HANDBOOK

CHAMBERS FOR THERMAL SHOCK TESTS

21/09/95 l\CS MN2038 AL 5500

TABLE OF CONTENTS

TECfINICAL DATA 3INSTALLATION 4PRELIMINARY OPERATIONS FOR THE CHAMBER START-UP .5STARTING-UP 6MAINTENANCE 10SAFETY EQUIPMENTS INSTALLED IN THE SYSTEM 11GRAPHIC RECORDER 12GASEOUS NITROGEN PURGING (optional) 12COOLING WITH LN2 (optional) 12

ENCLOSED HANDBOOKS:- UNOP controller- SIEMENS P.L.C.

ENCLOSED DRAWINGS:- LAY-OUT- REFRIGERATION SYSTEM DIAGRAM- ELECTRICAL WIRING DIAGRAM:

POWER CIRCUITPOWER CIRCUITCONTROL PANEL

C 21.486C 21.486 - SI

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

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

21/rB/95 ~cs MN2038 AL 5500

TECHNICAL DATA

Type

Serial numberTesting

Useful volume of the basket

Temperature range

- in the upper chamber

- in the lower chamber

Temperature accuracy

Mains supply voltage

Remote control voltage

Mains supply power

Cooling unit

Refrigerants

21/09/95

3

: CST157 2T

: 5500:15500

: 157 1approx

: from - 800e to + 220°C

: from 200e over the ambient to up to + 220°C

: from ambient to to -70°Cwith possibility of undercooling to -80oe

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

: 24 V

:30Kw

: running with water HP 10 + 10

: HP80 + R23

J:\CS MN2038 AL 5500

: +/-1°C

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 switchfor the connection of the chamber mains supply.Inside the remote control switches board (in the machines unit) there is aterminal board: the "R", "5" and "T" terminals must be connected to thethreephase 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 thecondensation water, the chamber must be placed in its final location, otherwiseflexible 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 watertemperature is + 15°C ± 3°C.

In this last case, it is recommended to install an overflow switch that stops theequipment running if the water does not regularly flow in the condenser.

Azote connection

See instructions in the chapter nitrogen purging (optional).

21/Cf)/95 J:\CS MN2038 AL 5500

5PRELIMINARY 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 toreverse the "R" and "S" terminal connections at the feeding input.At the doors side of the chambers, there are applicated two microswitches whichavoid the running of the chamber when the doors are opened.Remind that to start fans working with opened chambers, it is necessary to switchon both the microswitches contacts placed beside the door.

THIS OPERATION IS NECESSARY TO ENSURE THE CORRECT ROTATION WAYOF THE BASKET MOVEMENT MOTOR, AND TO PERMIT THE RUNNING OF THESAFETIES; OTHERWISE RELEVANT DAMAGES COULD BE CAUSED TO THESTRUCTURE.

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.

21/09/95 ~cs MN2038 AL 5500

6

STARTING-UP

1. PROGRAMMING

a. Select the running mode; with the Fl key select the manual running, with the F2 keyselect the automatic running.

b. If you press the F3 key you enter in the programming MENU. To insert data press the Inskey, a lighting cursor appears on the exact point you have to programme the value; if youpress 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 isnecessary 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 alllines of the MENU.When you have finish the programming of the temperature sets and times sets, press onemore 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 theprogramming.

Example of programming in automatic cyclePress the F2 and F3 keys

.............. SET PARAMETERS PROGRAMMING ................ AUTOMA TIC CYCLE .COLD CHAMBER TEMPERAT. SET POINT: -65COLD CHAMBER DWELL TIME SET POINT : 0:15COLD CHAMBER DECREASE TEMPERATURE:-lOHOT CHAMBER TEMPERAT. SET POINT: 160HOT CHAMBER DWELL TIME SET POINT: 0:15HOT CHAMBER INCREASE TEMPERATURE: 15TEST CYCLES TOTAL NUMBER: 30000CYCLES NUMBER BEFORE DEFROSTING: 200COLD CHAMBER UNDERTEMP. SET POINT: -85HOT CHAMBER OVERTEMP. SET POINT: 200FORCED 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 timesare 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 baskettakes 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 takesplace in the hot chamber.This time can vary from 0 to 5 minutes according to the internal load. The minimum timeof stabilization on all chambers is of 1 minute.

21/rB/95 l\CS MN2038 AL 5500

7

Example of programming in manual cyclePress the Fl and F3 keys

......... SET PARAMETERS PROGRAMMING .

... .MANU AL CyCLE .COLD CHAMBER TEMPERAT. SET POINT: -65HOT CHAMBER TEMPERAT. SETPOINT: 160COLD CHAMBER UNDERTEMP. SET POINT: -75HOT CHAMBER OVERTEMP SET POINT: 180PRES. F3 : FOR OTHER COMMANDS .

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 arrowkey you may do the SCROOLof pages in order to check the correct set of data.The checking function can be done in any moment. Leaving out of consideration the typeof visualized data if you press the F4 key the control MENU appears.

d. ATTENTIONWhen you set an overtemperature or undertemperature lower or higher to the runningtemperature including the increment or the decrement at the starting, the chamber will goin alarm indicating on display these messages :

................................ WARNING .OVERTEMPERA TURE SWITCH SET POINT LOWERTHAN HOT CHAMBER SET POINT................... PRES. F3 : TO PROGRAMMING .

................................ WARNING .UNDERTEMPERATURE SWITCH SET POINT HIGHERTHAN COLD CHAMBER SET POINT................... PRES. F3 : TO PROGRAMMING .

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

21/09/95 ~cs MN2038 AL 5500

82. 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 hotchamber.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 (AUTOMATICCYCLERUN) for the cycle starting.The basket cycle will start only when the cold chamber will be in the ±2°C temperaturerange.If you open the chamber door during the running, the cycle stops. If you close the chamberdoor the basket cycle will start again only when the temperature of the cold chamber will bein the ±2°C range.When you open the door of the ambient chamber, the basket will take place in the centralchamber 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 ambientchambers stop and in the cold chamber the thermoresistances heat in order to set free of icethe 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.

2.5Cycles end

When the chamber reaches the set total cycles, it will stop and the basket will remain in thehot chamber.

2.6 Timer reset and general reset

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

21/09/95 ~cs 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 theintervention 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 controlpanel.

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 senseand 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 theother 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 thehour and the date.When you have set the hour and the date press again for about 5 seconds the above key andthe 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 thecontrary.The 2 push buttons control the manual movement of the basket.

21/09/95 ~cs MN2038 AL 5500

10MAINTENANCE

Refrigeration units

To obtain maximum performance from cooling machine, some rules should befollowed:

- Air condenserClean every 3 months the refrigerating unit and specially the condenser from dust toallow 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 asuitable checklamp).

- Substitute unfreezable oil of the compressors every 4000 hours running, using theFUCHS SP32 oil for HP80 compressor and CASTROLoil for R23 compressor; the oilmust not contain any sign of humidity;

- Take the opportunity to substitute the dewaterer filter. On the R 23 circuit the filtermust have molecular sieves.

Electrical part and controlling instruments

- Test every 1000 cycles approx. the protections running.

21/rE/95 ~cs MN2038 AL 5500

11

SAFETYEOUIPMENTS INSTALLED IN THE SYSTEM

- Thermic protections set on the two compressors frame. They stop the motorcompressor running in case of overtemperature.

- Overpressure switches.At HP80 stage, the intervention of the pressure switch can be caused by the lack ofwater or insufficient quantity.

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

- MOTORS PROTECTIONSThe above-mentioned alarm is indicated by writting "FAILURE: MOTORSPROTECTION" and stops the running of the system. The alarm intervention is dueto the extra-absorption of the motors or to the motors overheating making openingthe relative magneto thermic switch.To reset the running of the system, turn on again the switch intervened. Thiscomponent is placed in the switch box. and push "F12"key situated on the controlpanel.

- ADJUSTABLE OVERTEMPERATURE SWITCHThis alarm is indicated by writting "FAILURE: OVERTEMPERATURE SWITCHTEMPER. 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 resetthe running of the system rectify the temperature and press "F12" key placed on thecontrol panel.

- UNDERTEMPERATURE SWITCHThis alarm is indicated by writting "FAILURE:UNDERTEMPERATURE SWITCHTEMPER. 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 resetthe running of the system rectify the temperature and press "F12" key placed on thecontrol panel.

21/09/95 ~cs MN2038 AL 5500

12GRAPHIC RECORDER

A three steps (hot chamber, cold chamber and specimens) temperature graphic recorderprovides for the continuous recording of occurred events.It is equipped with an index of the temperature real value.

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/hourand with continuous writing. The temperature scale is programmable.

Original standard equipment includes 2 parcels of paper which has the "2" formfolding.

The third probe, '" 4mm about, is connected to the recorder, in order to measure thespecimens temperature.This probe is inserted through two special holes made on the top of the "hot" chamberand on the upper steel plug.When the probe is not used, it is placed in a circular seat under the above-mentionedsteel 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 iceformation in the cold cabinet that could make more difficult the movement ofthe basket.On the left side of the chamber is installed a coupling for the connection of acylinder with a pressure reducing valve. The working pressure must be between0,5 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 therefrigerating unit until the cold chamber temperature set point is reached.

2- Cooling with nitrogen, press F14 key (LN2 cooling). Cooling with liquid nitrogensubstitutes the refrigerating unit, cooling of the cold chamber is achieved by LN2only.

21/09/95 ~cs MN2038 AL 5500

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AC§; WIRING DIAGRAM LEGEND C 21.486-SERev.25/10/95Pag. n. l/vg

page 1 - Rev. A

1Q2 = Main switch1M5 = Cold chamber ventilation motor1M7 = Cold chamber ventilation motor1M10 = Hot chamber ventilation motor1M13 = Low stage compressor motor1M15 = High stage compressor motor1M17 = Hot chamber ventilation motor

page 2 - Rev. A

2M3 = Basket movement reducer motor2E12 = Hot chamber heaters2E18 = Defrosting heaters

page 3 - Rev. A

3E2 = Compressor oil heater3Q4 = Compressor thermal protection3Q6 = Compressor thermal protection3T13 = 24V line transformer3Q15 = Door frame and inspection window heaters line protection switch3Q16 = 24V line protection switch

page 4 - Rev. A-B

4G3 = 24VDC line power supply

page 5 - Rev. A-B

5G8 = PLC power supplier5Kll = Cold chamber ventilation motor remote control switch5K13 = Cold chamber ventilation motor remote control switch5K14 = Hot chamber ventilation motor remote control switch5K15 = Chamber ventilation motor remote control switch5F17 = Switching off safety coil5B17 = Cold chamber fixed overtemperature switch5B18 = Hot chamber fixed overtemperature switch5519 = Machines room door microswitch

IAJ!2§ WIRING DIAGRAM LEGEND C 21.486-5ERev.25/10/95Pag. n. 2/vg

page 6 - Rev. A

6K2 = Low stage compressor motor remote control switch6K5 = Low stage compressor reiay655 = Compressor safety switch6B5 = Low stage compressor overpressure switch3Q4 = Low stage compressor thermal protection6Y8 = Low stage compressor injection solenoid valve6Y10 = Low stage compressor hot gas solenoid valve6Yll = Low stage compressor line solenoid valve6Bll = Solenoid pressure switch6K16 = Defrosting heaters remote control switch6Y19 = Normally open solenoid valve6B19 = Recovery pressure switch

page 7 - Rev. A

7K2 = High stage compressor motor remote control switch7K5 = High stage compressor relay755 = Compressor safety switch7B5 = High stage compressor overpressure switch3Q6 = High stage compressor thermal protection7Y9 = High stage compressor injection solenoie valve7Y10 = High stage compressor hot gas solenoid valve7Yll = High stage compressor line solenoid valve7Bll = Solenoid pressure switch7Y13 = Compressors heads water solenoid valve

page 8 - Rev. A

8K2 = Solid state relay safety remote control switch8V5 = Hot chamber heaters solid state relay856 = Automatic /manual movement commutator857 = Manual basket movement push button8K8 = High position basket movement motor remote control switch859 = Hot chamber safety microswitch10K10 = Low position basket movement motor remote control switch8510 = Cold chamber safety microswitch8511 = Manual basket movement push button8Y12 = Nitrogen solenoid valve

AC§ WIRING DIAGRAM LEGEND C 21.486-SERev.25/10/95Pag. n. 3/vg

page 9 - Rev. A

9K2 = Frame and inspection window heaters remote control switch9E5 = Door frame heater9E6 = Door frame heater9E7 = Inspection window heater9E9 = Internal light lamp9EI0 = Internal light lamp9K12 = Internal lighting relay

page 10 - Rev. A

page 11 - Rev. A

lQ5 = Cold chamber ventilation motor switchlQ7 = Cold chamber ventilation motor switchlQI0 = Hot chamber ventilation motor switchlQ13 = Compressor motor switchlQ15 = Compressor motor switchlQ18 = Soundproofing fan motor switch2Q3 = Basket movement motor switchlQ17 = Hot chamber ventilation motor switch

page 12 - Rev. A

AC§ WIRING DIAGRAM LEGEND

page 13 - Rev. A

13P4 = Positive logic 8 inputs moduleL+ = Positive pole power supply terminalE32.0 = Chambers door microswitch consent input1357 = Hot chamber door microswitch1356 = Cold chamber door microswitchE32.1 = Cold chamber ventilation consent inputE32.2 = Hot chamber ventilation consent input1358 = High position basket movement control microswitch1359 = Low position basket movement control microswitch13BI0 = Control pressure switchE33.0 = Motors protection intervention inputE33.3 = Low stage compressor consentE33.4 = High stage compressor consentE33.5 = Cold chamber hot request inputE33.7 = Cold chamber cold request inputM- = Negative pole power supply terminal

page 14 - Rev. A

page 15 - Rev. A

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

AC§; WIRING DIAGRAM LEGEND

page 16 - Rev. A

16P3 = Positive logic 8 outputs moduleL+ = Positive pole power supply terminal16K5 = Cold chamber ventilation start output relay16K6 = Hot chamber ventilation start output relayA2.3 = Low stage compressor start output16K7 = Low stage hot gas solenoid valve output relay16K8 = Low stage line solenoid valve output relayA2.4 = High stage compressor start output16K10 = High stage hot gas solenoid valve output relay16K11 = High stage line solenoid valve output relayM- = Negative pole power supply terminal18P3 = Positive logic 8 outputs moduleL+ = Positive pole power supply terminalA33.0 = Hot chamber heaters outputA33.1 = Cold chamber basket position warning lamp output16K14= Defrosting heaters remote control switch output relay16K15= Purge with nitrogen solenoid valve output relay16K16= High position basket movement output relay16K17= Low position basket movement output relay16K18= Alarms summation output relayA33.7 = Hot chamber basket position warning lamp outputM- = Negative pole power supply terminal

page 17 - Rev. A

page 18 - Rev. A

page 19 - Rev. A

page 20 - Rev. A

20R4 = Hot chamber PTI00 probe24R6 = Cold chamber PT100 probeIP262 = Regulation board

page 21 - Rev. A

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

AC§ WIRING DIAGRAM LEGEND C 21.486-5ERev.25/10/95Pag. n. 6/vg

page 22 - Rev. A

22F2 = Control panel 24VAC line fuses22F5 = Control panel 24VCC line fusesUNIOP = Control panel22H10= Cold chamber basket position warning lamp22H12= Hot chamber basket position warning lamp22513 = Internal light luminous switch22H13= Internal light warning lamp22Q15= Emergency mush room push button22H8 = Alarms intervention warning lamp

page 23 - Rev. A

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