6010 SERIES ENVIRONMENTAL CHAMBER OPERATIONS MANUAL FOR MODELS 6010 6011 6012 6013 6015 6017 PO Box 715 Marietta, OH 45750 800-648-3042 740-373-6809 Fax 740-374-3760 www.caronproducts.com service@caronproducts.
Dear Valued Customer: Thank you for purchasing CARON Products & Services equipment. We appreciate your business and look forward to being your preferred supplier of controlled environment equipment products in the future. At CARON, we are committed to continuous quality improvement. Our goal is to supply our customers with highly reliable equipment at a fair price. In order to openly monitor our performance, we would appreciate your feedback on our products and services.
TABLE OF CONTENTS Section 1 – Warranty .................................................................................... 5 Section 2 – Equipment Overview ............................................................... 10 Section 3 – Installation ...............................................................................
Section 7 – Calibration ............................................................................... 52 Calibrating the Temperature Calibrating the Humidity Section 8 – Alarms ...................................................................................... 54 Alarm System Overview Changing Alarm Set-points Section 9 – Preventative Maintenance ...................................................... 55 Section 10 – Specifications ........................................................................
SECTION 1- WARRANTY INFORMATION EQUIPMENT LIMITED WARRANTY Please review this section before requesting warranty service. At CARON, one of our primary goals is to provide customers with high levels of personal service and top quality products, delivered on time, backed by technical service and supported for the life of the product. Before contacting us for warranty service, please be aware that there are repairs that are not covered under warranty. WARRANTY DEFINED Caron Products & Services, Inc.
This writing is a final and complete integration of the agreement between CARON and the customer. CARON makes no other warranties, express or implied, of merchantability, fitness for a particular purpose or otherwise, with respect to the goods sold under this agreement. This warranty cannot be altered unless CARON agrees to an alteration in writing and expressly stated herein shall be recognized to vary or modify this contract. Ohio Law governs this warranty.
EQUIPMENT INTERNATIONAL LIMITED WARRANTY Please review this section before requesting warranty service. At CARON, one of our primary goals is to provide customers with high levels of personal service and top quality products, delivered on time, backed by technical service and supported for the life of the product. Before contacting your distributor for warranty service, please be aware that there are repairs that are not covered under warranty. WARRANTY DEFINED Caron Products & Services, Inc.
This writing is a final and complete integration of the agreement between CARON and the customer. CARON makes no other warranties, express or implied, of merchantability, fitness for a particular purpose or otherwise, with respect to the goods sold under this agreement. This warranty cannot be altered unless CARON agrees to an alteration in writing and expressly stated herein shall be recognized to vary or modify this contract. Ohio Law governs this warranty. Caron Products & Services, Inc.
INTERNATIONAL SYMBOLS AND DEFINITIONS ? Help i Information Warning of hazardous area Warning of dangerous electric voltage Earth (ground) protective conductor WARNINGS Local government may require proper disposal 6010 Series Operations Manual Rev E 2/14/2012 Page 9 of 68
SECTION 2 – EQUIPMENT OVERVIEW Congratulations! You have just purchased the latest technology in environmental chambers. Before using the equipment, familiarize yourself with key components of the product and thoroughly read this manual.
SECTION 2 – EQUIPMENT OVERVIEW -- CONTINUED Humidity Enable Switch Temperature Controller Alarm Silence Switch Humidity Controller Visual Alarm Indicator Options Panel 6010 Series Operations Manual Rev E 2/14/2012 Page 11 of 68
SECTION 3 -- INSTALLATION Unpacking Your new unit has been thoroughly packaged to avoid shipping damage. However, the unit should be fully inspected upon arrival before signing for receipt. If the package has visual damage, notes should be made on the freight bill and signed by the delivery company. In the event of concealed damage after the unit is uncrated, keep the carton and packaging material.
The unit requires a dedicated electrical connection. Power requirements vary depending upon the chamber model, see Connecting Electrical Power section. Choose a location where these facilities are, or can be made available. If a water source, or a drain is not available, contact CARON customer service and ask about our CRYS102 product line or click this weblink for information on the product: http://www.caronproducts.
Do not have multiple loaded shelves out simultaneously or the chamber may tip. Stacking two Units The CARON 6010 family is designed to allow two units to be stacked. When units are stacked they must be bolted together for safety. A stacking adaptor kit, STCK301 with instructions is available through CARON customer service. Failure to install the stacking adaptor kit can result in the top unit falling causing serious injury or death.
The drain line relies on gravity to remove water from the chamber. The drain line must remain below the chamber to drain properly. Kinks or elevations in the drain line above the cabinet drain will not allow the chamber to drain. If a local floor drain is not available, a variety of accessories are available through CARON customer service. These accessories can also be viewed at www.caronproducts.com. For non-humidified chambers operated above 15°C, a drain is not needed.
Connecting Electrical Power Connect each chamber to a grounded circuit. Failure to do so could result in electrical shock. The unit requires a dedicated electrical outlet. See table below for model specific power required and connection. Model # -1 -2 -3 Power Requirements 115V, 60Hz, 12A FLA 230V, 60Hz, 8A FLA 230V, 50Hz, 6A FLA Plug Connection NEMA 5-15 NEMA 6-15 CEE 7/7 When the required electrical connection is available, plug the provided power cord into the unit and the electrical outlet.
SECTION 4 – ACCESSORY INSTALLATION Connecting Alarm Contacts (ALRM301) With the purchase of ALRM301, a set of terminals on the rear of the unit is provided to monitor temperature and humidity (6010 & 6015 only) alarms. With the alarm contacts, the terminals provided allow for a NO (normally open) output, a NC (normally closed) and COM (common) connection. In the event of an alarm condition or power failure, the NO contact will close, and the NC contact will open.
Installing Carboy Water System (BOTL301) Models 6010, 6015 & 6017 can be purchased with an optional 2.5 gallon carboy water system. The carboy system is preassembled and shipped inside the chamber. The four ¼” bolts required to mount the carboy to the unit will be mounted in the right hand side of the chamber. Remove the carboy assembly from inside the chamber and attach it to the chamber using the ¼” bolts.
Connecting Communications or Analog Outputs (DLUX301 & DLUX302) With the purchase of DLUX301 or DLUX302, the controllers are upgraded with additional features such as RS485 communications, and analog outputs. A set of terminals are provided to connect to RS485 communications and analog outputs.
RS-485 communications are intended to communicate with a PC using ModBus RTU or Standard Bus. The maximum number of chambers connected to a single PC is limited to 247 controllers (Modbus) or 16 controllers (Standard Bus). Chambers 6011, 6012, and 6013 have one controller each. 6010 and 6015chambers have two controllers each. Connect shielded wires to the RS-485 Communications terminal blocks. Communications wires should be shielded and routed away from power wires.
Installing the Heatless Dryer Package (DRYR301) The Heatless Dryer Package extends the operational limits to a minimum humidity control point of 2% RH and improves the dehumidification rate by purging the chamber with dry air. Air flows through the Dryer Package only when dehumidification is required to maintain the humidity set point. It uses compressed air at 90 to 100 psig to operate. Maximum airflow required is 480 SCFH (8 CFM).
Incoming compressed air must be free of dirt, oil, moisture and filtered to 10 microns minimum. Incoming compressed air must not exceed 100 psig. CARON recommends installing a pressure gauge, filter, and shutoff prior to the dryer to monitor incoming air pressure. The air supply (either house air or other compressed air source) must be 90 to 100psig at the air supply inlet. An oil-less compressor may be used. A Sound Suppression Kit maybe used to reduce the dryer noise (contact CARON service for details).
3. Attach 3/8” orange tubing from the chamber to the flow meter outlet. Flow Meter Outlet 4. Connect compressed air to dryer package inlet fitting (1/4 NPT) Dryer Inlet See Operations section of the manual for instructions on setting the pressure regulator and flow meter.
Connecting the Fluorescent Lighting (LGHT303) Chambers with optional fluorescent lighting (or standard on model 6012) have two independent light banks consisting of two lamps each. The light banks are suspended to the shelf underside. The lights shipped fully installed in place from the factory. See the Operations or Maintenance sections of the manual for more details. Lights should only be used in a non-condensing environment.
Installing Drain Water Pump (PUMP301) In applications where a floor drain is not available and a CARON water recycling system is not being used, a drain pump can be purchased to pump any excess condensate from the chamber to a local sink or drain. The pump is located near the middle of the back of the chamber. Connect the supplied tubing from the pump to the sink / drain. The tubing may be run vertically into a ceiling but should not exceed 15 feet height.
Installing the Stacking Kit (STCK301) Two environmental chambers can be stacked using a stacking kit. The kit contains brackets and bolts to secure them together. Each chamber weighs in excess of 400 pounds. Ensure that sufficient resources are available to safely lift and move the product. Place the bottom chamber into its location. Using a lift or jack, place the other chamber on top. Bolt into place both brackets (back side, right & left) and secure the two together with 12 screws.
SECTION 5 – OPERATION With the chamber properly installed and the appropriate utilities connected, the power switch on the upper left of the control bezel can be turned on. Within a few minutes, the temperature and humidity will begin to approach set-points. Allow the unit to stabilize for 12 hours before use or prior to making any calibration adjustments. Changing the Temperature Set-point The standard cabinet has a temperature set-point range of 5C to 70C.
Changing the Humidity Set-point The standard cabinet has a humidity set-point range of 20% to 98% relative humidity. With the purchase of an optional dryer package (DRYR301), the low end humidity range can be extended. For information on the operation of DRYR301, refer to the accessories section.
SECTION 6 – ACCESSORY OPERATION Using the Carboy Water System (BOTL301) To fill the carboy while attached to the chamber, unscrew the cap. Fill carboy with distilled or deionized water (see Connecting the Water Supply section for details). The carboy holds 2.5 liters. If the carboy must be removed in order to fill it up, first disconnect the tubing between the carboy and chamber by pressing the metal lever at the tubing connects / disconnects at the bottom of the carboy.
Operation of the Defrost System (DEFR301) A Defrost System is used to maintain operational temperature below 5ºC. When the chamber temperature is below 4.5ºC, the defrost system is enabled automatically. When the chamber temperature is above 4.5ºC (except during a defrost cycle), the defrost system is disabled automatically. When the defrost system is enabled (below 4.5ºC), a defrost cycle will occur once every 12 hours and lasts for 20 minutes.
Operation of the Delux Controller System (DLUX301 & DLUX302) The chambers can be purchased with upgraded controllers. The controllers have additional features of RS485 communications, analog outputs, and ramp & soak. RS485 Communications: Each controller on the network (connected to the same PC or master device) must be programmed with a unique address. If multiple chambers are being connected, each controller will have to be assigned a unique address.
Analog Outputs: With DLUX301 & DLUX302 controllers, there is an analog output signal for temperature and humidity which represents the actual chamber values. This allows the chamber to be connected to an in-house data acquisition or alarm system. The analog signal outputs are selectable as either voltage DC or milliamp. In both cases, the output is scalable from 0.0 to 20.0. Common settings are 0-1V, 0-5V, 1-5V, 0-10V, 0-20mA, and 4-20mA. The factory default settings are 0-5V.
Set the Scale Low value to correspond with the minimum value of the process output in electrical units. For 0-5V, set to 0. For 1-5V, set to 1. For 4-20mA, set to 4. Set the Scale High value to correspond with the maximum value of the process output in electrical units. For 0-5V, set to 5. For 1-5V, set to 5. For 4-20mA, set to 20. Set the Range Low value to the minimum temperature (or humidity) that will correspond with the Scale Low value (default is 0.0).
Ramp & Soak: A ramp and soak control system is included with DLUX301 & DLUX302 controllers. This allows the user to store up to 40 steps spanning 4 profiles. A step consists of a change in set-point (or ramp). Another step is used to maintain a set-point for a fixed duration (or soak). Steps can also be repeated any number of times. The temperature and humidity control systems are independent. Temperature can run through a profile while humidity is maintained constant and visa versa.
Operation of the Heatless Dryer Package (DRYR301) The flow meter shows the flow rate of dry air entering the chamber. It is adjustable by the knob at the bottom of the meter. Maximum performance is obtained at 300 SCFH (or 5 CFM). Operating the unit above or below this purge rate may decrease performance!! A pressure regulator is installed between the tower dryers and glass flow meter to limit the pressure into the flow meter. The regulator should be set at a maximum of 100psi. 1.
Controlling the Diurnal Lights (6012) and Optional Fluorescent Lights (LGHT303) The diurnal chamber comes with a fluorescent lighting system used to simulate day and night testing. This option is also available on the model 6010 & 6015 as LGHT303. There are separate temperature and humidity (optional) set-points that correspond with the lights on (day) and lights off (night). The set-points can also be made the same if continuous conditions are needed throughout the light cycles.
Operating the timer The power switch enables and disables the lights and cycle timer. When the timer is “on”, the 2nd set-point (also known as “idle set point”) on the controllers is enabled as well as the lights. The timer will display “OUT” corresponds to lights being enabled. The timer has an adjustable “on” and “off” cycle times which repeat continuously. SET1 corresponds to the lights “off” cycle time and SET2 to the lights “on” cycle time.
Examples for how to start your timer during day or night modes Night Start Procedure: 1. 2. 3. 4. 5. 6. 7. 8. Set the timer to SET 1 Enter the length of time you would like the lights off (night setting) Example 12 Hrs. Set the timer to SET 2 Enter the length of time you would like to have the lights on (day setting) Example 12 Hrs. Determine what time you would like to have the timer change between day/night Example 7:00 P.M. switch to night setting (lights off) At 7:00 P.M.
Accumulate or Reset Factory default is set so the timer continues where it left off after a power cycle (accumulate). This prevents the timer from re-starting in the event of an electrical brown-out or power outage. To change the setting so the timer re-starts to zero when power is cycled, follow the steps below. A power outage will not change the cycle time (SET1 & SET2) values. 1. 2. 3. 4. 5. Hold the MODE button down for 3 seconds The red display will show ōFtr.
Controlling the LED Lighting (LGHT304) The LED lighting system creates low-level internal lighting. There are separate temperature and humidity (optional) set-points that correspond with the lights on (day) and lights off (night). The set-points can also be made the same if continuous conditions are needed throughout the light cycles.
Operating the timer The power switch enables and disables the lights and cycle timer. When the timer is “on”, the 2nd set-point (also known as “idle set point”) on the controllers is enabled as well as the lights. The timer will display “OUT” corresponds to lights being enabled. The timer has an adjustable “on” and “off” cycle times which repeat continuously. SET1 corresponds to the lights “on” cycle time and SET2 to the lights “off” cycle time.
Accumulate or Reset Factory default is set so the timer continues where it left off after a power cycle (accumulate). This prevents the timer from re-starting in the event of an electrical brown-out or power outage. To change the setting so the timer re-starts to zero when power is cycled, follow the steps below. A power outage will not change the cycle time (SET1 & SET2) values. 6. Hold the MODE button down for 3 seconds 7. The red display will show ōFtr. 8.
Interior Electrical Outlet (OUTL301) An optional interior electrical outlet is available to supply power to small interior appliances such as shakers or stirrers. The outlet is GFI protected. The interior outlet is fused at 2.0 Amps. It is not intended to power high current draw devices.
Operation of Front Mounted 6” Recorders (RCDR307, RCDR308) Built in 6” ink pen temperature and or humidity recorders can be purchased with CARON chambers. The recorders are shipped installed on the outer door of the chamber from the factory and require no installation. Changing the chart paper: Press and hold the “change chart” button on the recorder (#3) for approximately one second until the pen begins to move to the left of the chart and then release the button.
and metal pen arm be removed as an assembly. Unsnap the plastic "U" clip tab of the pen cartridge from the metal pen arm, remove and discard the old pen cartridge. Replace the new cartridge by opening the hinge and snapping it securely around the metal pen arm.
If a calibration adjustment is required for a single pen recorder, use the left (#1) and right (#2) arrow push buttons on the recorder to calibrate (or move) the pen’s position on the chart to correspond to the temperature of the solution. The arrow buttons must be held for approximately five seconds before the pen will begin to move. For two pen recorders, you must first select the pen that you wish to calibrate.
Operation of Front Mounted 10” Recorders (RCDR309, RCDR310) Built in 10” thermal pen recorders can be purchased with CARON chambers. The recorders are shipped installed on the outer door of the chamber from the factory and require no further installation. Unlike ink pen recorders, the thermal recorders draw their own chart and control lines. The 10” recorders have been setup at the factory in the following configuration: 7 Day / 24 Hour / Temperature 0-100°C / Humidity 0-100% (for dual input recorders).
move off of the chart allowing you to place the recording chart paper onto the recorder. Press and release the Change Chart button to begin recording. Changing the Chart Paper: Press and hold the Change Chart button (#3) for approximately one (1) second until the pen begins to move off scale and then release the button. Note: The green LED light will flash fast while the thermal pen arm is moving off scale.
Recorder Calibration: If calibration is required for single input recorders, use the Left (#1) and Right (#2) arrow buttons on the recorder to calibrate the temperature being recorded on the chart to correspond to the temperature of the solution. The arrow buttons must be held for approximately eight (8) seconds before the pen begins to move. If calibration is required for dual input recorders, you must first select the input that you wish to calibrate.
Operation of Side Mounted Recorders (RCDR311, RCDR312) Side mounted Honeywell DR 4300 General Purpose Circular Chart Recorders are also available with CARON chambers. This chart recorder uses reliable microprocessor operation to generate dependable pen drawn analog traces on preprinted 10-inch (250 mm) charts. The two-pen model accepts inputs from a temperature sensor and a humidity sensor. The single-pen model records temperature only.
4. Slip the new chart under the pen lifter, pens and time index; and press the chart into place over the chart hub and locating pin. 5. Grasp the chart hub and locating pin and turn the chart until the desired time line on the chart is aligned with the time index on the chart plate and Pen #1. Push down the lifter to return the pens to the chart. 6. Close the door and apply power.
SECTION 7 – CALIBRATION The temperature and humidity systems can all be calibrated as necessary. CARON recommends an annual calibration check of each system. Before making a calibration adjustment, allow the cabinet to stabilize a minimum of 12 hours from a power off condition. If the unit has been in operation, allow a minimum of 3 hours of stable operation at all set-points.
Calibrating the Humidity If humidity calibration is needed, the following steps can be taken: Infinity Key Advance Key Locate the reference instrument’s temperature sensor in close proximity to the cabinet’s geometric center. Be sure that the stabilization times described earlier have been satisfied prior to performing this calibration. Press the advance key until the green display reads i.CAL (calibrate). Pressing the UP arrow will increase the Humidity calibration offset by 1%.
SECTION 8 – ALARMS Alarm System Overview The chamber control system is equipped with an alarm system that constantly monitors temperature, and humidity (on humidified models) to ensure the user is notified if the cabinet goes into an alarm condition. Notification occurs via a RED indicator light and an buzzer. Each alarm condition has been factory programmed to minimize nuisance alarms while maximizing warning time.
SECTION 9 – PREVENTATIVE MAINTENANCE The CARON chamber has been robustly designed to minimize performance problems. However, regular maintenance is very important for continuous trouble free operation. As a general rule, CARON recommends an annual calibration check of the temperature, and humidity systems. CARON offers a full range of on-site calibration and validation services. We also offer preventative maintenance contracts on our equipment.
SECTION 10 – SPECIFICATIONS MODEL Temperature Range 6010/6015 6011 6012 6013 5°C to 70°C 6017 Amb +10 to 70C Temperature Control ± 0.1°C Temperature Uniformity ± 0.3°C Temperature Sensor 3-wire RTD Humidity Range Humidity Control Humidity Sensor Interior Lighting Interior Dimensions 20 to 98% RH* ± 2% RH Capacitive Optional Amb to 98% N/A Standard 23" W x 25.8" D x 29.8" H ± 3% RH Capacitive Optional (58.4cm x 65.5cm x 75.
This graph illustrates the operating temperature & humidity range of models 6010 and 6015. The “Standard Range” is without options and the “Dryer Package” is with the optional DRYR301. All models have a forced internal air flow of 225 cfm (6,400 LPM).
SECTION 11 – ELECTRICAL SCHEMATICS 6010 Series Operations Manual Rev E 2/14/2012 Page 58 of 68
6010 Series Operations Manual Rev E 2/14/2012 Page 59 of 68
SECTION 12 – TROUBLESHOOTING Problem -- Unit will not turn on Is the unit connected to a dedicated electrical circuit as defined in the installation section of the manual? Is there power at the electric outlet the unit is plugged into? Is the unit’s power switch turned on? Problem -- Unit temperature is above / below temperature set-point Has the unit’s temperature set-point been recently lowered / raised and if so has the unit been allowed 12 hours stabilize at the new set-point? Has the inner do
SECTION 13 – SPARE / REPLACEMENT PARTS General Part Number MTR-130 BLW-113 CTR-131 CTR-134 POW-108 FLTR303 CRD-113 STP-101 Description Blower Motor Blower Wheel Watlow Standard controller Watlow Delux Controller 24V DC Power Supply Condenser Filter Replacement Kit Power Line Cord 2” rubber port stopper Temperature Related Part Number HTR-150 RMT-114 RMT-116 RTD-101 REL-103 CND-135 CND-137 CND-138 REL-152 REL-154 SOL-108 Description Air Heater 107C Air Heater Thermostat 121C Air Heater Thermostat Temp Sen
FUS2 FUS3 FUS4 FUS5 FUS6 FUS7 FUS8 FUS10 FUS11 FUS12 Side mount chart recorder fuse Internal duplex outlet fuse Internal outlet transformer fuse Compressor fuse Condensate pump fuse Condensate pump transformer fuse Air & door heater fuse Dryer package fuse Humidity injection pump fuse Fluorescent light bank fuse FUS-157 (0.32A) FUS-151 (2A) FUS-160 (15A) FUS-157 (0.32A) FUS-103 (10A) FUS-159 (1.25A) FUS-159 (1.25A) FUS-151 (2A) FUS-156 (0.16A) FUS-151 (2A) FUS-164 (3A) FUS-103 (10A) FUS-157 (0.
SECTION 14 – ADVANCED USERS SECTION Unlocking the Controllers The temperature and humidity controllers are factory programmed for precise control. Unlocking the controllers gives the user access to all parameters. Modifying parameters that are not thoroughly understood can adversely affect chamber performance that will not be covered under warranty.
APPENDIX A – RAMP & SOAK EXAMPLE General An efficient way to program a profile is to first outline what the temperature controller should do. If the chamber has humidity control, an outline should be generated for this too. Example of a temperature profile outline: Profile 1 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Ramp to 20ºC as quickly as possible Stay at 20ºC for 2.
8. Select the step type by pressing the ADVANCE button. 9. Use the UP and DOWN arrow buttons to define each parameter and the ADVANCE button to go to the next parameter. The parameters are described below: Parameter Target set-point Hours Minutes Seconds Rate Wait for process instance Wait for process value Wait Event 1 Wait Event 2 Jump Step Jump Count End Type Off Hold User Event Output 1 Event Output 2 10. 11. 12.
Event Output 1 Event Output 2 Ent1 Ent2 oFF oFF Step 2 Soak step type Time in hours Time in minutes Time in seconds Event Output 1 Event Output 2 P1 S.tyP hoUr Min SEC Ent1 Ent2 2 SoAH 2 30 0 oFF oFF Step 3 Rate step type Target set-point (50ºC) Ramping rate (1ºC per minute) Event Output 1 Event Output 2 P1 S.tyP T9.SP rAtE Ent1 Ent2 3 rAtE 50 1 oFF oFF Step 4 Soak step type Time in hours Time in minutes Time in seconds Event Output 1 Event Output 2 P1 S.
End step type Type of profile end (hold 30ºC) S.tyP End End HoLd Step 8 Un-used step P1 S.tyP 8 UStP Step 9 Un-used step P1 S.tyP 9 UStP Step 10 Un-used step P1 S.
DECLARATION OF CONFORMITY Caron Products and Services, Inc.
