The ES2000 photostability chamber, a product of Bahnson Environmental Specialties (ES) developed in the late 1990’s specifically tailored to pharmaceutical testing requirements, is a reach in environmental chamber designed for high demand light testing. To provide maximum efficiency of the visible and ultraviolet A light banks, high wattage biax fluorescent bulbs are used in combination with reflective specular aluminum to transmit the highest, most uniform light levels. General features of the photostability chamber include:

• High performance electronic and mechanical systems
• User friendly microprocessor controls in a single panel
• Industrial grade construction for continuous use
• Heavy duty refrigeration system with reserve BTU removal capability
• Modular component design with upgrade flexibility
• Temperature control to within ± 0.20°C (0.40°F) and uniformity of ± 2.0°C (3.6°F)
• Relative humidity control to within ± 5%
• Automatic alarm mode deactivation when parameter returns to normal
• Optional EIA RS 485 or 4 to 20 mAdc output for computer monitoring
• Stainless steel (type 304) exterior of light bank for durability and corrosion resistance
• Highly transparent, easily removable acrylic light lens for maximum transmission of ultraviolet A and visible energy
• Mirrored chamber and light bank interior featuring specular aluminum for maximum reflectivity of ultraviolet A and visible energy
• Electronic dimming ballasts internally mounted within light banks.
• Microprocessor PID controller and photodiode sensor combination for fully automatic light level control, and maintenance of light level during lamp depreciation
• Adjustable sensor stand for measuring light levels at different product heights

The ES2000 photostability chamber is designed to support up to 3 simultaneous light studies at one time, each bank offering one (or a combination of two) of three standard light sources. Each bank can be offered with “cool white” (CW), “ultraviolet?A” (UV), or “full spectrum” (FS) lamps as standard; or a combination of any two above. Special wavelength lamps can be offered upon customer request. The basic operation of the light chamber must include familiarization with the control panel components; all items noted in later sections. Once the user is comfortable with the controller readouts and changing of setpoints, a light study may be performed by simply placing product in the boundaries as defined by the black lines on each shelf. This region has been factory tested at ES to give equal to or better than +/- 10.0% uniformity from setpoint (both single and combination systems). The area outside of the boundary line cannot be guaranteed to offer the stated uniformity; but this may be tested to specification by the user. The setpoint for each bank, or light system, will be indicated on the digital controllers. Each digital controller will clearly indicate the respective bank; with Banks1 through 3 going from top to bottom. Optional combination systems will indicate Bank number and whether it applies to cool white lamp set ‘A’ or ultraviolet lamp set ‘B’.

Model Designations

There are two standard models within the ES2000 photostability product line:

• ES2000 C: Refrigerant cooled, temperature control only
• ES2000 CDM: Refrigerant cooled, with humidification and refrigerant based dehumidification, temperature and humidity control

There are two standard sizes within the ES2000 photostability product line, indicated with suffixes:

• No suffix: 33 cu.ft. “upright”
• BT: 12 cu.ft. “benchtop”

There is a standard operational option of low temperature within the ES2000 product line, indicated with suffix “LT”. This option provides operation at the setpoints of 4 / 5°C (39 /41°F). Note: There are various other special operational options provided upon request. These are specified with the “S” suffix.

ES will be glad to assist in any questions about the ES2000 Photostability Chamber by contacting our Sales Department at (800) 688-5859.

The CCS-3000, developed to provide the modern, intuitive control systems that customers desire, is a chamber control system consisting of a controller combined with a color Touch Screen interface. It is a complete chamber control system with standard inputs for temperature and humidity control which can be expanded to handle up to 6 additional RTD sensors for chamber uniformity monitoring. The Touch Screen interface is a 5.7”, 28-oz, embedded industrial PC with all software included. No external PC software is required for setup or configuration. All chamber data variables are saved to its internal memory (128MB CF Card storage).

The CCS-3000 comes equipped with all digital and analog outputs required for complete chamber operation. All chamber and user adjustable alarms are monitored and logged during normal system operation.

The CCS-3000 can be run in Manual or optional Automatic Profile Control modes. Profile entry is made simple by the use of copy/paste/delete menu selections. Profile plotting and monitoring also provides the user with easy-to-use screens for monitoring profile operations. Auto Profile Start based on time or remote input are standard when the Profile option is ordered.

Data file analysis tools (for example, automatic real time and historical trending) make reviewing historical data a simple task. Any control variable saved to the CCS-3000 CF Card can be plotted on the Historical Data Trend for any time frame within the data file’s total time range. Full “USB” print capabilities from the interface to a standard HP inkjet printer (models 6540, 6940, 6980 with USB interface) eliminates the need for a PC or strip or circular chart recording device. Real time trends, historical trends and report print functions are standard.

The built in Ethernet “Web Server” provides access to all chamber data (view only) via a local Intranet connection (wired or wireless) or the World Wide Web using standard software like Microsoft’s Internet Explorer©.

An optional 2 wire (RS-485) Modbus connection is available to connect up to thirty-one CCS-3000s to a PC in order to meet remote monitoring/controlling and data acquisition requirements. The CCS-3000 provides a rich set of tools for control interaction and data analysis. Views include: Chamber Overview, Trends, Alarms, and Profiles as well as Historical Data, Alarm History and Audit Trail. The menu-driven interface eliminates screen “clutter” by providing an easy-to-use Windows interface for interaction between the user and CCS-3000 system.

The system can store more than 1 year of data on its 128MB internal CF card. Data logging is enabled manually or automatically on System Startup as configured by the user. The user can assign file names, batch and lot numbers before data logging is started. Data backup is provided with the 128MB “USB I-Stick” for plug-and-play transfer of files to any PC running Microsoft Windows XP© operating system.

The CCS-3000 provides the required tools to conform to the requirements of 21 CFR Part 11 and supports full security, audit trail, encryption and digital signatures.

The CCS-3000 control system includes the following interface features:

• Overview screen that displays all chamber runtime information

• Profile Run and Monitor views

• Current Alarm and Alarm History views (alarm history for more than 1 year)

• Real Time Trends (with adjustable X,Y limits) for control temperature and relative humidity inputs and setpoints

• Monitor Probes view for additional temperature probes connected to system

• Profile Entry, Open, Save and Download interface screens

• System Setup that includes Chamber Setup (defrost settings, control tuning, etc.)

• Data logging interface screens to include log point’s selection and historical viewing

• Plug-and-Play memory stick functionality for data transfer/backup

• Full USB print capabilities and on-line help screens

• Web server for intranet/internet access (view only)

ES will be glad to assist in any questions about the CCS-3000 Touch Screen Control System by contacting our Sales Department at (800) 688-5859.

The ES2000, a product of Bahnson Environmental Specialties (ES) developed over 15 years ago, is a reach?in environmental chamber designed for high demand testing, processing or conditioning.

Five standard models cover temperature ranges from 2°C (36°F) to +70°C (158°F), with controlled humidification and special operational options available on select models. Four standard sizes of 12, 33, 74, and 114 cu. ft. (usable internal volume) are available. General features include:

• High performance electronic and mechanical systems
• User friendly microprocessor controls with touch screen in a single panel
• Industrial grade construction for continuous use
• Heavy duty refrigeration system with reserve BTU removal capability
• Modular component design with upgrade flexibility
• Temperature control to within ± 0.20°C (0.40°F) and uniformity of ± 0.3°C (0.5°F) (±1.0°C (1.8°F) for 74, 114 cu.ft. models)
• Relative humidity control to within ± 3% (± 5% for 74, 114 cu.ft. models)
• Automatic alarm mode deactivation when parameter returns to normal
• Standard Ethernet connectivity for remote monitoring
• Optional EIA RS 485 or 4 to 20 mA dc output for remote monitoring

Model Designations

There are five standard models within the ES2000 product line:

• ES2000 A: Ambient air cooled, temperature control only
• ES2000 AM: Ambient air cooled, with humidification, temperature and humidity control
• ES2000 C: Refrigerant cooled, temperature control only
• ES2000 CDM: Refrigerant cooled, with humidification and refrigerant based dehumidification, temperature and humidity control
• ES2000 CDMD: Refrigerant cooled, with humidification and desiccant based dehumidification, temperature and humidity control

There are four standard sizes within the ES2000 product line, indicated with suffixes:

• No suffix: 33 cu.ft. “upright”
• BT: 12 cu.ft. “benchtop”
• DW: 74 cu.ft. “doublewide”
• TW: 114 cu.ft. “triplewide”

There are four standard operational options within the ES2000 product line, indicated with suffixes (Note: There are various other special operational options provided upon request.

These are specified with the “S” suffix)

• ?LT: Low temperature capability, ?25 C. or lower (NOT applicable to 12 cu.ft. models)
• ?R: Ramping / profiling control system
• ?AT: Compressed air tower desiccant drier
• ?EX: Explosion safe interior design (exterior is NOT designed for explosion safe standards)
• ?CO2: CO2 controlled interior, 0?20% range

For more information or a quotation please contact our Sales Department at (800) 688-5859.

In the past few years, Environmental Specialties has undertaken a ‘green initiative’.  This initiative has been to look for, and incorporate, energy efficient elements of environmental chamber design relating to mechanical, electrical, and architectural.  States such as California already require certain design elements by specification, while other states may soon follow with similar design requirements.

Examples of energy efficient design elements are:

-          Hot gas (i.e. three pipe) refrigeration and defrost systems:  ES promotes the three pipe refrigeration system based on using the hot gas of the refrigeration system to provide heating as needed for temperature control and to heat warm rooms.  This is done in lieu of using a two pipe system to overcool the air then electric ‘reheat’ing the air back up to the room condition.  This requires the electricity demand for both the refrigeration system and the electrical heater(s).  A hot gas / three pipe system requires only the electricity for the refrigeration system.  On larger systems, operating 24 hours a day, every day, this translates to $1,000’s of savings in annual operating costs.  ES also promotes hot gas for defrost considering that the refrigeration system electricity is useful in defrosting the coil with only minor supplemental electric heating.  Without hot gas defrost, more electricity is required, and for longer intervals, to provide adequate defrosting.

-          Compressor-to-load matching:  As noted above, ES uses three pipe systems which allows for constant operation (no cycling) and excellent temperature control.  A benefit of three pipe systems is that they are provided with a special compressor pressure regulating valve which limits the suction pressure of a given compressor.  By limiting suction pressure and therefore cooling capacity, the actual compressor capacity, via the valve, can be matched closely to the normal steady state cooling demand of the room.  The lower suction pressure results in lower amperage draw from the compressor, resulting in lower operational costs.

-          PSC and EC evaporator motors:  ES uses primarily PSC (permanent split capacitor) and EC (electronically commutated) motors in the environmental chamber unit coolers.  Both motor types are very energy efficient versus traditional shaded pole motors (EC is the most energy efficient of the two).  Energy efficiency translates into lower electricity demand to the motors, lowering operational cost.  The lower efficiency also translates into lower heat output, reducing cooling system size and ultimately reducing operational cost.

-          Fluorescent and LED lighting:  ES uses modern T-8 fluorescent lamps, energy efficient ballasts, and special 95% back-reflective fixtures for low electricity demand per lumen of light in the room (lumen is unit of visual measure).  The ballasts are also high output, meaning that they drive the T-8 lamps for considerably higher lumen output than traditional ballasts.  ES also uses T-5 fluorescent fixtures in freezers down to -25 C.  This type of fixture is much more efficient than traditional incandescents, generally requiring only 20-30% of the light count with the fluorescents.  LED fixtures are also considered as they offer very low electricity demand per lumen of light output, direct light downward more efficiently into the workspace vs fluorescent, and are provided in color temperatures which provide high visual acuity (i.e. easier to see by).  This can actually translate to lower light count due to the higher visual acuity.  As LED’s become more popular in the lighting market, increased efficiency and lower costs will result.

-          Chilled water cooling:  By using building chilled water for direct cooling of the chamber, or indirect cooling of the refrigeration system, ES can provide simple, energy efficient cooling systems.  Direct cooling chilled water is commonly considered for warm rooms, or those operating at 10 C or higher.  This does not require the electricity demand for an intermediate air cooled refrigeration system; the heat transfer is direct air-to-water.  Chilled water is also used for indirect cooling of the condenser for water cooled refrigeration systems, such that the heat rejection from the refrigeration system is not into the ambient space, thus avoiding the upsizing of the air conditioning system for that space.  This ultimately avoids an increase in the size and operational cost of the space air conditioning system.

-          Foamed panel floors:  Many customers suggest the use of the building concrete floor for cold rooms and, sometimes, freezers.  ES often suggests the consideration of foamed panel floors as it pertains to energy efficiency, electricity demand, and operational costs.  The concrete floor acts as a poor insulator and constant heating source for such cold rooms, and this affects the refrigeration system size and operational costs of such.  An insulated floor, however, is an excellent insulator, allowing smaller refrigeration equipment and lower operational costs.  An insulated floor does carry an initial material and installation cost, but long term payback is relatively quick on larger rooms which generally require very large refrigeration equipment.

-          Custom internal air conditioning (plenum) units:  As we see many requests for external AHU (air handling units), ES recommends consideration of internal air conditioning (plenum) units with the room/chamber space.  Air handling units involve ductwork, often insulated, and the static pressure to move the air over long distances.  This static pressure requires more motor power.  Air handling units also have leak points, as well as the ductwork.  This introduces more cooling demand from incoming warm air leakage.  Both the static and cooling demand increase electricity demand from the system, and operational costs.  ES internal air conditioning (plenum) units avoid the use of external ductwork and the resulting leakage, as well as the static from long duct runs.  Electricity demand and operational costs are reduced.

Choosing a Photostability Chamber

Environmental Specialties manufactures quality photostability chambers meeting ICH Q1B guidelines. Our time proven technology has served the pharmaceutical industry for over 15 years as well as assisting other industries in developing photostability guidelines for their products. Our knowledgeable team can assist in choosing a photostability chamber to meet your specific needs.

The following items should be considered when choosing a photostability chamber.

Chamber Size

ES offers a 12 cubic foot (benchtop) chamber with a single light bank, or a 33 cubic foot (upright) chamber with three individual light banks.

Temperature Control / Humidity Control

Chambers are available with temperature only control or temperature and humidity control. The standard chamber temperature range is 20°C to 40°C. Low temperature operation at 4°C can also be provided.

ICH Q1B Options

Option 1: ES offers a custom-made full spectrum fluorescent lamp which combines visible and ultraviolet-A outputs.

Option 2: ES offers custom-made cool white and ultraviolet-A lamps to meet the specific emission guidelines.

Light Bank Configuration

ES offers both single source light banks and dual source light banks. Our 12 cu ft chamber is standard with one dual source light bank combing both cool white (CW) and ultraviolet (UV) lights. Our 33 cu ft chamber provides three individual light banks. The standard configuration is two light banks with CW bulbs and one light bank with UV bulbs. Dual source lights can be provided for any or all light banks.

Chamber Monitoring

Local display of chamber temperature/humidity and light is provided. High/low temperature/humidity/light levels are both audible and visual. Dry contacts are provided for remote monitoring of alarms. Continuous chamber monitoring can be provided via chart recorders. A 6-channel strip chart recorder can be provided to monitor temperature, humidity and light intensities. When more than 6 channels are required (multiple dual source banks), a 6-channel strip recorder can be utilized for monitoring light intensities in combination with a circular chart recorder for recording temperature/humidity.

Remote monitoring capabilities can be provided via 4-20mA output signals or RS-485 for continuous monitoring.  One signal is required for each channel.

Chamber Utilities

The chambers require 208-230 V/1ø electrical supply. RO water or low grade DI water is required for humidity controlled chambers. Condensate removal is required for humidity chambers via floor drain, condensate pump or heated condensate pan.

ES is devoted to ensuring you are completely satisfied with your photostability chamber purchase. Your questions are important and we welcome the opportunity to speak with you concerning your specific interests and lighting requirements. Feel free to call our 800 number or email our Sales associates. We will be happy to assist.

Programmable ramping chambers, also known as freeze/thaw chambers, are capable of controlled ramping of setpoints between low and high temperatures and humidities. The standard chamber has a temperature range of 2 to 70°C., with –20°C and lower capability available upon special request. The primary function of a ramping chamber is automatic setpoint change sequences which does not require manual user control or moving of product from one chamber to another. A chain of setpoints can be programmed and automatically run for days and weeks without stop.

The entire series of setpoint changes is called a "profile", and each setpoint change is called a "step". Each profile allows up to 99 steps with each step having up to 99 recycles back to a previous step for a virtually unlimited number of profile steps. To maintain a setpoint for a specified period of time is to "soak", and to change from one point to another is to "ramp".

The CCS-3000 touchscreen controller provides the following features:

Profile Status view: Provides the user with all current data related to the Profile that is currently running. The Profile Status View screen also displays the name of the current Profile running as well as the current active segment function (Ramp, Soak, Auto Start, etc.).

Profile Entry screen: Allows the user to enter step data for each Profile. Hundreds of Profiles can be stored in memory storage. The Edit menu provides Copy, Paste, Insert and Delete functions to simplify Profile entry.

Profile Run menu: Allows the user to manually run, hold or stop a profile or advance to the next or previous step.

Profile Recycle: Allows the Profile to jump between different steps within the profile. It can also be referred to as profile "looping". This is useful for repeating the same sequence of steps over and over again without having to enter them into a profile multiple times. It is valuable for life cycle testing of product in which the same temperature (and/or humidity) Profile steps need to be repeated multiple times in order to determine longevity of a product.

Guaranteed Soak Limits: Allows the operator to set a "global" band for temperature and humidity during ramp and soak steps. Ramp steps are steps where the current step setpoint is different from the previous step setpoint. Soak steps are steps where the current step setpoint is the same as the previous step setpoint. This provides a guarantee that a ramp or soak step maintains the set temperature/humidity for the specified period of time. This function is used when process changes are expected due to chamber doors opening which might drop the chamber temperature (and the product under test in the chamber) below the desired setpoint for a period of time. During the Ramp or Soak period, if the temperature or humidity falls outside of the band set in the Guaranteed Soak Limits, the Profile timer will be put on hold until the process values fall back within the band limits set. This provides a guarantee that a ramp or soak step maintains the set temperature/humidity for the specified period of time.

Profile Plot: Plots a trend of the current Profile.

Profile Auto Start: Allows the user to select the month, day, hour and minute at which a Profile loaded into the CCS-3000 control module will automatically start.

Environmental Specialties pre-programs each chamber to customer setpoint requirements and can be of assistance when entering new profiles. The CCS-3000 provides on screen Help for instructions. Each chamber comes with a detailed Operation Manual which features detailed information on the functions of the CCS-3000. ES will be glad to assist in any questions about ramping chambers by contacting our Sales Department at (800) 688-5859.

In recent years, customers have become more and more conscious of the price per square foot of storage space, energy efficiency, and the ease of installation.  As engineering firms have become more involved with environmental chamber purchases, these issues have become critical to the review of options.

When a situation arises where the chamber is small, i.e. a ‘step-in’ chamber less than 8’ x 8’ in footprint, ES recommends consideration of a large reach-in chamber in lieu of the step-in.  For information on both products, refer to the website tabs on walk-in chambers and reach-in chambers.

For a specific comparison, let’s consider the following step-in chamber scenario:

-          Overall size:  7’ wide x 6’-6” deep x 8’-6” high, 4” insulated panels; 345 cu ft interior

-          Left and right wall shelving (usable):  41.5” long x 17.5” deep x 6 tiers spaced at 12”

-          Back wall shelving (usable):  71.5” long x 17.5” deep x 6 tiers spaced at 12”

-          Overall shelving area:  ( 41.5” x 17.5” x 6 ) x 2  +  71.5” x 17.5” x 6 = 16,222 sq in. = 113 sq ft.

Notes:

- Usable shelving is slightly smaller than nominal size due to end posts and shelf edging.

- There is an allowance of approximately 38” width x 48” depth for the user to enter the room and move product into place.

Let’s compare this to a triplewide reach-in chamber:

-          Overall size:  10’-3” wide x 3’ deep x 7’-8” high, 2.5” insulated walls; 114 cu ft interior (usable)

-          Shelving (usable):  116” long x 28” deep x 5 tiers spaced at 12”

-          Overall shelving area:  ( 116” x 28” x 5 ) = 16,240 sq in. = 113 sq ft.

This example shows that a triplewide reach-in chamber, at a nominal 114 cu ft, can provide the same shelf storage area as a step-in chamber, at a nominal 345 cu ft. 

Note that the step-in chamber requires field erection, meaning that site construction and site start-up and testing is required.  The reach-in chamber, on the other hand, is factory assembled, factory tested, then shipped to site. 

Between the two options, the triplewide reach-in chamber is considerably less overall cost (materials and labor), and is a much faster installation (simply unload and roll into the final location).  Both options are energy efficient, but the cost and installation considerations make the triplewide reach-in chamber a highly favorable choice for small to medium volume storage needs.

Environmental Specialties has supplied hundreds of ‘standard’ cold rooms, warm rooms, and freezers over the past 30 years.  While this still represents a large part of the business, a growing part of the business in recent years has included cold cleanrooms and ultra low freezers.  As a Product Engineer, I find these types of rooms most interesting, and a good fit for a company such as ours with depth in engineering and project management resources.

The cold cleanrooms (40 F +/-) are a niche market for environmental chambers companies such as Environmental Specialties, understanding that standard temperature (70 F +/- range) cleanrooms are generally provided by typical cleanroom builders.  Environmental Specialties provides Class 100 to Class 100,000 cleanrooms, with internal stainless steel conditioning units or external air handlers.  Of important note, ES offers the custom internal conditioning units in order to provide a more energy efficient, cost efficient, and space efficient method of cooling and air circulation.  This unique approach has gained popularity over the years with major pharmaceutical companies, using such an approach versus the more traditional (and more expensive) air handler approach.

Ultra-low freezers have been a part of the product line for many years, but have gained more interest in the recent years as biorepository designers have become aware of, and even promote, the revolutionary designs of Environmental Specialties.  Traditional biorepositories rely upon numerous, individual reach-in chambers.  While this is easy to order through a catalog, it is not energy efficient, not cost efficient, and not space efficient.  ES offers multiple solutions for biorepositories, including multiple reach-in units operated by singular (or redundant) cooling systems, multiple chest units operated by similar cooling systems, or the popular walk-in style with multiple ultra-low compartments, operated by similar cooling systems.  The walk-in approach is extremely attractive considering that multiple storage compartments (10, 20, or more) are offered within (1) walk-in system.

Contact the Sales Department at Environmental Specialties to discuss cleanrooms, ultra-low freezers, or any other special design chambers you may require.

Brian Philbeck, PE

Senior Product Engineer