Thunder Scientific 2900 User manual

Model 2900 System Manual – Document #OM2900 - Edition 1.6 22 March 2019
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Thunder Scientific Corporation
Model 2900 System Manual

Model 2900 System Manual – Document #OM2900 - Edition 1.6 22 March 2019
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1
TABLE OF CONTENTS
2Getting Started 8
2.1 About...........................................................................................................................8
2.2Notice .......................................................................................................................... 9
2.3 Safety Information....................................................................................................... 9
2.3.1 Live Power Source ..........................................................................................9
2.3.2 Electro Static Discharge .................................................................................. 9
2.3.3 Compressed Gas..............................................................................................9
2.3.4 Personal Protective Equipment ....................................................................... 9
2.3.5 Safety Symbols ...............................................................................................9
2.4 Technical Support...................................................................................................... 10
2.5 License Agreement.................................................................................................... 10
2.6 Warranty.................................................................................................................... 11
2.7 Copyright................................................................................................................... 12
2.8 Trademarks................................................................................................................ 12
2.9 Specifications ............................................................................................................ 13
2.10 Uncertainty ............................................................................................................... 14
2.11 Facility Requirements................................................................................................ 15
2.11.1 Environment................................................................................................ 15
2.11.2 Floor Space ................................................................................................. 15
2.11.3 Power .......................................................................................................... 15
2.11.4 Air Supply................................................................................................... 15
2.11.5 Distilled Water Supply ................................................................................ 15
2.12 Installation ................................................................................................................. 16
2.12.1 Uncrating..................................................................................................... 16
2.12.2 Positioning .................................................................................................. 16
2.12.3 Chamber Fluid............................................................................................. 16
2.12.4 Reservoir Initial Filling Procedure.............................................................. 17
2.12.5 Setting Supply Pressure Regulator .............................................................. 17
2.13 Quick Start................................................................................................................. 18
2.13.1 Power-Up .................................................................................................... 18
2.13.2 Loading Screen............................................................................................ 19
2.13.3 ControLog Screen ....................................................................................... 20
2.13.4 Control Parameters...................................................................................... 22
2.13.5 Control Modes............................................................................................. 25
2.13.6 Generating and Shutting down .................................................................... 26
2.13.7 Power-Off.................................................................................................... 27
2.13.8 Set Date and Time....................................................................................... 28
2.13.9 Help............................................................................................................. 30
3Principle of Operation 31
3.1 Pre-Saturation (TPsat ) ................................................................................................. 31
3.2 Expansion Valve (TExV) ............................................................................................ 31
3.3 Saturation Temperature (TS) ..................................................................................... 32
3.4 Chamber Temperature (TC)....................................................................................... 32
3.5 Saturation Pressure (PS) ............................................................................................ 32
3.6 Chamber Pressure (PC).............................................................................................. 32
3.7 Humidity Formulas.................................................................................................... 32

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4ControLog Interface 33
4.1 Menu Bar................................................................................................................... 34
4.1.1 File Menu Tab ............................................................................................... 34
4.1.2 Home Menu Tab ........................................................................................... 38
4.1.3 Units Menu Tab............................................................................................. 41
4.1.4 Operation Menu Tab ..................................................................................... 42
4.1.5 Profile Menu Tab .......................................................................................... 45
4.1.6 Utilities Menu Tab ........................................................................................ 47
4.1.7 Graph Menu Tab ........................................................................................... 50
4.1.8 Data Menu Tab.............................................................................................. 52
4.1.9 Device Settings Menu Tab ............................................................................ 55
4.1.10 Help............................................................................................................. 57
4.2 Parameters Tab Group............................................................................................... 58
4.2.1 Tiles............................................................................................................... 61
4.2.2 2900 Parameter Tab ...................................................................................... 65
4.2.3 Device Parameter Tabs.................................................................................. 71
4.3 Data and Graph Tab Group ....................................................................................... 73
4.3.1 Data Tabs ...................................................................................................... 74
4.3.2 Graph Tabs.................................................................................................... 74
4.3.3 Profile Tab..................................................................................................... 74
4.4 Information Tab Group.............................................................................................. 75
4.4.1 Status Log ..................................................................................................... 77
4.4.2 2900 Reported Errors .................................................................................... 77
4.4.3 System timing ............................................................................................... 77
4.4.4 2900 Interface Console ................................................................................. 77
4.4.5 Device Interface Console .............................................................................. 78
4.5 Status Bar .................................................................................................................. 79
4.5.1 Connection and Run Status ........................................................................... 79
4.5.2 Auto Profile Controls and Status................................................................... 80
4.5.3 Current Point Time........................................................................................ 81
4.5.4 Set Date and Time......................................................................................... 81
5Fluid Levels 83
5.1 Water Reservoir Level............................................................................................... 83
5.1.1 Fill Water Reservoir ...................................................................................... 84
5.2 Liquid Level Sensors ................................................................................................. 85
5.2.1 Pre-Saturator Level ....................................................................................... 85
5.2.2 Flow Switch .................................................................................................. 86
6Calibration 87
6.1 Temperature Calibration............................................................................................ 87
6.1.1 Equipment Required...................................................................................... 88
6.1.2 Calibration Procedure.................................................................................... 88
6.2 Pressure Transducer Calibration.............................................................................. 108
6.2.1 Equipment Required.................................................................................... 108
6.2.2 Calibration Procedure.................................................................................. 108
6.2.3 Supply Pressure........................................................................................... 126
6.3 Mass Flow Meter Calibration .................................................................................. 127
6.3.1 Equipment Required.................................................................................... 127
6.3.2 Calibration Procedure.................................................................................. 127
6.4 Viewing and Editing Calibration Coefficients......................................................... 143

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7Graphing 147
7.1 Creating a New Graph ............................................................................................. 148
7.1.1 Line Properties ............................................................................................ 150
7.1.2 Chart Properties........................................................................................... 151
7.2 Customizing a Graph............................................................................................... 152
7.2.1 Pan............................................................................................................... 152
7.2.2 Zoom ........................................................................................................... 153
7.2.3 Zoom Graph’s X Axis ................................................................................. 154
7.2.4 Zoom Graph’s Y Axis................................................................................. 155
7.2.5 Auto Scale ................................................................................................... 155
7.2.6 Scale............................................................................................................ 155
7.2.7 Scale X Axis................................................................................................ 155
7.2.8 Scale Y Axis................................................................................................ 155
7.2.9 Graph Properties.......................................................................................... 156
7.3 Saving a Graph ........................................................................................................ 159
8Data and Data Summary 161
8.1 Device Data Tabs .................................................................................................... 165
8.2 File Data Tabs ......................................................................................................... 166
8.3 Data Summary Tabs ................................................................................................ 169
8.3.1 Creating a Data Summary ........................................................................... 170
8.4 Recorded Data Points Tab ....................................................................................... 177
8.4.1 How to Record a Data Point........................................................................ 178
9Auto Profiling 183
9.1 Creating a New Profile ............................................................................................ 185
9.2 Saving a Profile ....................................................................................................... 197
9.3 Opening a Profile..................................................................................................... 199
9.4 Running an Auto Profile.......................................................................................... 201
9.4.1 Understanding Profile Phases...................................................................... 203
9.4.2 Manual Override of Profile ......................................................................... 206
10 Connections 209
10.1 Serial Connection .................................................................................................... 210
10.1.1 Serial Connection Example 1.................................................................... 225
10.1.2 Serial Connection Example 2 .................................................................... 237
10.2 Analog Connection.................................................................................................. 254
10.2.1 Analog Connection Example .................................................................... 264
10.3 GPIB Connection .................................................................................................... 273
10.3.1 GPIB Connection Example ....................................................................... 289
10.4 Manual Connection ................................................................................................. 299
10.4.1 Manual Connection Example .................................................................... 303
10.5 Opening a Device Connection................................................................................. 312
11 External Communication 313
11.1 Read Percent Relative Humidity ............................................................................. 314
11.1.1 Syntax ....................................................................................................... 314
11.1.2 Response ................................................................................................... 314
11.1.3 Example .................................................................................................... 314
11.2 Read Frost Point Temperature................................................................................. 314
11.2.1 Syntax ....................................................................................................... 314
11.2.2 Response ................................................................................................... 314

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11.2.3 Example .................................................................................................... 314
11.3 Read Dew Point Temperature.................................................................................. 315
11.3.1 Syntax ....................................................................................................... 315
11.3.2 Response ................................................................................................... 315
11.3.3 Example .................................................................................................... 315
11.4 Read PPMv.............................................................................................................. 315
11.4.1 Syntax ....................................................................................................... 315
11.4.2 Response ................................................................................................... 315
11.4.3 Example .................................................................................................... 315
11.5 Read PPMw............................................................................................................. 316
11.5.1 Syntax ....................................................................................................... 316
11.5.2 Response ................................................................................................... 316
11.5.3 Example .................................................................................................... 316
11.6 Read Saturation Pressure......................................................................................... 316
11.6.1 Syntax ....................................................................................................... 316
11.6.2 Response ................................................................................................... 316
11.6.3 Example .................................................................................................... 316
11.7 Read Chamber Pressure........................................................................................... 317
11.7.1 Syntax ....................................................................................................... 317
11.7.2 Response ................................................................................................... 317
11.7.3 Example .................................................................................................... 317
11.8 Read Saturation Temperature .................................................................................. 317
11.8.1 Syntax ....................................................................................................... 317
11.8.2 Response ................................................................................................... 317
11.8.3 Example .................................................................................................... 317
11.9 Read Chamber Temperature.................................................................................... 318
11.9.1 Syntax ....................................................................................................... 318
11.9.2 Response ................................................................................................... 318
11.9.3 Example .................................................................................................... 318
11.10 Read Mass Flow Rate.............................................................................................. 318
11.10.1 Syntax ..................................................................................................... 318
11.10.2 Response ................................................................................................. 318
11.10.3 Example .................................................................................................. 318
11.11 Read Water Reservoir Level.................................................................................... 319
11.11.1 Syntax ..................................................................................................... 319
11.11.2 Response ................................................................................................. 319
11.11.3 Example .................................................................................................. 319
11.12 Read Generator State............................................................................................... 319
11.12.1 Syntax ..................................................................................................... 319
11.12.2 Response ................................................................................................. 319
11.12.3 Example .................................................................................................. 319
11.13 Read All................................................................................................................... 320
11.13.1 Syntax ..................................................................................................... 320
11.13.2 Response ................................................................................................. 320
11.13.3 Example .................................................................................................. 320
12 Data Backup 321
13 System 322
13.1 Control System ........................................................................................................ 322
13.1.1 Control Computer...................................................................................... 322
13.1.2 HMI Computer .......................................................................................... 323
13.1.3 ControLog® Software............................................................................... 323
13.1.4 HumiCalc with Uncertainty®Software ..................................................... 324
13.2 Electrical System..................................................................................................... 324

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13.2.1 Solid State Relays ..................................................................................... 325
13.3 Pneumatic System ................................................................................................... 326
13.3.1 Pressure Measurement .............................................................................. 326
13.3.2 Mass Flow Rate Measurement .................................................................. 326
13.3.3 Pre-Saturator ............................................................................................. 327
13.3.4 Reservoir ................................................................................................... 327
13.3.5 Saturator .................................................................................................... 327
13.3.6 Flow Control Valve................................................................................... 327
13.3.7 Expansion Valve ....................................................................................... 328
13.3.8 Chamber Pressure...................................................................................... 328
13.3.9 Test Chamber ............................................................................................ 328
13.4 Fluid System............................................................................................................ 328
13.4.1 Liquid Level Measurement ....................................................................... 328
13.4.2 Fluid Flow Measurement .......................................................................... 328
13.4.3 Temperature Controlled Chamber Fluid ................................................... 329
13.4.4 Chamber Fluid Heating ............................................................................. 329
13.4.5 Chamber Fluid Refrigeration .................................................................... 329
13.4.6 Temperature Measurement........................................................................ 329
13.4.7 Fluid Jacket Door Option .......................................................................... 329
14 Maintenance 330
14.1 Drain Pre-Saturator.................................................................................................. 330
14.2 Chamber Fluid......................................................................................................... 330
14.3 Air Input Filters (Mobile Cart) ................................................................................ 330
14.4 Circulation Pump Motor.......................................................................................... 331
14.5 Pre-Saturator Liquid Level Checkout...................................................................... 331
14.6 Reservoir Liquid Level Checkout............................................................................ 331
14.7 Warning and Error Messages .................................................................................. 332
14.7.1 Saturation Temperature at Minimum Limit .............................................. 332
14.7.2 Saturation Temperature Over Range or at Maximum Limit ..................... 332
14.7.3 Pre-Saturation Temperature at Minimum Limit........................................ 332
14.7.4 Pre-Saturation Temperature Over Range or at Maximum Limit............... 332
14.7.5 Expansion Valve Temperature at Minimum Limit.................................... 332
14.7.6 Expansion Valve Temperature Over Range or at Maximum Limit........... 333
14.7.7 Chamber Temperature at Minimum Limit ................................................ 333
14.7.8 Chamber Temperature Over Range or at Maximum Limit ....................... 333
14.7.9 Cabinet Temperature Over Range or at Minimum/Maximum Limit ........ 333
14.7.10 Insufficient Supply Pressure to Generate ................................................ 333
14.7.11 Supply Pressure Over Range or at Maximum Limit ............................... 333
14.7.12 Saturation Pressure at Minimum Limit ................................................... 333
14.7.13 Saturation Pressure Over Range or at Maximum Limit .......................... 333
14.7.14 Saturation Pressure Transducer Not Responding .................................... 334
14.7.15 Chamber Pressure at Minimum Limit ..................................................... 334
14.7.16 Chamber Pressure Over Range or at Maximum Limit............................ 334
14.7.17 Chamber Pressure Transducer Not Responding...................................... 334
14.7.18 Mass Flow Rate at Minimum Limit ........................................................ 334
14.7.19 Mass Flow Rate Over Range or at Maximum Limit ............................... 334
14.7.20 Refrigeration Compressor Low Side Pressure at Minimum Limit.......... 334
14.7.21 Refrigeration Compressor Low Side Pressure Over Range or at Max .... 334
14.7.22 Refrigeration Compressor High Side Pressure at Minimum Limit ......... 335
14.7.23 Refrigeration Compressor High Side Pressure Over Range or at Max ... 335
14.7.24 Flow Valve Reported Error:.................................................................... 335
14.7.25 Flow Valve Failed to Find Home Position.............................................. 335
14.7.26 Flow Valve at Minimum Limit ............................................................... 335
14.7.27 Flow Valve at Maximum Limit............................................................... 335

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14.7.28 Expansion Valve Reported Error: ........................................................... 335
14.7.29 Expansion Valve Failed to Find Home Position ..................................... 335
14.7.30 Expansion Valve at Minimum Limit - Check for air leaks ..................... 335
14.7.31 Expansion Valve at Maximum Limit - Reduce Mass Flow Rate ............ 335
14.7.32 Distilled Water Reservoir is Empty......................................................... 336
14.7.33 Distilled Water Reservoir is Low............................................................ 336
14.7.34 Unable to Fill Pre-Saturator .................................................................... 336
14.7.35 No Fluid Flow ......................................................................................... 336
14.7.36 No Saturation Fluid Heat......................................................................... 336
14.7.37 No Pre-Saturator Heat ............................................................................. 336
14.7.38 No Expansion Valve Heat ....................................................................... 336
14.7.39System Failed to Vent Pressure on Shutdown......................................... 336
14.7.40 Mass Flow Rate is being limited to achieve Humidity setpoint. ............. 337
14.7.41 Insufficient Supply Pressure to reach setpoint ........................................ 337
15 Drawings and Diagrams 338
15.1 18D29901-1 - Part List............................................................................................ 339
15.2 18D29901-2 – 2900 Components............................................................................ 340
15.3 18D29901-3 – 2900 Components (Back) ................................................................ 341
15.4 18D29901-4 – 2900 Components (Top).................................................................. 342
15.5 18D29901-5 – Pneumatic Schematic....................................................................... 343
15.6 18D29901-6 – Fluid Schematic............................................................................... 344
15.7 18D29901-7 – Refrigeration Schematic .................................................................. 345
15.8 18D29901-8 – Pneumatic Components ................................................................... 346
15.9 18D29901-9 – Refrigeration Components............................................................... 347
15.10 18D29901-10 – Electrical Components................................................................... 348
15.11 18D29901-11 – Data Acq. Components.................................................................. 349
15.12 18D29908 – Chamber Fan Components.................................................................. 350
15.13 18D29909-1 – Chamber Fluid Filling Instructions.................................................. 351
15.14 18D29909-2 – Chamber Fluid Draining Instructions .............................................. 352
15.15 18D29910-1 – Cart / ACS Assembly ...................................................................... 353
15.16 18D29910-2 – Filter / Regulator Assembly............................................................. 354
15.17 18D29910-3 – Cart Pneumatic System Schematic .................................................. 355
15.18 18S29911 – AC / DC Power Distribution ............................................................... 356
15.19 18S29912 – Temperature Probe Schematic............................................................. 357
15.20 18S29913 – Pre Tran/Stepper Drive Schematic ...................................................... 358
15.21 18S29914 – Transducer Schematic ......................................................................... 359
15.22 18S29915 – Pump / Comp / Flow Schematic .......................................................... 360
15.23 18S29916 – Exp. valve / Fluid Heater Schematic ................................................... 361
15.24 18S29917 – Pre Saturator Heater Schematic........................................................... 362
15.25 18S29918 – Solenoid Valve Control Schematic...................................................... 363
15.26 18S29919 – Fan Control Schematic ........................................................................ 364

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2
GETTING STARTED
This section will provide the user with information about the Model 2900 humidity generator, where to
obtain technical support, software license agreement, specifications, uncertainty, facility requirements and
installation. Following sections will provide further details on how to use and operate the Model 2900
generator using the ControLog software.
Note -All pressures are absolute unless noted otherwise.
2.1
ABOUT
The Thunder Scientific Model 2900 Humidity Generator is capable of producing known humidity values
using the fundamental, NIST proven, "two-pressure" principle. The Model 2900 uses this fundamental
“two-pressure” principle to continuously supply a known relative humidity, dew point, frost point, parts
per million, or other calculated value for instrument calibration and evaluation as well as precision
environmental testing.
The Model 2900 humidity generator encompasses a high-performance stand-alone Data Acquisition
Computer that performs all functions required for humidity generation and control and a second
dedicated Human Machine Interface (HMI) computer that runs ControLog. ControLog is a software
application that fully automates the operation of the Model 2900 humidity generator and allows various
device connections through a number of different interfaces. Data from the generator and connected
device or devices is automatically retrieved and stored for viewing in either numerical or graphical format
in real time or post process. Data can be transferred off the system via a USB drive for further viewing,
post processing and printing. The ControLog software also provides the primary interface to the operator
via the multi-point touch LCD and keyboard.
Key features of the of the ControLog software are:
•ControLog stores data into individual data sheets (tab). Each data sheet contains a spreadsheet
type view that consists of a date/time stamp and the measured data items corresponding to that
date/time stamp. Data sheets consist of three similar but different types: Device Data, File Data
and Data Summary. Each type has the same spreadsheet type view and operation, but all three
have different data sources.
•Graphing is a powerful tool used to view previously recorded data or to monitor the current data
in real-time. The graph works hand in hand with the data sheets. While the generator is in
operation, data sheets store the most recent data points from the generator and or connected
devices at the desired interval. A graph can be used to create a visual picture of this stored data.
•The Auto Profiling feature is very similar to the Generate mode with the main exception that
profiling relies on a predefined list of setpoints referred to as a profile. The user configurable
profile is used as ControLog's road map during Auto Profile operation. It defines which setpoint
values to go to, at what rate to go from one setpoint to another, and how long to stay at a specific
setpoint before moving to the next setpoint.
•ControLog supports a customizable interface that works with most devices. ControLog will allow
the user to create a new device connection using the “Connection Wizard” or open previously
saved connections. The wizard will open a separate dialog window containing various steps that
will guide the user in defining the communication required to receive the desired data items from

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the device. The user can create as many (up to 60) or as few data items as they see fit for any one
device. Each data item can be uniquely named and once connected will be recorded in its own
data sheet. ControLog also allows the user to save these interfaces for future use. The
“Connection Wizard” allows the user to step through the connection configuration. Using the
“Next” and “Back” buttons the user is allowed to progress through the connection configuration
steps. At any time, the user may cancel the new connection or opening of a connection by
selecting the “Cancel” button. Once the last step has been completed the “Finish” button will be
available to complete the new connection.
2.2
NOTICE
The specifications listed and the information contained in this document is subject to change without notice.
Screen shots shown in this document may differ slightly from the actual product and are given to show
functionality of the examples, procedures and program. Thunder Scientific Corporation makes no warranties,
either express or implied, regarding the examples, procedures and program, or the fitness of these examples,
procedures or program for a particular purpose. The examples, procedures and program are made available
solely on an "as is" basis and the entire risk as to their quality and performance rests with the user. Thunder
Scientific Corporation shall not be liable for any incidental or consequential damages in connection with or
arising out of the furnishing, use, or performance of the examples, procedures or program.
2.3
SAFETY INFORMATION
Important safety guidelines need to be observed when operating this equipment. Precautions are highly
advisable so that no personal injury will occur during the operation and maintenance of the system.
Observation of local and national regulations must be adhered to regarding safety standards.
2.3.1
Live Power Source
Warning! Make sure all power sources are turned off before making internal adjustments or replacing any
components. Only authorized technicians should perform any maintenance or repairs to equipment.
2.3.2
Electro Static Discharge
Caution! Electrostatic discharge (ESD) could possibly damage or destroy solid-stat parts when exposed to
static electric discharges. Be aware because electrostatic discharges may not be seen, felt or heard at levels
less than 4,000 volts.
2.3.3
Compressed Gas
Compressed gas is used on this system and if not properly vented may create an environment where the
state of foreign matter may be propelled. Proper safety precautions must be fallowed when applying any
pressure to the system. Before applying any pressure to the system, ensure that all pneumatic connections
are properly secured and tightened. Make sure all pressure settings are set to the proper specifications
before operation, testing, calibration or maintenance is performed.
2.3.4
Personal Protective Equipment
Safety glasses must be worn when preforming any maintenance, repairs or calibration when system panels
have been removed. Gloves may be needed on some maintenance or repairs.
2.3.5
Safety Symbols
Symbols used in this manual for safety and other disciplines can be found in table 1-1.

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Safety terminology used for identification of any safety conditions are as follows:
Warning indicates a potential hazard may exist and the user should be extremely careful.
Caution!identifies a condition or action that may cause damage to the system or the user.
Symbol
Description
The equipment has this symbol displayed
and indicates that the equipment meets
the requirements of the European safety
directives.
This symbol is shown from the WEEE
directive and indicates do not dispose of
this product in any municipal waste area.
This symbol means Caution should be
observed or important information.
This symbol indicates a potential shock
hazard may exist.
This symbol means Earth Ground.
Table 1-1
2.4
TECHNICAL SUPPORT
If the user requires assistance with any aspect of the 2900 Humidity Generating System or the ControLog
application, technical support can be obtained by contacting Thunder Scientific Corporation by any of the
following means:
Web: www.ThunderScientific.com
Email: [e-mail]
Tel : [phone]
FAX : [phone]
2.5
LICENSE AGREEMENT
THIS IS A LEGAL AGREEMENT BETWEEN YOU, THE END USER, AND THUNDER SCIENTIFIC
CORPORATION ("TSC"). THE ENCLOSED THUNDER SCIENTIFIC CORPORATION SOFTWARE PROGRAM
(THE "SOFTWARE ") IS LICENSED BY THUNDER SCIENTIFIC CORPORATION TO THE ORIGINAL
CUSTOMER AND ANY SUBSEQUENT TRANSFEREE OF THE PRODUCT FOR USE ONLY ON THE TERMS
SET FORTH HERE. PLEASE READ THIS LICENSE AGREEMENT. IF YOU DO NOT AGREE TO THESE
TERMS, RETURN THE FULL PRODUCT WITH PROOF OF PURCHASE WITHIN 30 DAYS FOR A FULL
REFUND.
• GRANT OF LICENSE. TSC grants to you the right to use one copy of the enclosed SOFTWARE on a single terminal
connected to a single computer (i.e. single CPU) or to a network server. If you install the SOFTWARE on a network
server, you must purchase a separate copy of the SOFTWARE for each computer terminal that will be used to operate
the SOFTWARE. If the anticipated number of users of the SOFTWARE will exceed the number of applicable Licenses,