HR2060 Manual Rev.H
Contents
1. Cable on rear of Chamber Switched Switched 6 PIN MOLEX Ground By Power On Off Switch 12 VDC By Alarm Condition COMPRESSOR F13 TRM25 F12 TRM25 lt 4KW Heater 4KW Heater 4KW Heater F11 TRM25 1 3 Phase 2 Line Monitor Hi Side Pres Low Side Pres PHASE 2 Red 1 K2 T Compressor 3l Bypass LED On When Phase OK 3 Solenoid PHASE 1 Black F4 AGC5 Solenoid FC A3T40 FB ON 3T40 FA A3T40 i 4 4 3 AC AC AC AC AC AC NEUTRAL l J ai SSR4 SSR3 SSR3 1 SSR 75A SSR 75A SSR 75A aea SSR1 ug SSR 40A i od e lt GROUND F5 RELAY TRM8 TRM8 OVERTEMP AC AC com no 7 K3 CONTROL 5 HJ Res 4 P1 i 1 Dehumidifier BLWR Off Delay Timer 2 SWITCH sw a P Control Line 12 VDC N o Power Pack sw x F10 AGC10 MAIN Load Line RELAY K1 6 Dehumidifier F1 15A BLOWER LS1 Nm E ehumidifier AC oe 4 F2 15 2 SONALERT F7 15 RS 232 to 7 WATLOW cku RJ 45 JP1 F8 15A 3 TEMP BOX o 4 t ls CONTROL mn F9 15 5 RxD G ON e he 7 14 13 12 t 10 9 8 7 6 5 3 2 1 Ji e i G D2 M T gt T Typ2. the Watlow 981 Temperature Controller when active will turn on the refrigeration solenoid by grounding the negative side of SSR1 At the same time relay SP2 on the CYB20480 module is energized which closes the contact to the Off Delay Timer The timer then applies 115 VAC thru the pressure switches the 3 Phase Line Monitor to contactor K2 to turn on the 208 VAC three phase to the compressor Time delay fuses F11 F12 F13 of 15 amp capacity are used for the compressor due to the motor start up current draw If the compressor has lost refrigerant the pressure switches will open disabling contactor K2 The timer will keep the compressor running for a minimum of 3 minutes even if Output 2 has turned off This extends the life of the compressor by as suring proper separation of the Freon and oil in the compressor The flow of Freon is controlled by the solenoid valve controlled by SSR1 When the Freon flow is turned off but the compressor is still running a hot gas bypass valve is opened to allow the Freon to re circulate This system uses a water cooled condenser that requires 10 gallons per minute of clean room temperature or colder water for proper operation Chamber cool ing performance is very dependent on the flow rate and water temperature Page 2 Dehumidifier System A Munters dehumidifier is installed centered on the rear of the chamber This dehu midifier is controlled by the Alarm 3 L3 output of the Watlow and is tur
3. 46 Over temperature Limit Control See Figure 1 2 for the layout of the control panel Front Panel The Front Panel contains the Watlow Model 981 Temperature Controller the UUT Power Control and the Alarm Control Please see Figure 1 3 for the layout of this panel The Watlow Temperature Controller is the brains of the chamber controlling all heating and cooling functions Output 1 L1 of the controller is connected to the heating circuit Output 2 L2 is connected to the cooling circuit The fourth output L4 is the RS 232 communications interface The L4 LED will flash whenever serial data is being sent from the controller An RJ 45 connector is mounted in the column on the rear of the chamber providing the serial connection Please see Figure 1 4 for a quick guide to the Watlow operation All further details of the Watlow can be found in the Watlow Series 982 User s Manual Data communications interfacing and commands can be found in the Data Communications with the Watlow Series 988 Family of Controllers User s Guide The UUT Power Control consists of a switch to control the On Off state of the AC to the UUT outlets in the optional CYB20440 AC Distribution Panel See Section III for a description of this unit if this option is installed An LED shows the status of this switch The Alarm Control consists of LED s showing the status of the Over temp and Blower alarms If the associated LED is on then an alarm condit
4. Cybortronics Inc Model HR2060W Chamber The Model HR2060W is a single bay water cooled temperature cycling chamber specifically designed for the commercial electronics environment Specifications for the chamber are as follows Revision B1 02 07 01 Temperature range of 10 C to 80 C Temperature rate of change of 6 C per minute with no live load and 50 Ibs of Fixtured Product 60 000 BTU Refrigeration System Self contained within the chamber R 507 Ozone Safe Refrigerant Compressor Inhibit if Refrigerant lost 40 000 BTU Heating System 1500 CFM Air Recirculation with Vertical Airflow design Watlow Model 981 Temperature Controller e 20 step Ramp amp Soak profiling e RS 232 RS 422 or EIA 485 Communications Interface Safety Alarms with LED Display and Audible alert Over Temperature e Blower Failure Front Panel Display and Control of Alarm Status and UUT Power Control Triple Pane Glass Doors for product visibility Brushed Stainless Steel and Granite Grey Powder Coat Exterior for High Tech appearance AC Power requirements of 208 VAC 3 Phase 60 Amps HR2060 Chamber Front View Watlow Temperature Controller UUT Power Control On Off Optional Over temp Alarm Reset Switch User Cable Pass thru Ports Door Stay Adjust Chamber Control Components under Hood HR2060 Chamber Rear View Removable access cover for Main Blower and Cooling Fan Main AC Input Disconnect and B Circui
5. ay on the front panel The chamber is shipped with the Over temp Alarm set to 75 C Access to this control is obtained by raising the hood of the chamber The Blower Alarm is an air flow switch which when activated due to a blower failure or slow spin condition will turn on relay K2 on the CYB20480 module A set of con tacts will then turn on the front panel LED indicating the alarm condition along with the Sonalert sounding A second set of contacts performs the same functions as the Over temp Alarm turning off the heaters and the AC to the UUT s This alarm is self resetting Page 3 MAIN POWER INPUT 208 VAC 3 PHASE 60 AMPS To Optional AC Distribution Panel CYB20477A
6. e L 2 Thermocouple 77 4 4 s ou Lin gt 4 _ 5 M d x gog PWR ON OFF E x E 9__ 5 AUDIBLE RESET Mom s2 FRONT PANEL T LED S AND SWITCHES 3 CYB20480 MODULE Rev On Off Control for External Device H Figure 1 1 45 C Alton Pkwy Irvine CA 92618 1 800 289 8203 Cybortronics Inc 3i Title HR 2060 MAIN CONTROL SCHEMATIC Size Document Number ev Custpm CYB2060 SCH ate Thursday February 05 2009 Sheet 1 of 8 1 HR Series Chamber Control Panel under front hood of chamber Heater SSR s Control Relay 3 Phase Line SSR2 SSR3 SSR4 Module Monitor 12 VDC Over temp Spare Fuse Power Supply Control Module Block 9 i a oe S Main AC Fuse Compressor Compressor Dehumidifier Compressor Block Off Delay Fuses Control Solenoid F1 thru F10 Timer F11 F12 F13 Relay SSR1 Figure 1 2 CHAMBER CONTROL PANEL INDICATES STATUS OF ALARM INDICATER LED s AC POWER TO POWER IF LIT INDICATES ALARM SUPPLY RACK CONDITION BLOWER ALARM SHOWN INDICATES CHAMBER ENABLES DISABLES PUSH DOWN TO 12 VDC POWER AC POWER TO THE UUT RESET THE SUPPLY IS AC POWER PANEL OR OVER TEMP OPERATIONAL POWER SUPPLY RACK ALARM MOMENTARY ACTION Figure 1 3 Watlow Controller Quick Operation Guide RED DISPLAY This d
7. ion exists The Audible switch allows resetting the Over temp alarm if this alarm condition exists Page 1 Air Recirculation System An 1500 CFM blower is powered continuously from 208 VAC through fuse F6 This blower pulls air vertically up through the product the refrigeration system s evaporator coil across the heating coils and then directs the airflow down the back wall of the chamber A separate 100 CFM cooling fan is attached to the blower motor Heating System The heating circuit is comprised of three 4000 watt nichrome heating elements mounted just above the evaporator coil in the top of the chamber For safety reasons three Solid State Relays SSR2 SSR3 SSR4 are used to control these heating elements Each heater is removable and is fused at 30 amps by fuses F1 F2 and The negative control line to all three SSR s is the L1 output of the Watlow 981 Temperature Controller If Output 1 L1 is on this terminal is grounded and will turn on the SSR s The positive control line to the three SSR s is a switched 12 VDC line This line will be opened by the K1 or K2 relays on the CYB20480 module if an Over temp or Blower alarm condition exists All three legs of the 208 VAC input power will then be removed upon an alarm condition Cooling System The cooling circuit consists of an 3 5 HP Copeland Compressor System with an asso ciated control circuit The system uses ozone safe R 507 refrigerant Output 2 L2 of
8. isplay will normally indicate the current temperature in the chamber It will also indicate the value of the parameters displayed in the GREEN display L1 thru L4 DISPLAY L1 Indicates that the heaters are on L2 Indicates that the cooling system is on L3 Dehumidifier Control L4 Indicates that data is flowing over the RS 232 port DISPLAY KEY This key will cause the GREEN display to step thru displaying the set point the deviation from set point the 96 of output power and wether the temperature is displayed in C or in F GREEN DISPLAY This display will normally indicate the current set point It will also indicate other functions depending on the use of the DISP key and the MODE key Values of these other functions are displayed in the RED display MODE KEY The 1st press of this key will enter the SYS menu Use up arrow key to step to PID menu or PROG menu See Watlow manual to set PROG values and steps UP and DOWN ARROWS These keys are normally used to change the set point of the controller When pressed simultaneously for approx 3 seconds you will enter the setup mode Please see the WATLOW MANUAL RUN HOLD KEY Pressing this key once will allow you to select which of the 4 Ramp and Soak profiles to run The RUN Led will flash at this time Pressing the key again will start the selected profile The RUN Led will be on steady while a profi
9. le is running Ifa profile is running pressing this key will stop execution of that profile and the RUN Led will be off Figure 1 4 Section Il Maintenance The following items require periodic maintenance on the Cybortronics HR2060 Chamber Condenser Water Cooling Line Strainer The Strainer for the water inlet line to the condenser should be cleaned ona monthly basis This strainer is shipped loose and should be mounted to the water inlet line external to the chamber Turn off water Remove the square tipped end cap from the strainer housing Have a small pail available to catch any water that may run out of the housing Remove the strainer and wash off any foreign matter that may have accumulated Apply more sealing compound or Teflon tape to the end cap re install the strainer and screw on the end cap tightly The water may now be turned back on Check that no water leaks from the end cap before operating the chamber All other refrigeration components are accessible by removing the access grill at the rear of the refrigeration compartment The grill hangs on two studs at the top and is held in place by magnetic strips Some models of chambers may also re quire the removal of the left side stainless panel of this compartment Strainer Location Outside of Chamber this side Bypass TXV Cooled V4 SR Drip Pan Condenser 2 ub S 8 DEHUMIDIFIER SYSTEM FILTERS The dehumidifier filters at the fro
10. ned on dur ing a specific temperature range typically between 1 and 35 deg C The SYS menu on the Watlow Controller is where these programmed temperatures can be found Fuse F10 provides AC power to the dehumidifier and the K1 relay contact is closed to turn on the dehumidifier via a low voltage control line The dehumidifier pulls in air from the chamber and blows it through a desiccant filled wheel that ab sorbs any moisture in the chamber The air is then returned to the chamber The desiccant wheel rotates to another part of the dehumidifier where the moisture is re moved by hot air being blown over it Alarm System The Over temp Alarm consists of a Watlow Model 146 Limit Control that when acti vated turns on relay K1 on the CYB20480 module This in turn will close contacts to turn on the front panel LED indicating an alarm condition and turn on the Sonalert audible device Another set of contacts will open the 12 VDC line controlling the SSR s used for the heating coils This switched 12 VDC line is also used in the in terface cable to the optional AC Distribution Panel This will turn off the SSR s in this panel and remove all AC from the UUT s removing all heat load from the inside of the chamber and protecting the UUT s from damage The Over temp Alarm is a latching alarm and will stay active until the problem is resolved and the alarm is manually reset The reset switch is a momentary rocker switch located below the Alarm Displ
11. nt and rear ends of the dehumidifier system should be checked and replaced as necessary every month dependent on factory condi tions These filters will slide out of their tracks with the dehumidifier still mounted to the chamber These filters can be disassembled washed in water dried and re used several times DEHUMIDIFIER REPLACEMENT FILTER DF 90 Filter Locations Front and Rear Lift up to remove Exhaust Restrictor Do Not Remove BLOWER MOTOR LUBRICATION The circulation blower on the HR2040 should be oiled once a year The oil filler holes are located at the rear and the front faces of the motor at the 12 00 o clock po sition Using any light machine oil or automotive oil apply only 2 drops of oil to each bearing port CAUTION ONLY US 2 DROPS OF OIL EACH SERVICE INTER VAL TOO MUCH OIL ADDED CAN CONTAMINATE THE INTERIOR OF THE SYSTEM AND IT S PRODUCT TENTS Oil hole locations Page 9 BLOWER REPLACEMENT INSTRUCTIONS Complete assembly Should the blower assembly need replacing disconnect all power from the chamber by removing the power cord from it s receptacle Remove the mounting screws for the stainless cover that houses the main disconnect On Off breaker Remove and rest this cover on top of the chamber The motor is mounted on an 8 x 10 inch aluminum mounting plate After removing the electrical connec tions from the blower terminal block remove the 4 8 screws from the mounting plate lift and dra
12. o the 6 UUT Outlets UUT AC Outlet Circuit Breaker and Indicator UUT AC Power Outlets RJ45 UUT Power Control Interface Temperature Controller RS 232 Serial Interface User Outlets and Circuit Breaker Page 11 Section IV Installation and Site Prep Power Requirements The Cybortronics Model HR2060W Chamber requires an AC input of 208 VAC Phase Y at 60 Amps Actual chamber current draw is typi cally 45 Amps Proper phasing of the AC line MUST be followed for the chamber to work properly An 3 Phase Line Monitor will inhibit com pressor operation if it detects an out of phase condition This Line Monitor is located under the control panel on the front of the chamber and has an LED indicator to indicate if the AC is connected in phase or not This indicator must be on If not reversing 2 of the 3 phase line will usually correct the problem If the chamber is to be connected directly to a Junction box and not using the provided plug the following is the color code of the line cord attached to the chamber Phase1 Black Phase 2 Red Phase 3 Orange Neutral White Ground Green Water Requirements The chamber requires clean water provided at a flow rate of at least 10 gallons per minute A throttle valve will regulate the flow rate as the chamber is going cold Proper performance depends on this water be ing 20 C or colder The ramp rate of the chamber going cold will be de termined by this wate
13. r temperature Dimensions and Electrical Water Connection Locations The following 3 pages show all chamber dimensions electrical and water connection locations Page 12 HR2060 Chamber Dimensions Front View Page 13 HR2060 Chamber Dimensions Side View Page 14 HR2060 Chamber Dimensions Footprint Water Connecti ons 1 Inch NPT Page 15
14. t Breaker nilitiililill Optional AC Distribution Panel CYB20440 With 6 Switched Outlets and 2 User Outlets Dehumidifier Temperature Controller Dehumidifier RS 232 Filters Interface Front and Rear HHHHHH Dehumidifier Exhaust Restrictor Do Not Remove ii i Main AC Input ee Connecter _ Lift Off Rear Access Grill 208 VAC 3 Phase 60 Amps Condensate Water Inlet Drip Pan and Outlet Connections Compressor Contactor Compressor Water Cleanout Filter Location mye Monies Model HR2060W Chamber User s Guide Section HR2060 Functional Description Section Il Maintenance Section III CYB20440 AC Distribution Panel Section IV Installation and Site Prep Section HR2060 Chamber Functional Description Following is a functional description of the various elements of the HR2060 Chamber These elements consist of the Front Panel the Air Recirculation System the Heating System the Cooling System and the Alarm System Please see Figure 1 1 for a complete schematic of the electrical components of the HR2060 Chamber All serviceable component parts with the exception of the blower and the refrigeration components are located under the hood of the chamber This hood is hinged at the top and has two knurled screws in the lower left and right corners to allow access to the Power Control Plate the CYB20480 Relay Module and the Watlow Model 1
15. tch If no contactor is heard when the L2 lamp is lit on the con troller signifying request for cooling and the compressor does not start the system should be checked for leaks Under normal operating conditions the high pressure side of the system should not exceed 350 pounds The low pressure side of the sys tem should not exceed 80 pounds of suction The total capacity of the HR2060 sys tem is 10 pounds of R507 Do not overfill Page 10 Section 111 CYB20440 AC Distribution Panel The CYB20440 AC Distribution Panel is an option available in both 115 VAC and 208 VAC single phase versions This panel provides six 6 Switched Outlets and two 2 User Outlets which are on continuously The 6 Switched Outlets are controlled by in dividual Solid State Relays Each of these SSR s are turned on or off by a connection to the DTR signal line on the RJ 45 interfaces located below the outlets Two RJ 45 s are provided for each outlet such that an serial control cable may be passed thru the panel to facilitate the connection to ground and DTR for the SSR s An LED is also at tached to each DTR line The ground line is passed thru a relay connected to the chamber control circuit This relay is controlled via the Power On Off switch located on the front panel of the chamber The relay will also be turned off if any alarm condi tion is present in the chamber This will then disable all SSR s and remove AC power to any product plugged int
16. w the motor plate and blower wheel from the air box cover Install the new pre assembled blower assembly and replace the 4 8 screws that secure it Before attaching the electrical make certain that the blower wheel spins freely and does not touch any surrounding metal If the blower wheel collides with the blower inlet ring remove the assembly and adjust the blower wheel back toward the motor face by 1 4 inch Re attach the electrical wiring to the correct terminals and replace the stainless cover and hardware BLOWER COMPLETE ASSEMBLY PART NUMBER BMA3M487 BLOWER MOTOR ONLY 3M487 REFRIGERATION SYSTEM CHECK This is only required if the cold cycle performance seems to be slow or if the refrig eration system does not run when cooling is commanded The refrigeration system is comprised of a 3 5 hp three phase 208 230 V compressor system charged with R507 refrigerant The lubrication oil is a synthetic oil know as Polyol Ester Oil At normal operating load the current draw by the compressor should measure approxi mately 8 to 13 Amps This chamber should transition from 70 C to 0 C in approxi mately 6 minutes with no heat generated internally by the product under test and a condensing water temperature of 20 C or less Should this transition test take 50 longer or more under these conditions a leak detection should be done on the sys tem and gas can be added as required Each system is configured with a low and high pressure gas swi
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