Thermal Shock Test System

Temperature Range	-75°C to +210°C
Test Basket High Temperature Range	70 °C to 200 °C / 158 °F to 392°F
Test Basket Low Temperature Range	0 °C to -65°C / 32°F to 149°F
Hot Chamber High Temperature range	Pre heating upper limit 210°C
Cold Chamber Low Temperature range	Pre cooling lower limit -75°C
Temperature Fluctuation	±1°C
Calibrated Values          Cold Chamber                                                                                       Hot Chamber	-40°C                                                                                                                         125°C
Altering time between Hot to Cold	±10sec
Basket Load Carrying Capacity	25 – 30KG
Basket Recovery Time*	Basket Recovery Time will be
Weight of the chamber	< 1000kg

Specification	Medium sized (PTS- 150, 300)	Large sized (PTS- 600, 900)
Basket Movement Type	2-Zone Vertical movement of specimen	2-Zone Horizontal movement of specimen
Movement Mechanism	Vibration free Pneumatic	Vibration free Pneumatic/Motorised mechanism
Transition Time	From Hot to Cold and Cold to Hot Zone < 5 Sec.	From Hot to Cold and Cold to Hot Zone < 10 Sec.

Model	Test Basket Volume	Load Resistance	Basket Dimensions (W x D x H)	External Dimensions (W x D x H)
PSTS-150	150L (5.3 cu.ft)	40 kg	600 x 500 x 500 mm	1050 x 2100 x (1700+700) mm
PSTS-300	300L (10 cu.ft)	50 kg	800 x 750 x 500 mm	1250 x 2350 x (1700+700) mm
PSTS-600	600L (21 cu.ft)	75 kg	900 x 900 x 750 mm	1350 x 2500 x (2150+950) mm
PSTS-900	900L (31 cu.ft)	100 kg	1000 x 1000 x 900 mm	1450 x 2700 x (2400+1100) mm

Test Basket

• High Temp Range: 70°C to 200°C (158°F to 392°F)
• Low Temp Range: 0°C to -65°C (32°F to -85°F)
• Fluctuation: +/- 1°C
• Gradient:

1. PTS-150: +/- 1°C
2. PTS-300/600: +/- 1.5°C
3. PTS-900: +/- 2°C

• Hot Chamber Pre-Heating: Upper limit 210°C; Ambient to 210°C within 40 min.
• Cold Chamber Pre-Cooling: Lower limit -75°C; Ambient to -75°C within 35 min.
• Basket Recovery Time: < 5 min at 200°C and -65°C.
• Ambient Recovery (without load):
  • Hot Zone: 120 min (200°C to 70°C)
  • Cold Zone: 60 min (-65°C to 25°C)

Note:

Recovery time of less than 5 minutes is achievable under pre-programmed conditions with a temperature variation                (ΔT) of 10–15°C in an empty chamber

Recovery time may vary depending on the load conditions, including the type, mass, and weight of the material placed inside the chamber

Function
1	Leakage breaker
2	Circuit breaker
3	Hot chamber overheat protection switch
4	Cold chamber overheat protection switch
5	Hot chamber overheat protector (Controller)
6	Cold chamber overheat protector (Controller)
7	Test area overheat / overcool protectors (Controller)
8	Test area overheat / overcool protectors
9	Circuit breaker for air circulator
10	Refrigerator high / low pressure switches
11	Compressor temperature switch
12	Air pressure switch
13	Test area door switch
14	Specimen power supply control terminal
15	Compressor circuit breaker
16	Heater circuit breaker

• The internal workspace is fabricated from stainless steel and provided with LED illumination for enhanced visibility
• Vertical basket changeover is achieved without the use of compressed air, utilizing an electro-pneumatic mechanism
• Baskets are sealed using an air-tight, single-line silicone gasket to ensure no air leakage between zones
• A high-resolution colour touchscreen controller is provided, featuring user-friendly graphical programming
• An automatic defrost cycle is provided for the cold zone to ensure continuous and long-duration operation
• A large, multilayer vacuum-insulated viewing window is provided, equipped with defog heaters for clear visibility
• The test chamber is provided with imported heavy-duty castor wheels and inbuilt manual level adjusters to facilitate smooth mobility and precise leveling
• Turbulent design Stainless steel hub with axil rust free blade is used for Uniform Air-Circulation for Better Temperature Gradient in The Working Space

 

Construction Features:

• The exterior shall be constructed from minimum 2 mm thick CRCS sheets with powder-coated panels and doors, ensuring high precision and superior aesthetics
• The interior (unobstructed workspace) shall be made of high-quality 18 SWG stainless steel with a brush finish, along with reinforced flooring designed to withstand heavy distributed loads
• The internal test chamber and outer body are insulated using mineral wool, ensuring uniform insulation with no air pockets, minimizing heat loss and thermal conduction
• The door and chamber are sealed using multi-level, diagonally joined airlock silicone rubber gaskets, supported by conduction-free isolation mounts to ensure superior thermal sealing and minimal heat transfer
• The test chamber is equipped with LED illumination featuring pre-set cut-off timings
• A multi-pane, condensation-free glass inspection window is provided on the hot zone door for clear viewing of the test basket specimen
• The chamber is mounted on 4-inch heavy-duty castor wheels along with leveling pads, ensuring easy installation, movement, and stability of the system
• Heavy-duty die-cast hinges are provided to ensure smooth and reliable swing operation of the chamber door

Test Space Conditioning Section

• Easy Maintenance Access:
  The conditioning plenum is designed for easy access, facilitating convenient inspection and maintenance
• Air Circulation System:
  A single-moulded, lightweight high CFM co-axial fan is provided to ensure uniform air circulation throughout the chamber
• Motor Assembly:
  A vibration-free, stainless steel, joint-free extended shaft induction motor with an external flange mounting is used for reliable and smooth operation
• Modular Conditioning Unit:
  The system features a modular conditioning unit comprising heat exchangers, an air circulation system, and a heating system for efficient thermal performance

Refrigeration Section (Water-Cooled)

• Refrigeration System:
  A mechanical cascade refrigeration system is provided, incorporating hermetic/semi-hermetic compressor(s) for reliable and efficient cooling performance
• Compressor Mounting:
  Semi-hermetic compressor(s) are mounted on a two-stage suspension system using compression springs and rubber bushes, tightened to the required torque to ensure vibration-free operation
• Refrigerant & Cooling Type:
  The system utilizes eco-friendly, non-CFC refrigerants (R-404A / R-23) in a water-cooled refrigeration configuration
• Evaporator Design:
  Evaporator heat exchanger coils are manufactured from oxidation-free materials and feature full-collared, bullet-expanded tubes to ensure highly efficient heat transfer and enhanced performance
• Automatic Bypass Control:
  An automatic bypass control system is provided, operating based on suction pressure and temperature to maintain precise temperature control under variable load and no-load conditions
• Oil Management System:
  An efficient oil return management system is incorporated to protect the compressor from lubrication failure and ensure long-term reliability
• Vibration & Noise Control:
  An additional isolation suspension channel with anti-vibration pads is provided to further minimize vibration and noise levels from the compressor assembly

Basket Movement System

• Electro-Pneumatic Basket Movement:
  An electro-pneumatic type vertical basket movement system is provided to transfer the test basket between the cold and hot zones efficiently
• Operation:
  The system enables smooth and reliable movement of the test basket from the cold zone to the hot zone and vice versa, ensuring consistent test performance

Heating System

• Heating Elements:
  Inconel-sheathed or bare nichrome air heaters are provided to achieve the desired temperature efficiently
• Heater Placement:
  The heaters are strategically placed within the conditioning section to prevent direct heat radiation onto the test specimen
• Temperature Control:
  Heater output is controlled zero-crossing relays or thyristors, ensuring precise temperature control and superior stability
• Electrical Isolation:
  The heaters are electrically isolated from the chamber body using high insulation resistance isolators to prevent earth leakage and ensure safe operation

• Controller Hardware:
  The colour touchscreen controller is built on high-performance core hardware with integrated functionality. It is housed in a robust cast aluminium enclosure with IP66 protection for the front panel
• Memory & Connectivity:
  The controller is equipped with dual USB host ports, onboard 256 MB non-volatile flash memory, and supports expandable external memory up to 2 GB for enhanced data storage and handling
• User Interface:
  A 7-inch resistive analog touchscreen provides a user-friendly interface, enabling easy monitoring and control of system parameters
• Remote Access & Data Handling:
  The controller supports web server functionality, allowing users to access and monitor the system via a PC. The USB host ports enable direct transfer of log files, program files, and reports to external storage devices such as USB drives or hard disks

Control System – Features

• 7” resistive analog colour touchscreen with WVGA (800 × 480 pixels), 16M colors and LED backlight
• Up to 4 fully isolated serial communication ports (2 × RS-232, RS-422/485)
• 10/100 Base-TX Ethernet port for external device communication and remote operation
• Dual USB host ports for USB mouse, keyboard and external storage devices
• 3 user-programmable soft keys with LED indication
• Onboard 256 MB memory with expandable SD card up to 32 GB
• Up to 99 programs with 1 segment and 999 repeat cycles per program
• Nested looping within programs and segments for flexible test requirements
• Graphical program editing for easy setup and monitoring
• Auto PID configuration for full temperature operating range
• Real-time trend display with user-defined scaling
• 3-level security for controlled user access
• Digital pressure monitoring for refrigeration compressor gas
• Subsystem/component lifecycle status and run hour display
• Calibration due warning
• Compressor diagnostics (oil level, discharge temperature, winding temperature, suction temperature, run hours) with auto report generation

Safety and Control

• Incoming supply electromagnetic interference (EMI) filter for suppression
• Surge protection for incoming power supply
•  MPCB protection for all individual 3-phase power devices
• MCB protection for all individual 1-phase power devices
• Protection against single phasing, phase reversal, under-voltage, and over-voltage for main input power
•  High and low temperature mechanical safety protection (floating type)
• High and low temperature software safety protection
• Over-temperature thermal protection for heaters
• Mechanical high/low pressure safety protection for the refrigeration system
• Software-based high/low pressure safety protection for the refrigeration system
• Inbuilt winding thermal protection for compressor (only for semi-hermetic type
• Compressor oil level protection (OPS) (only for semi-hermetic compressors < 10 HP)
• Compressor high discharge temperature protection