ACS CST157 THERMAL SHOCK MANUAL

HANDBOOK CHAMBERS FOR THERMAL SHOCK TESTS

21/09/95

l\CS

MN2038 AL 5500

TABLE OF CONTENTS TECfINICAL DATA INSTALLATION PRELIMINARY OPERATIONS FOR THE CHAMBER START-UP STARTING-UP MAINTENANCE SAFETY EQUIPMENTS INSTALLED IN THE SYSTEM GRAPHIC RECORDER GASEOUS NITROGEN PURGING (optional) COOLING WITH LN2 (optional)

3 4 .5 6 10 11 12 12 12

ENCLOSED HANDBOOKS: - UNOP controller - SIEMENS P.L.C. ENCLOSED DRAWINGS: - LAY-OUT - REFRIGERATION SYSTEM DIAGRAM - ELECTRICAL WIRING DIAGRAM: POWER CIRCUIT POWER CIRCUIT CONTROL PANEL

C 21.486 C 21.486 - SI C 21.486 - SE from page 1 to 16 C 21.486 - SE from page 18 to 21 C 21.486 - SE from page 22 to 23

ENCLOSED DOCUMENTS: - ACS test certificate - ACS quality assurance certificate

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MN2038 AL 5500

3 TECHNICAL DATA

Type

: CST157 2T

Serial number Testing

: 5500 :15500

Useful volume of the basket

: 157 1 approx

Temperature

: from - 800e to + 220째C

range

- in the upper chamber

: from 200e over the ambient to up to + 220째C

- in the lower chamber

: from ambient to to -70째C with possibility of undercooling

Temperature

: +/-1째C

accuracy

Mains supply voltage

: 380 V/50Hz/3+N+G

Remote control voltage

: 24 V

Mains supply power

:30Kw

Cooling unit

: running with water

Refrigerants

: HP80 + R23

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to -80oe

HP 10 + 10

MN2038 AL 5500

4

INSTALLATION For a proper running of the chamber the ambient temperature must not exceed +30oe.

Electric connection The customer must provide to the installation of a shunt box with a main switch for the connection of the chamber mains supply.

Inside the remote control switches board (in the machines unit) there is a terminal board: the "R", "5" and "T" terminals must be connected to the threephase mains.

The "N" terminals must be connected to the neutral of the mains.

The "YELLOW/GREEN" terminal must be connected to an efficient earth socket.

Hydraulic connection Before the installation of the equipment to the hydraulic network for getting the condensation water, the chamber must be placed in its final location, otherwise flexible piping is necessary.

The maximum pressure of the condensation water must not exceed 1 MPa (10 bar).

For well water the outlet must be available for inspection. Foreseen water temperature is + 15°C ± 3°C. In this last case, it is recommended to install an overflow switch that stops the equipment running if the water does not regularly flow in the condenser.

Azote connection See instructions in the chapter nitrogen purging (optional).

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MN2038 AL 5500

5 PRELIMINARY OPERATIONS FOR THE CHAMBER START-UP

Verify the correct rotation way of the fans in both cabinets, proceeding as follows : - Turn the main switch on; If the fans do not turn according to the arrow on the motor, it is necessary to reverse the "R" and "S" terminal connections at the feeding input.

At the doors side of the chambers, there are applicated two micros witches which avoid the running of the chamber when the doors are opened.

Remind that to start fans working with opened chambers, it is necessary to switch on both the microswitches contacts placed beside the door.

THIS OPERATION IS NECESSARY TO ENSURE THE CORRECT ROTATION WAY OF THE BASKET MOVEMENT MOTOR, AND TO PERMIT THE RUNNING OF THE SAFETIES; OTHERWISE RELEVANT DAMAGES COULD BE CAUSED TO THE STRUCTURE. Check that specimens discharge correctly into the basket, that is: - Basket in the hot chamber; - The specimens are some centimeters far from the basket borders; - During the basket removing, they can not drop out in order to avoid relevant damages.

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MN2038 AL 5500

6

STARTING-UP 1. PROGRAMMING a. Select the running mode; with the Fl key select the manual running, with the F2 key select the automatic running. b. If you press the F3 key you enter in the programming MENU. To insert data press the Ins key, a lighting cursor appears on the exact point you have to programme the value; if you press the ENTER key you confirm the programmed value.

Remember that when the 4 lines of the display with the down arrow key are finished it is necessary to do the SCROOL in order to see the other lines.

It is important to perform the above-mentioned operation in order to insert the data on all lines of the MENU. When you have finish the programming of the temperature sets and times sets, press one more time the F3 key and then you return to the control MENU. It is very important to select the running (manual or automatic) before doing the programming.

Example of programming in automatic cycle Press the F2 and F3 keys .............. SET PARAMETERS PROGRAMMING . ...............

AUTOMA TIC CYCLE .

COLD CHAMBER TEMPERAT. SET POINT: -65 COLD CHAMBER DWELL TIME SET POINT : 0:15 COLD CHAMBER DECREASE TEMPERATURE:-lO HOT CHAMBER TEMPERA T. SET POINT: 160 HOT CHAMBER DWELL TIME SET POINT: 0:15 HOT CHAMBER INCREASE TEMPERATURE: 15 TEST CYCLES TOTAL NUMBER: 30000 CYCLES NUMBER BEFORE DEFROSTING: 200 COLD CHAMBER UNDERTEMP. SET POINT: -85 HOT CHAMBER OVERTEMP. SET POINT: 200 FORCED COOLING TIME SET POINT: 3 Min (max 5 rnin) FORCED COOLING TIME SET POINT: 2 Min (max 5 rnin) PRES. F3 : FOR OTHER COMMANDS

To insert data press the Ins Key and confirm them with ENTER key. The stabilization times are activated when the basket takes place in the respective chamber.

The times values are in hours and minutes.

The set cold shrinking time is the time when the cold request is forced when the basket takes place in the cold chamber.

This time can vary from 0 to 5 minutes according to the internal load.

The set hot shrinking time is the time when the hot request is forced when the basket takes place in the hot chamber.

This time can vary from 0 to 5 minutes according to the internal load. The minimum time of stabilization on all chambers is of 1 minute.

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MN2038 AL 5500

7

Example of programming in manual cycle Press the Fl and F3 keys ......... SET PARAMETERS PROGRAMMING ... .MANU AL CyCLE COLD CHAMBER TEMPERAT. SET POINT: HOT CHAMBER TEMPERA T. SET POINT: COLD CHAMBER UNDERTEMP. SET POINT: HOT CHAMBER OVERTEMP SET POINT: PRES. F3 : FOR OTHER COMMANDS

. .

-65 160 -75 180 .

To insert data press the Ins key and confirm them with ENTER key. c. If you press the F4 key you can check the programmed set, with the down and up arrow key you may do the SCROOL of pages in order to check the correct set of data.

The checking function can be done in any moment. Leaving out of consideration the type of visualized data if you press the F4 key the control MENU appears. d. ATTENTION When you set an overtemperature or undertemperature lower or higher to the running temperature including the increment or the decrement at the starting, the chamber will go in alarm indicating on display these messages : ................................

W ARNING .

OVERTEMPERA TURE SWITCH SET POINT LOWER THAN HOT CHAMBER SET POINT ................... PRES. F3 : TO PROGRAMMING . ................................

W ARNING .

UNDERTEMPERATURE SWITCH SET POINT HIGHER THAN COLD CHAMBER SET POINT ................... PRES. F3 : TO PROGRAMMING .

If the above-mentioned anomalies appear, return back in programming and modify the set point of the faulty temperatures.

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MN2038 AL 5500

8 2. CHAMBER STARTING 2.1. Manual cycle In manual running the chamber becomes 2 distinct chambers.

If you press the F5 (cold) and F6 (hot) keys you activate the running of the cold and hot chamber.

If you press the F9 key the basket takes place in the cold chamber.

If you press the Fl0 key the basket takes place in the hot chamber.

2.2. Automatic cycle Select the chambers in which you want to perform the test, F5 (cold) and F6 (hot).

Press the F16 key (AUTOMATIC CYCLERUN) for the cycle starting.

The basket cycle will start only when the cold chamber will be in the ±2°C temperature range.

If you open the chamber door during the running, the cycle stops. If you close the chamber door the basket cycle will start again only when the temperature of the cold chamber will be in the ±2°C range.

When you open the door of the ambient chamber, the basket will take place in the central chamber and then will stop the running of the chamber.

The 2 other chambers will continue to thermoregulate the set temperature.

2.3 Defrosting When the chamber reaches the number of set cycles, for the defrosting, the hot and ambient chambers stop and in the cold chamber the thermoresistances heat in order to set free of ice the evaporator.

The set temperature for the defrosting is of 40°C and the time is of 30 minutes.

The time start will begin only when the cold chamber will reach 30°e.

2.4 Cleaning with nitrogen If you press the F15 key, you activate the solenoid valve for the cleaning with nitrogen.

2.5 Cycles end When the chamber reaches the set total cycles, it will stop and the basket will remain in the hot chamber.

2.6 Timer reset and general reset The Fll key: general reset (cycles reset and timer for the chambers stabilization duration).

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MN2038 AL 5500

9

2.7 Alarms The alarms set on this chamber are : "FAILURE: MOTORS PROTECTION" "FAILURE: OVERTEMPERATURE SWITCH" "FAILURE: UNDERTEMPERATURE SWITCH"

When the above-mentioned alarms are activated they can be controlled according to the intervention sequence.

The intervention of these alarms stops the chamber and place the basket in the rest position.

You can find the anomaly on video and on lighting red led ALARM placed on the control panel.

2.8 Emergency push button On the chamber front panel you can find an emergency push button.

If you press it the chamber goes in OFF opening the main switch.

In order to reset the power supply release the push button turning counterclockwise sense and switching the main switch off.

2.9 Alarms reset For the reset of the alarms, follow these instructions: Press the F12 key (alarms reset).

2.10 Time data On the back side of the control panel you will find 2 lithium batteries type CR2430.

These batteries have a life of about 2 years. For the substitution remove one battery after the other because you may loose all the data memorized in RAM. The panel programme is memorized in EPROM. If you press the arrow at right key for about 5 seconds, you can enter in the MENU to set the hour and the date.

When you have set the hour and the date press again for about 5 seconds the above key and the programme returns in the normal modality.

Note: Inside the remote control switches panel, there are 2 push buttons and 1 commutator.

The commutator turns the basket movement on and off from automatic to manual and the contrary.

The 2 push buttons control the manual movement of the basket.

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MN2038 AL 5500

10 MAINTENANCE Refrigeration units To obtain maximum performance from cooling machine, some rules should be followed: - Air condenser Clean every 3 months the refrigerating unit and specially the condenser from dust to allow good air circulation; - Eliminate the possible refrigerant leaks; (The equipments function only with FREON type refrigerants, which are odourless, not toxic and not combustible; it is then possible to find the leaking points with a suitable checklamp).

- Substitute unfreezable oil of the compressors every 4000 hours running, using the FUCHS SP32 oil for HP80 compressor and CASTROLoil for R23 compressor; the oil must not contain any sign of humidity; - Take the opportunity to substitute the dewaterer filter. On the R 23 circuit the filter must have molecular sieves.

Electrical part and controlling instruments - Test every 1000 cycles approx. the protections running.

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MN2038 AL 5500

11

SAFETYEOUIPMENTS INSTALLED IN THE SYSTEM - Thermic protections set on the two compressors frame. They stop the motor compressor running in case of overtemperature.

- Overpressure switches.

At HP80 stage, the intervention of the pressure switch can be caused by the lack of water or insufficient quantity.

- At R 23 stage the intervention of the overpressure switch can be caused by the missing running of the HP80 stage.

- MOTORS PROTECTIONS The above-mentioned alarm is indicated by writting "FAILURE: MOTORS PROTECTION" and stops the running of the system. The alarm intervention is due to the extra-absorption of the motors or to the motors overheating making opening the relative magneto thermic switch.

To reset the running of the system, turn on again the switch intervened. This component is placed in the switch box. and push "F12" key situated on the control panel.

- ADJUSTABLE OVERTEMPERATURE SWITCH This alarm is indicated by writting "FAILURE: OVERTEMPERATURE SWITCH TEMPER. TOO HIGH IN THE HOT CHAMBER"and stops the running of the system.

The alarm intevention is due to the wrong running temperature regulation. To reset the running of the system rectify the temperature and press "F12" key placed on the control panel.

- UNDERTEMPERATURE SWITCH This alarm is indicated by writting "FAILURE: UNDERTEMPERATURE SWITCH TEMPER. TOO LOW IN THE COLD CHAMBER"and stops the running of the system.

The alarm intevention is due to the wrong running temperature regulation. To reset the running of the system rectify the temperature and press "F12" key placed on the control panel.

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MN2038 AL 5500

12 GRAPHIC RECORDER A three steps (hot chamber, cold chamber and specimens) temperature provides for the continuous recording of occurred events.

It is equipped with an index of the temperature real value.

graphic recorder

The electronic type recorder is equipped with two 100 Ohms at a °C platinum probes (thermoresistances), strenghtened by a thin stainless steel coat.

The silver conductors are teflon sheathed.

The recorder is 100 mm wide, and the paper speed is from 5 mm to 12.000 mm/hour and with continuous writing. The temperature scale is programmable.

Original standard equipment folding.

includes 2 parcels of paper which has the "2" form

The third probe, '" 4mm about, is connected to the recorder, in order to measure the specimens temperature.

This probe is inserted through two special holes made on the top of the "hot" chamber and on the upper steel plug.

When the probe is not used, it is placed in a circular seat under the above-mentioned steel plug.

See the enclosed instruction

manual for the use of the graphic recorder.

GASEOUS NITROGEN PURGING (optional) By the purging system with gaseous nitrogen are avoided hoarfrost and/or ice formation in the cold cabinet that could make more difficult the movement of the basket.

On the left side of the chamber is installed a coupling for the connection of a cylinder with a pressure reducing valve. The working pressure must be between 0,5 and 1 bar (50 and 100 kPa).

COOLING WITH LN2 (optional) There are 2 kinds of cooling with liquid nitrogen (LN2): 1- Increasing with nitrogen, press F13 key (LN2). Increasing with nitrogen helps the refrigerating unit until the cold chamber temperature set point is reached.

2- Cooling with nitrogen, press F14 key (LN2 cooling). Cooling with liquid nitrogen substitutes the refrigerating unit, cooling of the cold chamber is achieved by LN2 only.

21/09/95

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MN2038 AL 5500

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C 21.486-SE Rev. 25/10/95 Pag. n. l/vg

page 1 - Rev. A 1Q2 1M5 1M7 1M10 1M13 1M15 1M17

= = = =

= =

=

Main switch Cold chamber ventilation motor Cold chamber ventilation motor Hot chamber ventilation motor Low stage compressor motor High stage compressor motor Hot chamber ventilation motor

page 2 - Rev. A 2M3 = Basket movement reducer motor 2E12 = Hot chamber heaters 2E18 = Defrosting heaters page 3 - Rev. A 3E2 = Compressor oil heater 3Q4 = Compressor thermal protection 3Q6 = Compressor thermal protection 3T13 = 24V line transformer 3Q15 = Door frame and inspection window heaters line protection switch 3Q16 = 24V line protection switch page 4 - Rev. A-B 4G3

= 24VDC line power

supply

page 5 - Rev. A-B 5G8 = PLC power supplier 5Kll = Cold chamber ventilation motor remote control switch 5K13 = Cold chamber ventilation motor remote control switch 5K14 = Hot chamber ventilation motor remote control switch 5K15 = Chamber ventilation motor remote control switch 5F17 = Switching off safety coil 5B17 = Cold chamber fixed overtemperature switch 5B18 = Hot chamber fixed overtemperature switch 5519 = Machines room door microswitch

IAJ!2ยง

WIRING DIAGRAM LEGEND

C 21.486-5E Rev. 25/10/95 Pag. n. 2/vg

page 6 - Rev. A 6K2 6K5

=

Low stage compressor motor remote control switch

= Low stage compressor reiay = Compressor safety switch

655 6B5 = Low stage compressor overpressure switch 3Q4 = Low stage compressor thermal protection 6Y8 = Low stage compressor injection solenoid valve 6Y10 = Low stage compressor hot gas solenoid valve 6Yll = Low stage compressor line solenoid valve 6Bll = Solenoid pressure switch 6K16 = Defrosting heaters remote control switch 6Y19 = Normally open solenoid valve 6B19 = Recovery pressure switch page 7 - Rev. A 7K2 7K5 755 7B5 3Q6 7Y9 7Y10 7Yll 7Bll 7Y13

=

High stage compressor motor remote control switch High stage compressor relay = Compressor safety switch = High stage compressor overpressure switch = High stage compressor thermal protection = High stage compressor injection solenoie valve = High stage compressor hot gas solenoid valve = High stage compressor line solenoid valve = Solenoid pressure switch = Compressors heads water solenoid valve =

page 8 - Rev. A 8K2

8V5 856 857 8K8

859 10K10

8510 8511 8Y12

Solid state relay safety remote control switch chamber heaters solid state relay = Automatic /manual movement commutator = Manual basket movement push button = High position basket movement motor remote control switch = Hot chamber safety micros witch = Low position basket movement motor remote control switch = Cold chamber safety microswitch = Manual basket movement push button = Nitrogen solenoid valve =

= Hot

ACยง

WIRING DIAGRAM LEGEND

C 21.486-SE Rev. 25/10/95 Pag. n. 3/vg

page 9 - Rev. A 9K2 9E5 9E6 9E7 9E9 9EI0 9K12

= =

Frame and inspection window heaters remote control switch Door frame heater = Door frame heater = Inspection window heater = Internal light lamp = Internal light lamp = Internal lighting relay

page 10 - Rev. A page 11 - Rev. A lQ5 = Cold chamber ventilation motor switch lQ7 = Cold chamber ventilation motor switch lQI0 = Hot chamber ventilation motor switch lQ13 = Compressor motor switch lQ15 = Compressor motor switch lQ18 = Soundproofing fan motor switch 2Q3 = Basket movement motor switch lQ17 = Hot chamber ventilation motor switch page 12 - Rev. A

ACยง

WIRING DIAGRAM LEGEND

page 13 - Rev. A 13P4 = Positive logic 8 inputs module L+ = Positive pole power supply terminal E32.0 = Chambers door microswitch consent input 1357 = Hot chamber door microswitch 1356 = Cold chamber door microswitch E32.1 = Cold chamber ventilation consent input E32.2 = Hot chamber ventilation consent input 1358 = High position basket movement control micros witch 1359 = Low position basket movement control microswitch 13BI0 = Control pressure switch E33.0 = Motors protection intervention input E33.3 = Low stage compressor consent E33.4 = High stage compressor consent E33.5 = Cold chamber hot request input E33.7 = Cold chamber cold request input M= Negative pole power supply terminal page 14 - Rev. A page 15 - Rev. A

C 21.486-5E Rev. 25/10/95 Pag. n. 4/vg

ACยง;

WIRING DIAGRAM LEGEND

page 16 - Rev. A 16P3 L+

= Positive = Positive

logic 8 outputs module pole power supply terminal 16K5 = Cold chamber ventilation start output relay 16K6 = Hot chamber ventilation start output relay A2.3 = Low stage compressor start output 16K7 = Low stage hot gas solenoid valve output relay 16K8 = Low stage line solenoid valve output relay A2.4 = High stage compressor start output 16K10 = High stage hot gas solenoid valve output relay 16K11 = High stage line solenoid valve output relay M= Negative pole power supply terminal 18P3 = Positive logic 8 outputs module L+ = Positive pole power supply terminal A33.0 = Hot chamber heaters output A33.1 = Cold chamber basket position warning lamp output 16K14= Defrosting heaters remote control switch output relay 16K15= Purge with nitrogen solenoid valve output relay 16K16= High position basket movement output relay 16K17= Low position basket movement output relay 16K18= Alarms summation output relay A33.7 = Hot chamber basket position warning lamp output M= Negative pole power supply terminal page 17 - Rev. A page 18 - Rev. A page 19 - Rev. A page 20 - Rev. A 20R4 24R6 IP262

= Hot

=

=

chamber PTI00 probe Cold chamber PT100 probe Regulation board

page 21 - Rev. A

C 21.486-SE Rev. 25/10/95 Pag. n. 5/vg

ACยง

WIRING DIAGRAM LEGEND

page 22 - Rev. A 22F2 = Control panel 24VAC line fuses 22F5 = Control panel 24VCC line fuses UNIOP = Control panel 22H10= Cold chamber basket position warning lamp 22H12= Hot chamber basket position warning lamp 22513 = Internal light luminous switch 22H13= Internal light warning lamp 22Q15= Emergency mush room push button 22H8 = Alarms intervention warning lamp page 23 - Rev. A

C 21.486-5E Rev. 25/10/95 Pag. n. 6/vg

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