OPERATION AND MAINTENANCE MANUAL MINI TWO-PRESSURE HUMIDITY GENERATOR SERIES 1200 THUNDER SCIENTIFIC MINI 1200 TWO-PRESSURE HUMIDITY GENERATOR OPERATION AND MAINTENANCE MANUAL Copyright © 2004 THUNDER SCIENTIFIC CORPORATION 623 WYOMING BLVD. S.E. ALBUQUERQUE, NEW MEXICO 87123-3198 www.thunderscientific.com Printed 2004 Document Edition 1 March 2004 Tel: 505.265.8701 a Fax: 505.266.6203 Software Version 2.0.0 E-mail: [email protected] Model 1200 Two-Pressure Two-Temperature Humidity Generator TABLE OF CONTENTS Section 1 - GENERAL INFORMATION 1.1 INTRODUCTION ------------------------------------------------------------------------------- 1-1 1.2 PRINCIPLE OF OPERATION --------------------------------------------------------------- 1-1 1.2.1 General Description ---------------------------------------------------------------------- 1-1 1.2.2 Humidity Formulas------------------------------------------------------------------------ 1-2 1.2.2.1 Saturation Vapor Pressure, e ----------------------------------------------------- 1-2 1.2.2.2 Enhancement Factor, ƒ ------------------------------------------------------------ 1-3 1.2.2.3 Relative Humidity, %RH------------------------------------------------------------ 1-4 1.2.2.4 Frost Point----------------------------------------------------------------------------- 1-7 1.2.2.5 Dew Point------------------------------------------------------------------------------ 1-8 1.2.2.6 Part Per Million by Volume, PPMv----------------------------------------------- 1-9 1.2.2.7 Parts Per Million by Weight, PPMw --------------------------------------------- 1-9 1.3 SPECIFICATIONS --------------------------------------------------------------------------- 1-10 1.3.1 General ------------------------------------------------------------------------------------ 1-10 1.3.2 Facility Requirements ------------------------------------------------------------------ 1-10 1.3.3 Environmental---------------------------------------------------------------------------- 1-10 1.4 COMPUTER / CONTROL SYSTEM----------------------------------------------------- 1-11 1.4.1 General Description -------------------------------------------------------------------- 1-11 1.4.2 Computer System----------------------------------------------------------------------- 1-11 1.4.2.1 MCU Controller--------------------------------------------------------------------- 1-11 1.4.2.2 Thin Film Transistor Display (TFT) -------------------------------------------- 1-11 1.4.2.3 USB and Ethernet Interface ----------------------------------------------------- 1-11 1.5 ELECTRICAL SYSTEM--------------------------------------------------------------------- 1-12 1.5.1 Power Distribution----------------------------------------------------------------------- 1-12 1.5.1.1 Power Supply +24 VDC (DC1)------------------------------------------------- 1-12 1.5.1.2 Power Supply +5/+12 VDC (DC2) -------------------------------------------- 1-12 1.5.2 System Control Blocks----------------------------------------------------------------- 1-12 1.5.2.1 Analog to Digital Converters ---------------------------------------------------- 1-12 1.5.2.2 Flow Valve--------------------------------------------------------------------------- 1-12 1.5.2.3 Expansion Valve ------------------------------------------------------------------- 1-12 1.5.2.4 Thermoelectric Assembly-------------------------------------------------------- 1-12 1.5.3 Analog Inputs ---------------------------------------------------------------------------- 1-13 1.5.3.1 Temperature Measurement ----------------------------------------------------- 1-13 1.5.3.2 Mass Flow Transducer (T0)----------------------------------------------------- 1-13 1.5.3.3 System Pressure Transducer (T1) -------------------------------------------- 1-13 1.5.3.4 Supply Pressure Transducer (T2) --------------------------------------------- 1-13 1.5.3.5 Reservoir Level Monitor ---------------------------------------------------------- 1-14 1.5.3.6 Presaturator Level Monitor ------------------------------------------------------ 1-14 1.5.4 Control Logic ----------------------------------------------------------------------------- 1-14 1.5.4.1 Air Supply Solenoid Valve ------------------------------------------------------- 1-14 1.5.4.2 Pressure Bleed Solenoid Valve ------------------------------------------------ 1-14 1.5.4.3 Pressure Select Solenoid Valve------------------------------------------------ 1-14 1.5.4.4 Presaturator Heater --------------------------------------------------------------- 1-14 1.5.4.5 Presaturator Fill Solenoid Valve------------------------------------------------ 1-15 1.5.4.6 Expansion Valve Heaters -------------------------------------------------------- 1-15 1.5.4.7 Fluid Circulation Pump ----------------------------------------------------------- 1-15 1.5.4.8 Console Fans----------------------------------------------------------------------- 1-15 i 1.6 PNEUMATIC SYSTEM---------------------------------------------------------------------- 1-16 1.6.1 General Description--------------------------------------------------------------------- 1-16 1.6.1.1 Reservoir----------------------------------------------------------------------------- 1-16 1.6.1.2 Presaturator ------------------------------------------------------------------------- 1-16 1.6.1.3 Saturator ----------------------------------------------------------------------------- 1-17 1.6.1.4 Expansion Valve-------------------------------------------------------------------- 1-17 1.7 FLUID SYSTEM------------------------------------------------------------------------------- 1-17 1.7.1 General Description--------------------------------------------------------------------- 1-17 1.7.1.1 Temperature Conditioning ------------------------------------------------------- 1-17 Section 2 - INSTALLATION 2.1 GENERAL ----------------------------------------------------------------------------------------2-1 2.2 FACILITIES REQUIRED ----------------------------------------------------------------------2-1 2.2.1 Bench Space -------------------------------------------------------------------------------2-1 2.2.2 Power-----------------------------------------------------------------------------------------2-1 2.2.3 Air Supply------------------------------------------------------------------------------------2-1 2.2.4 Distilled Water Supply--------------------------------------------------------------------2-1 2.3 PREPARATION ---------------------------------------------------------------------------------2-1 2.3.1 Chamber Fluid Filling Procedure ------------------------------------------------------2-1 2.4 CONNECTIONS --------------------------------------------------------------------------------2-2 2.4.1 Air Supply------------------------------------------------------------------------------------2-2 2.4.2 AC Power------------------------------------------------------------------------------------2-2 2.5 INITIAL START-UP ----------------------------------------------------------------------------2-2 Section 3 - OPERATION 3.1 GETTING STARTED --------------------------------------------------------------------------3-1 3.1.1 Power Up------------------------------------------------------------------------------------3-1 3.1.2 Initiating the Generate Mode------------------------------------------------------------3-2 3.1.3 Changing the %RH Setpoint------------------------------------------------------------3-4 3.1.4 Shutdown------------------------------------------------------------------------------------3-4 3.2 WINDOWS---------------------------------------------------------------------------------------3-5 3.2.1 Main Screen --------------------------------------------------------------------------------3-5 3.2.2 Calculated Humidity Parameters ------------------------------------------------------3-6 3.2.3 Graph-----------------------------------------------------------------------------------------3-9 3.2.4 Status Log--------------------------------------------------------------------------------- 3-10 3.2.5 Tabular Data------------------------------------------------------------------------------ 3-10 3.2.6 Profile -------------------------------------------------------------------------------------- 3-11 3.2.7 System Timing --------------------------------------------------------------------------- 3-11 3.2.8 Calibration Coefficients ---------------------------------------------------------------- 3-11 3.2.9 Water Level and Supply Pressure--------------------------------------------------- 3-12 3.2.10 Auxiliary Parameters-------------------------------------------------------------------- 3-12 3.2.11 Remote Desktop Control -------------------------------------------------------------- 3-13 ii 3.3 GENERATING -------------------------------------------------------------------------------- 3-14 3.3.1 Initiating a Generate-------------------------------------------------------------------- 3-14 3.3.2 What Happens in Generate ---------------------------------------------------------- 3-14 3.3.3 Special Considerations in Generate ------------------------------------------------ 3-14 3.4 SHUTDOWN ---------------------------------------------------------------------------------- 3-15 3.4.1 Initiating a Shutdown ------------------------------------------------------------------- 3-15 3.4.2 What Happens during Shutdown---------------------------------------------------- 3-15 3.4.3 Special Considerations during Shutdown -----------------------------------------