed information on profiling screens and setup. 3.4 Typical Start Up Procedures Verify that all appropriate utilities are turned on and are of the proper voltage, correct water purity, pressure, etc. Refer to the SPECIFICATIONS section at the end of this manual for more information. DO NOT plug in, turn on or attempt to operate a unit, which is obviously damaged. The following steps should be followed: 1. Turn the chamber power switch to ON and allow the CCS 3000 system to boot up to the Control Monitor screen. ES2000 USER MANUAL VER

20 2. Push the ALARM SILENCE switch or navigate to the Alarm Monitor screen and touch the Silence pushbutton if the audible alarm is activated (see Figure C and section 3.1.6). 3. On the Control Monitor screen (see Figure D) re set the temperature and humidity setpoints as required (factory standard settings are generally 25 C (77 F)/60% RH or 40 C (104 F)/75% RH) (see section 3.2.1). 4. On the Alarm Setpoints screen (see Figure E) re set the high and low alarm setpoints as required (factory standard settings are generally +/ 10 C (18 F) and +/ 20% RH of the temperature and humidity setpoints) (see section 3.2.2). 5. Make sure that the door(s) is/are closed tightly; gasket(s) are properly sealing, and locked as required. 3.5 Typical Shut Down Procedures If the chamber remains off for an extended period of time (two weeks or longer), care must be taken to prevent damage to the mechanical systems. This includes the refrigeration, humidification and de humidification systems, and the electrical system. The following steps should be followed: 1. Turn the chamber off by the front panel POWER switch (see section 3.1.1). 2. Turn off the electrical breaker to the chamber or if plug and cord connected, unplug the cord from the power receptacle. 3...M models only Shut off the water supply to the steam generator and drain the water from inside the steam generator (see section 2.7). 4...MD models only Remove the flexible ducting from the drier and cap the outlets of the drier (see APPENDIX K). 5. Clean the interior of the chamber fully; remove the evaporator drain pan and clean the interior surface (see section 4.1). 6. If the chamber has an optional recorder, remove the chart paper and replace the caps on the felt tipped pens. ES2000 USER MANUAL VER

21 CHAPTER 4. CONFIGURATION 4.1 Airflow System Precise environmental control in the ES2000 is achieved through a unique air distribution technique that moves conditioned air horizontally across the product shelves. Side wall plenum ports are arranged to deliver even flow for maximum uniformity and efficient thermal transfer. Figure J. The ES2000 is provided with a stainless steel top mounted plenum with an external motor driving a stainless steel blower assembly (with aluminum wheel on explosion safe EX models). The plenum also contains air and defrost heaters, evaporator coil (standard: copper tube with aluminum fins), latent coil (on..dm models), and condensate drain pan. The conditioning system forces the conditioned air continuously across the shelving area through the perforated stainless steel walls. 4.2 Heat Conditioning System Heating is accomplished by modulating the refrigeration system in conjunction with a fast responding open coil nichrome wire heater element encased in a stainless steel frame (or stainless steel finned heater for explosion safe EX models). See Figure J. in the previous section. This heater is proportionally controlled by the temperature controller in conjunction with the process alarm board utilizing a zero switching solid state relay for electrical operation that is virtually noise free. ES2000 USER MANUAL VER

22 4.3 Cooling Systems Refrigeration System C Models Only A proportional liquid hot gas refrigeration technique is provided to maintain straight line temperature, to allow rapid acceleration to setpoint, and to extend compressor life by modulating refrigerant flow as required to maintain control. The system uses extended life solenoids in alternating action to control both liquid and hot gas flow. Figure K. The standard compressor/condenser unit consists of an air cooled hermetic compressor mounted on top of the chamber. The unit is supplied with high and low safety pressure control, liquid line drier with sight glass, suction accumulator, crankcase pressure regulator, and thermal protection. For maximum compressor life and flexibility of cooling control, the temperature controller features an alarm contact that will switch off the refrigeration unit at any predetermined temperature; standard cutoff at 61 C (142 F). The LT models feature a larger compressor / condenser unit which provide for the low temperature capability of 25 C ( 13 F) and lower. This model also features special defrost heating systems, as described in section 4.4. For more information on the refrigeration system, refer to the refrigeration schematic and separate manuals found separately within the ES2000 OPERATION & MAINTENANCE MANUAL Air Cooling System A Models Only Through adjustable intake and exhaust dampers, cool ambient air provides the required chamber cooling. ES2000 USER MANUAL VER

23 Figure L. For proper chamber performance, ambient controlled models require damper adjustment when the user changes setpoint. These dampers are located in the rear mechanical section of the chamber. For detailed adjustment information, refer to APPENDIX B at the end of this manual. When selecting a location to position the chamber, be sure to provide adequate room for user access. Also consider that the ideal chamber ambient is 25 C (77 F) / 50% RH. The intake and exhaust dampers have 2.5 in OD stubs for connection to duct lines. Note that runs longer than approximately 3 m (10 ft) may require an optional booster blower due to duct pressure loss. 4.4 Defrost Control System C Models Only The refrigerated models are supplied with an automatic hot gas/electric defrost system with time initiation and time/temperature termination control. A coil temperature sensing RTD provides for an adaptive defrost system. The adaptive defrost function automatically disables defrost action when not required, and enables defrost action when required. The defrost frequency is factory set to optimize the defrost cycle for duration and temperature variation. The LT models feature an additional defrost heating system. A silicon flex heater is provided within the plenum pan for de icing of the pan and coil condensate. The flex heater is fully encased in silicon to be fully waterproof, and is covered with a stainless steel pan. The drain stub is wrapped with a silicon flex heater to provide gentle heating at all times, allowing for proper drainage after defrost cycles. An additional rod heater is provided on the evaporator coil to enhance defrosting. Note: Since this is a temperature termination system, defrost times may vary from as little as 1 to more than 15 minutes for the total defrost duration. Refer to the CCS 3000 USER MANUAL for more information on the defrost system. ES2000 USER MANUAL VER

24 4.5 Humidity Conditioning System..M Models Only The humidified models use an independent steam generator to create moisture within the chamber. The steam generator tank is constructed of 316 stainless steel, and the heaters are Incoloy for excellent corrosion resistance. All other wetted parts are constructed of highly corrosion resistant materials. The steam generator features switch actuation of a stainless steel water fill valve, and also features a stainless steel automatic safety switch that shuts down the electric heater if the water supply is low, or shut off. Steam enters the chamber air stream through a stainless steel steam header mounted in the conditioning plenum. The steam generator is mounted in the cabinet s mechanical section. Purified water is mandatory for proper performance of the steam generator. LES will not warranty steam generator components in the event that purified water is not supplied. The water must meet the following criteria: 25 K to 15 megohm resistivity, hardness of 20 PPM or less (1 grain per gallon or less), ph level 6.7 or greater, and be supplied in a pressure range of bar (10 25 PSIG). Note that this type of water quality is to be expected of quality RO and basic deionizer / demineralizer systems, but may not be expected of untreated city water sources. This water quality information is critically important, and further referenced in the SPECIFICATIONS section at the end of this manual, and on a label affixed to the rear of the chamber. For locational information, refer to Figure K. For detailed information on the steam generator, refer to APPENDIX F at the end of this manual. 4.6 Dehumidification Conditioning Systems Latent Coil Dehumidification..DM Models Only A separate refrigeration coil, called the latent coil, is provided below the sensible coil. This coil is regulated to a temperature below the air dewpoint, thus providing dehumidification of the air stream. The regulation of the latent coil is by the humidity controller, and pulsing of a secondary liquid solenoid valve Desiccant Drier Dehumification..MD Models Only A desiccant wheel drier and damper assembly are supplied pre installed on the rear of the chamber. Both systems are fed by a switched 120 VAC receptacle mounted at the rear of the chamber, and thus does not require a separate power feed. The drier is not proportionally regulated, only enabled and disabled by the CCS 3000 control system. For detailed information on de humidify / drier enabling specific to this model, see APPENDIX C at the end of this manual. Note: In the CCS Manual Operation screen, the dehumidification latent coil and drier are active / permitted at all times the De Hum On box is checked. The Drier Enable checkbox, also in the CCS Manual Operation screen, activates and de activates the desiccant drier, only. ES2000 USER MANUAL VER

25 In the event that the De Hum On box is unchecked, the desiccant drier is also de activated (slave to the De Hum function). For detailed information on the drier and damper assembly, refer to APPENDIX K at the end of this manual Compressed Air Tower Dehumidification -AT Models Only A permeable membrane air tower drier is supplied pre installed on the rear of the chamber. The drier provides an air stream dewpoint of approximately 40 C ( 40 F). The drier operates through membrane permeation method, in lieu of the typical desiccation method. The drier has no heating system or tower solenoid valve. This drying system is most effective for ultra low dewpoint chambers, and chambers requiring frost free operation. Refer to APPENDIX A for optimum performance range. The regulation of the dry air is by the humidity controller, and pulsing of an air solenoid valve. For detailed information on the dry air tower assembly, refer to APPENDIX L at the end of this manual. ES2000 USER MANUAL VER

26 CHAPTER 5. OPTIONS & ACCESSORIES 5.1 Design Options Listed below are popular design options, defined as options which modify the mechanical, electrical, or architectural design of the standard chamber. Special request design options may have been provided with the chamber(s), and are detailed in separate documentation within the ES2000 OPERATION & MAINTENANCE MANUAL C Capability -LT Models The optional 25 C ( 13 F) chamber package (available only 33, 74, 114 cu. ft. models) includes a larger compressor / condensing unit, and additional defrost heating systems. A silicon flex heater is provided within the plenum pan for de icing of the pan and coil condensate. The flex heater is fully encased in silicon to be fully waterproof, and is covered with a stainless steel pan. The drain stub is wrapped with a silicon flex heater to provide gentle heating at all times, allowing for proper drainage after defrost cycles. An additional rod heater is provided on the evaporator coil to enhance defrosting. For detailed performance information, refer to the SPECIFICATIONS sheets at the end of this manual Profiling Capability R Models The optional profiling capability provides automatic ramping of setpoints between low and high temperatures and humidities. The CCS 3000 control system can store over 100 programs that can be up to 99 steps (segments) with 4 event outputs per step (segment) (please refer to the electrical schematics to determine if events are used for your chamber). Each ʺstepʺ either has a final set point, time and event associated with it, or a program instruction. These instructions can link one program to another, allowing multiple cycles of the same program, or the program can be ended after the last programmed step. For further information, refer to section Compressed Air Tower Dehumidification -AT Models The optional air tower drier is supplied pre installed on the rear of the chamber. The drier provides an air stream dewpoint of approximately 40 C ( 40 F). The drier operates through membrane permeation technique, in lieu of typical desiccation technique. The drier has no heating system nor tower solenoid. This drying system is most effective for ultra low dewpoint chambers, and chambers requiring frost free operation. Refer to APPENDIX A for optimum performance range. The regulation of the dry air is by the humidity controller, and pulsing of an air solenoid valve. ES2000 USER MANUAL VER

27 For detailed information on the dry air tower assembly, refer to APPENDIX L at the end of this manual Explosion Safe Interior -EX Models The optional explosion safe design allows for a Class I, Division II interior designed for closed container, volatile product storage. The package includes a special low watt density finned heater designed to operate below the lower explosive limits of Cl. I, Div II products. The temperature of the finned heater is limited by watt density, but secondary temperature protection is provided by a thermostat with remote sensing bulb. On chambers with high temperature and humidity requirements, classified rated heat trace, or embedded cable, is supplied in the door frame. The temperature detector (RTD) and relative humidity sensor (if provided) are protected by intrinsic barriers, which limit current flow, i.e. sparking, of the devices. The blower wheel is provided as aluminum to prevent sparking against the stainless steel blower housing. All electrical penetration are protected by explosion proof fittings with explosion proof filling compound. Automatic venting devices and door disconnect switches may be installed depending upon the specific application. The EX package provides a classified rating to the interior, only. mechanical and electrical items are not compatible with classified areas. Exterior CO2 Control System The CO2 control option provides an injection system consisting of a solenoid and injector tube located in the conditioning plenum for uniform mixing of gas concentration. The conditioning coil is specially coated for corrosion resistance to CO2 / carbonic acid. The CO2 sensor is infrared type specially designed for high accuracy and long term repeatability. A door interlock is provided to stop gas injection while the door is opened to reduce gas consumption. A PID microprocessor controller provides for optimum recovery time, and tight control, of the desired gas level after the door is closed. The customer should consider any local code ventilation requirements prior to operating a gas control chamber International Voltage The international voltage option provides modified mechanical and electrical systems for operation between VAC, 1 phase, 50 Hz. This option includes the internationally recognized CE mark (as required), and a special crating system for air / sea shipments V Voltage The 120V voltage option provides modified mechanical and electrical systems for operation at VAC, 1 phase, 60 Hz. An additional option of a NEMA 5 plug and receptacle set is offered. ES2000 USER MANUAL VER

28 5.1.8 Water Cooled Condensing Unit The water cooled condensing unit option provides a cooling system alternative to the air cooled condensing unit. By using building water, the chamber heat is rejected to the water in lieu of ambient air. This option is valuable for chamber locations with limited cooling capacity Mechanical Redundancy DW, TW Models Only The mechanical redundancy option provides a duplicate refrigeration and airflow system (100% mechanical redundancy). The control system periodically alternates between the primary and backup system, and will automatically lock into one system upon detection of a fault with the other system. The system features two condensing units, two cooling coils, two blowers, two air heaters, and two defrost heaters Interior Lighting The interior lighting option provides fluorescent or incandescent light fixtures for general product inspection. The light fixture(s) can be mounted at the top of the chamber, along the back wall at various locations, or under shelves, depending upon the specific customer needs. The lights are enabled by a rocker switch located in the control panel area Glass Door The optional glass door provides a large view window of triple pane heated glass for easy viewing of products in test. Note: This option limits the low end range to 2 C (36 F), and is not applicable with the -LT option (see section 5.1.1) Pass-Thru Door An optional back door provides the capability for pass thru from front to back of chamber. Door interlocks may be installed, depending upon the application Stainless Steel Exterior The stainless option provides a corrosion resistant exterior of 304 or 316 stainless steel, #3/4 finish. This option is popular in cleanroom areas, and allows for more aggressive cleaning agents generally used for interior and exterior decontamination Multi-Point Monitoring System The multi point monitoring option provides up to 6 additional temperature inputs. The inputs are all monitored and recorded, with each input featuring a dedicated display, alarm settings, and trending. The monitoring option is useful for verification of temperature uniformity, as well as penetration readings in product(s). ES2000 USER MANUAL VER