Thermo Scientific
Upright Freezer
Forma Model 900 Series -86C ULT Upright Freezer Operating and Maintenance Manual Rev 18
Operating and Maintenance Manual
84 Pages
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Page 1
User Manual
Forma Model 900 Series -86C ULT Upright Freezer Operating and Maintenance Manual 7090902 Rev. 18
Visit us online to register your warranty www.thermoscientific.com/labwarranty
Preface
Important installer and user information: A redundant temperature sensing device has been included in this ULT freezer. This device is a type “T” thermocouple. For convenient access, the thermocouple (Figure 1-3) terminates in an interconnect jack (Figure 1-5) behind the base front cover. (May be located differently in chests. See Section 1.) It is strongly recommended that this thermocouple be attached to a redundant 24 hour 7 day monitoring system with alarm capabilities. Connecting the sensor to a monitoring and alarm system separate from the freezer provides the utmost in product safety, should the integral system fail. ▲ Models Covered
Packing List
Catalog No.
Capacity (cu ft)
Voltage
902
13
230/50
903
13
120/60
909
13
208-230/60 Hz
904
17
120/60
905
17
230/50
910
17
208-230/60 Hz
906
23
230/50
956
23
120/60
957
23
208-230/60 Hz
907
28
230/50
908
28
208-230/60 Hz
Part No. Description
Quantity
122005
Key
2 (4 for DD)
380520
Neoprene Cap
2
510016
¼-20 x 5-½” Bolt
2
195763
Retaining Clip
1
370563
Remote Alarm Connector
1
Double Door (DD) Units 991
13
230/50
992
13
120/60
986
13
208-230/60 Hz
993
17
120/60
994
17
230/50
988
17
208-230/60 Hz
990
23
120/60
995
23
230/50
989
23
208-230/60 Hz
MANUAL NUMBER 7090902 18
40634
10/31/17
Updated exploded drawings
bpg
17
41728
10/02/17
Added Door operation info (1-6)
bpg
16
31514
8/25/17
Updated 195964 High/Low temp stage drawings
bpg
15
41370
8/14/17
Updated BUS board information
bpg
14
41159/41348
5/12/17
Corrected oerational temp range and D-volt rating
bpg
Thermo Scientific
Model 900 and 5900 Series
i
Preface
CAUTION Contains Parts and Assemblies Susceptible to Damage by Electrostatic Discharge (ESD)
Important Read this instruction manual. Failure to read, understand and follow the instructions in this manual may result in damage to the unit, injury to operating personnel, and poor equipment performance. ▲
Caution All internal adjustments and maintenance must be performed by qualified service personnel. ▲
Material in this manual is for information purposes only. The contents and the product it describes are subject to change without notice. Thermo Fisher Scientific makes no representations or warranties with respect to this manual. In no event shall Thermo be held liable for any damages, direct or incidental, arising out of or related to the use of this manual.
The -86C Freezers (see page i for specific list of models) described in this manual are high performance units which can be used for research and in situations that directly support medical applications. When these products are used to support a medical application, it is an accessory to a medical device and is therefore considered as a medical device in its own right by the regulatory body (e.g. FDA). This product is intended for use: • As cold storage in research use. • As a medical device for diagnostic use (storage of samples not intended to be re-introduced to human body). Registration: This medical application is considered a Class I medical device by the FDA. This product is classified as product code – JRM, regulation number 862.2050 and is considered a Class 1 device, 510(K) exempt.
©2014 Thermo Fisher Scientific. All rights reserved.
ii
Model 900 and 5900 Series
Thermo Scientific
Preface
Important operating and/or maintenance instructions. Read the accompanying text carefully.
Potential electrical hazards. Only qualified persons should perform procedures associated with this symbol.
Equipment being maintained or serviced must be turned off and locked off to prevent possible injury.
Extreme temperature hazards, hot or cold. Use special handling equipment or wear special, protective clothing.
WEEE Compliance: Thermo Fisher Scientific has contracted with companies for recycling/disposal in each EU Member State. For further information, send an email to [email protected].
✔
Always use the proper protective equipment (clothing, gloves, goggles, etc.)
✔ Always dissipate extreme cold or heat and wear protective clothing. ✔ Always follow good hygiene practices. ✔ Each individual is responsible for his or her own safety.
Thermo Scientific
Model 900 and 5900 Series
iii
Preface
Do You Need Information or Assistance on Thermo Scientific Products? If you do, please contact us 8:00 a.m. to 6:00 p.m. (Eastern Time) at: 1-740-373-4763 1-800-438-4851 1-877-213-8051 http://www.thermofisher.com [email protected] www.unitylabservices.com
Direct Toll Free, U.S. and Canada FAX Internet Worldwide Web Home Page Tech Support Email Address Certified Service Web Page
Our Sales Support staff can provide information on pricing and give you quotations. We can take your order and provide delivery information on major equipment items or make arrangements to have your local sales representative contact you. Our products are listed on the Internet and we can be contacted through our Internet home page. Our Service Support staff can supply technical information about proper setup, operation or troubleshooting of your equipment. We can fill your needs for spare or replacement parts or provide you with on-site service. We can also provide you with a quotation on our Extended Warranty for your Thermo Scientific products. Whatever Thermo Scientific products you need or use, we will be happy to discuss your applications. If you are experiencing technical problems, working together, we will help you locate the problem and, chances are, correct it yourself...over the telephone without a service call. When more extensive service is necessary, we will assist you with direct factory trained technicians or a qualified service organization for on-the-spot repair. If your service need is covered by the warranty, we will arrange for the unit to be repaired at our expense and to your satisfaction. Regardless of your needs, our professional telephone technicians are available to assist you Monday through Friday from 8:00 a.m. to 6:00 p.m. Eastern Time. Please contact us by telephone or fax. If you wish to write, our mailing address is: Thermo Fisher Scientific (Asheville) LLC 401 Millcreek Road, Box 649 Marietta, OH 45750 International customers, please contact your local Thermo Scientific distributor.
iv
Model 900 and 5900 Series
Thermo Scientific
Table of Contents
Thermo Scientific
Section 1
Installation and Start-up... 1-1 Control Panel Keys, Displays, Indicators... 1-4 Operation of the Keypad... 1-5 Install Freezer...1-5 Choose Location... 1-5 Door Operation... 1-6 Install Wall Bumpers...1-6 Install Shelves... 1-6 RS-232 Communications... 1-6 Remote Alarm Contacts... 1-7 Attach Power Cord... 1-8 Connect Unit to Electrical Power... 1-8 Run Mode... 1-8 Freezer Start-Up...1-9 Set Operating Temperature...1-9 Set High Temperature Alarm... 1-10 Set Low Temperature Alarm... 1-10
Section 2
Calibrate... 2-1 Calibrate Control Probe...2-1
Section 3
Alarms... 3-1 High Stage System Failure... 3-2 Probe Failure Alarm... 3-2 Alarm Error Charts... 3-3
Section 4
Maintenance... 4-1 Clean Cabinet Exterior... 4-1 Clean Air Filter... 4-1 Clean Condenser... 4-1 Clean Water-cooled Condenser...4-2 Prepare Unit for Storage... 4-2 Long Term Storage with Water-cooled Condenser... 4-3 Defrost Chamber... 4-3
Model 900 and 5900 Series
v
Table of Contents
Clean Door Gasket... 4-4 Vacuum Relief Port... 4-4 Check Battery(s)... 4-5 Replace Battery(s)... 4-5 PREVENTIVE MAINTENANCE... 4-6
vi
Section 5
Factory Installed Options...5-1 Back Up System (BUS)...5-1 Install Vent Stack, Solenoid and Injection Assembly...5-1 Install Temperature Probe...5-3 Connect Probe/Solenoid Harness... 5-4 BUS Control Panel... 5-5 Configure Optional BUS (Back-Up System)...5-7 Set Optional BUS Set Point... 5-8 Test BUS Operation... 5-8 Clean Vent Stack... 5-8 Disconnect Fitting Asm. and Transfer Hose... 5-9 Chart Recorder... 5-9 Installing the Chart Paper... 5-9 Change Recorder Temperature Range...5-9 Recorder Calibration...5-10 Water-cooled Condenser...5-10 Water Connections... 5-12 Five Inner Door Option... 5-13
Section 6
Specifications... 6-1 Single Door Units... 6-1 Double Door Units...6-3
Section 7
Spare Parts... 7 - 1
Section 8
Refrigeration Schematics...8 - 1
Section 9
Electrical Schematics... 9 - 1
Section 10
Warranty... 10 - 1
Appendix
Handling Liquid Nitrogen... A - 1 Handling Liquid CO2... B - 1 First Aid... C - 1
Model 900 and 5900 Series
Thermo Scientific
Section 1 Installation and Start-up
Control Panel
Optional Back Up System Controls Temperature Recorder (Optional)
Figure 1-1. Freezer Front View Components
Thermo Scientific
•
Control panel - keypad, displays and indicators
•
BUS (Optional Back Up System) control panel
•
Optional temperature recorder or datalogger
Model 900 and 5900 Series
1-1
Section 1 Installation and Start-Up
Wall Bumper (pre-tapped holes)
Optional Back-up System Connections RS-232 or RS-485 Interface Power Switch (mains disconnect) Remote Alarm Contacts
Power Inlet
Figure 1-2. Freezer Rear View Components •
Remote alarm contacts
•
Power inlet for power cord connection
•
Optional BUS connections for probe and solenoid
•
RS-232 (default) or RS-485 interface
•
Power switch (mains disconnect)
Shelf Bracket Optional Miscellaneous Accessories Probe Optional - Recorder Probe/Datalogger Probe Sealant (Caution: This is a critical seal. Seal must be maintained.)
Control RTD/Redundant Type T Thermocouple Probe
Figure 1-3. Chamber Probe(s)
1-2
Model 900 and 5900 Series
Thermo Scientific
Section 1 Installation and Start-Up
Vacuum Relief Port
Chamber Probe Cover
Figure 1-4. Vacuum Relief and Probe Cover Location •
Vacuum relief port - pressure equalization port
•
Probe cover - houses control, optional recorder, datalogger, or optional miscellaneous accessory probes
Battery power switch
To remove filter
Thermocouple interconnect jack Battery mounting bracket
O
Freezer battery and optional BUS battery
Figure 1-5. Battery(s) location and switch
Thermo Scientific
•
Battery mounting bracket(s)
•
Battery power switch (freezer and BUS)
•
Freezer battery
•
Optional BUS battery
•
Freezer filter location
Model 900 and 5900 Series
1-3
Section 1 Installation and Start-Up
Control Panel Keys, Displays, Indicators
Temperature Display
Mode Key
Alarm Silence Alarm Indicator Key Panel
Up and Down Arrows
Enter Key
Figure 1-6. Control Panel
1-4
Model 900 and 5900 Series
•
Temperature Display - Displays temperature in degrees Celsius.
•
Mode Select Switch - Used to select Run, Set Temperature, Set High Alarm, Set Low Alarm, Calibrate, Backup.
•
Alarm Indicator - Light pulses on/off during an alarm condition of the cabinet.
•
Silence - Silences the audible alarm. See Section 4 for alarm ringback times.
•
Alarm Panel - indicates the current alarm condition.
•
Up and Down Arrows - Increases or decreases values, toggles between choices.
•
Enter - Stores the value into memory
Thermo Scientific
Section 1 Installation and Start-Up
Operation of the Keypad
The Model 900 Series freezer has five basic modes which allow freezer setup and operation. Press the Mode key to scroll through the mode selections. Up Arrow: Increases or toggles the parameter value. Enter: Must press Enter key to save to memory all changed values. Down Arrow: Decreases or toggles the parameter value. Silence Key: Press to silence the audible alarm. See Section 4 for alarm ringback times.
Install Freezer
Note If tipped more than 45°, allow the unit to sit upright for 24 hours before start up. ▲ To remove the freezer from the pallet, use a 1/2" wrench to remove all the bolts securing the shipping bracket to the pallet. Remove the shipping bracket. Remove the ramp boards from the pallet and place the slotted end over the ramp brackets on the pallet. The support blocks on the ramps will be facing down. Before moving the freezer, make sure the casters are unlocked and moving freely. Align the caster with the ramp boards. Use adequate personnel to roll the freezer off the pallet.
Choose Location
The freezer can be easily pushed to the desired approved location, described below. If necessary, the doors and lower front panel may be opened to move the unit through tight openings. When the freezer is in position, set the front caster brakes. Note The freezer must not be moved with the product load inside. ▲ Note For proper ventilation and airflow, a minimum clearance of 5” at the rear and top and a clearance of 8” on the side of the freezer is required. Allow adequate space in the front of the freezer for door opening. ▲ Locate the freezer on a firm, level surface in an area with an ambient temperature between 18°C and 32°C. Provide ample room to reach the mains disconnect switch (power switch) located on the rear of the freezer.
Thermo Scientific
Model 900 and 5900 Series
1-5
Section 1 Installation and Start-Up
Door Operation
Upright freezer models are equipped with an advanced assembly specifically designed for ultra-low temperature freezers. Features include:
Install Wall Bumpers
•
One-hand operation
•
A front-accessible lock
•
Hasps for a standard padlock to provide additional security. Length of the shackle must be between ¾ inch (1.9 cm) and 1½ inch (3.8 cm).
•
Durable construction for reliable operation and safe product storage.
The parts bag, located inside the cabinet, contains the following parts. Quantity 2
Stock # 510016
Description 1/4-20 x 5-1/2” Bolt
Purpose Wall Bumper
2
380520
Neoprene Cap
Cap Protector
Table 1-1. Parts bag Install the bolts into the pre-tapped holes on the back of the compressor section. Install a neoprene cap on each bolt. Refer to Figure 1-2 for the locations of the pre-tapped holes.
Install Shelves
Install the shelf clips into the shelf pilasters (front and back) at the desired shelf level. Install the shelves in the cabinet onto the clips. Note Maximum shelf load is 100 lbs (45.4 kg) per shelf. ▲ Note On units having the optional 5 inner door option, refer to the instructions accompanying the inner door kit. ▲
RS-232 Communications
The Model 900 Series freezer has a data communications interface. The factory default setting is RS-232. The wiring identification for the interface is shown in Figure 1-7. One nine pin, sub "D" style connector is Figure 1-7. RS-232 Interface located on the back of the freezer. See Figure 1-2 for the location of the connector on the freezer. The freezer transmits temperature information every 60 minutes. A standard DB9 serial extension cable can be used to connect the freezer to a serial device. Some serial devices may require a null modem adapter.
1-6
Model 900 and 5900 Series
Thermo Scientific
Section 1 Installation and Start-Up
RS-232 Communications (continued)
Data format: Baud... 1200 Data bits... 8 (7 bit ASCII with leading zero) Start bits... 1 Stop bits... 2 Parity... none The data transfer sequence is transmitted in the following format. X refers to numerical temperature data. (NUL) (-) XXX (SP) C (SP) (Error Message) (SP) (LF) (CR) (EOT) (SP) In the event of a CNTRLFAIL, Er07, or the control probe is out of range error, the numerical temperature data (XXX) in the transmission would be replaced by T_ERR. If no alarm condition exists, spaces will be sent. A total of 20 characters will be sent. SP - Space LF - Line feed CR - Carriage return EOT - End of text (4) NUL - Null character (00) If an alarm condition does exist, “Error Message” in the protocol will be replaced by the following: UNDERTEMP (temperature above the low alarm setpoint) OVERTEMP (temperature below the high alarm setpoint) PWRFAIL (AC power failure) CNTRLFAIL (Control probe failure) Er07 (micro failure) HSHX FAIL (Heat exchanger failure) HOT COND (Hot condenser)
Remote Alarm Contacts
IMPORTANT USER INFORMATION CAUTION! Stored product should be protected by a redundant 24 hour/day monitoring system with alarm capability. An interconnect jack and thermocouple are installed for centralized monitoring, should on-board system fail.
Thermo Scientific
See Figure 1-2 for the location of the remote alarm contacts. The remote alarm connector is located in the parts bag provided with the manual. It must be installed if connecting the freezer to an alarm system. After installing the wiring from the alarm system to the connector, install the connector to the freezer microboard and secure with the two screws provided. The remote alarm provides a NO (normally open) output, a NC normally closed) output and COM (common). The contacts will trip on a Figure 1-8. Remote Alarm Contacts Model 900 and 5900 Series
1-7
Section 1 Installation and Start-Up
Remote Alarm Contacts (cont)
power outage and high temperature or low temperature alarms. They will also trip on high stage, control probe or microboard failures. Figure 1-8 shows the remote contacts in the alarm state.
Attach Power Cord
Insert the power cord into the power inlet module. Place the retaining bracket (P/N 195763) over the connector. Tighten retaining screws to secure. Figure 1-9. Power Cord Connection
Connect Unit to Electrical Power
Caution See the serial tag on the side of the unit for electrical specifications or refer to the electrical schematics in this manual. ▲ Caution If the factory installed option water-cooled condenser is present, do not turn the freezer on without water connected and flowing. Damage to the refrigeration system could occur within 5 minutes if water is not connected and flowing on unit start-up. Refer to Section 5. ▲ The freezer should be operated on a dedicated grounded service. Check the voltage rating on the serial tag of the unit and compare it with the outlet voltage. Then, with the power switch turned off, plug the line cord into the wall outlet. First, turn on the freezer power switch. Then open the lower front door by grasping the bottom left corner. Locate the battery switch (Figure 1-5) and turn it to Standby mode ( ). During initial freezer start-up, the system battery may require charging and the Low Battery indicator may illuminate. Caution Ensure the battery switch is turned to Standby mode ( ). The rechargeable batteries require 36 hours to charge at initial start-up. A “Low Battery” alarm may occur until the batteries are fully charged. Should a power failure occur during the initial start-up period, the electronics will have limited operation. ▲
Run Mode
1-8
Model 900 and 5900 Series
Run mode is the default mode for the freezer. This mode displays the cabinet temperature on the temperature display under normal operating conditions. In addition, the Run mode allows display of the high stage heat exchange temperature.
Thermo Scientific
Section 1 Installation and Start-Up
Run Mode (cont)
This information scrolls by pressing the up or down arrow keys. The display returns to the operating temperature in 10 seconds if no keys are pressed.
Freezer Start-Up
With the freezer properly installed and connected to power, system set points can be entered. The following set points can be entered in Settings mode: Control temperature, high temperature alarm set point, low temperature alarm set point, and (optional) BUS set point. Default settings are shown in the table below. Table 1-2. Default Settings Default Settings
Temperature
Control Set Point
-80°C
High Temperature Alarm
-70°C
Low Temperature Alarm
-90°C
Optional BUS Set Point
-60°C
Note If the set point is changed and the low temp and high temp alarms are set 10° from the set point, the alarm set points will be adjusted automatically to maintain a distance of at least 10° from set point. ▲ Caution If the factory installed option water-cooled condenser is present, do not turn the freezer on without water connected and flowing. Damage to the refrigeration system could occur within 5 minutes if water is not connected and flowing on unit start-up. Refer to Section 5. ▲
Set Operating Temperature
Model 900 and 5900 Series freezers have an operating temperature range of -50°C to -86°C, depending on ambient temperature. The freezer is shipped from the factory with a temperature set point of -80°C. To change the operating temperature set point: 1. Press the Mode key until the Set Temperature indicator lights. 2. Press the up/down arrow key until the desired temperature set point is displayed. 3. Press Enter to save the set point. 4. Press the Mode key until the Run indicator lights for Run mode If no keys are pressed, the freezer will automatically return to RUN mode after 5 minutes. Note If the set point is changed and the low temperature and high temperature alarms are set 10° from the set point, the alarm set points will be adjusted automatically to maintain a distance of at least 10° from set point. ▲
Thermo Scientific
Model 900 and 5900 Series
1-9
Section 1 Installation and Start-Up
Set High Temperature Alarm
The high temperature alarm will activate an audible/visual warning when the freezer chamber temperature has reached or exceeded the high temperature alarm set point. To set the high temperature alarm set point: 1. Press the Mode key until the Set High Alarm indicator lights. 2. Press the up or down arrow key until the desired high temperature alarm set point is displayed. 3. Press Enter to save the setting. 4. Press the Mode key until the Run indicator lights for Run mode If no control keys are pressed, the freezer will automatically return to RUN mode after 5 minutes. Note The high alarm set point must be set at least 5°C from the control set point. ▲ Note At initial start-up, the high temperature alarm is disabled until the cabinet reaches set point or 12 hours elapse. ▲
Set Low Temperature Alarm
The low temperature alarm will activate an audible/visual warning when the freezer chamber temperature has reached or decrease below the low temperature alarm set point. To set the low temperature alarm set point: 1. Press the Mode key until the Set Low Alarm indicator lights. 2. Press the up or down arrow key until the desired low temperature alarm set point is displayed. 3. Press Enter to save the setting. 4. Press the Mode key until the Run indicator lights for Run mode If no control keys are pressed, the freezer will automatically return to RUN mode after 5 minutes. Note The low alarm set point must be set at least 5°C from the control set point. ▲
1-10
Model 900 and 5900 Series
Thermo Scientific
Section 2 Calibrate Once the freezer has stabilized, the control probe may need to be calibrated. Calibration frequency is dependent on use, ambient conditions and accuracy required. A good laboratory practice would require at least an annual calibration check. On new installations, all parameters should be checked after the stabilization period. Caution Before making any calibration or adjustments to the unit, it is imperative that all reference instruments be properly calibrated. ▲
Calibrate Control Probe
Plug a type T thermocouple reader into the receptacle located inside the lower door (see Figure 1-5). Compare the control temperature set point to the temperature of the measuring device. 1. Press the Mode key until the Calibrate indicator lights. 2. Press up/down arrow to match the display to calibrated instrument. 3. Press Enter to store calibration. 4. Press the Mode key to return to Run mode.
Temperature Stabilization Periods
Startup - Allow 12 hours for the temperature in the cabinet to stabilize before proceeding. Already Operating - Allow at least 2 hours after the display reaches set point for temperature to stabilize before proceeding. During calibration, the temperature display will not be available. ▲ If no keys are pressed for approximately five minutes while in calibration mode, the system will reset to Run mode.
Thermo Scientific
Model 900 and 5900 Series
2-1
Section 3 Alarms The Model 900 and 5900 Series freezer alarms are displayed on the freezer control panel. When an alarm is active, the indicator next to the alarm description will light and there will be an audible alarm. Press the Silence key to disable the audible alarm for the ringback period. The visual alarm will continue until the freezer returns to a normal condition. The alarms are momentary alarms only. When an alarm condition occurs and then returns to normal, the freezer automatically clears the alarm condition. Table 3-1. Alarm Indicators Description
Delay
Ringback
Relay
Power Failure
1 min.
15 min.
Yes
High Temperature Alarm
1 min.
15 min.
Yes
Low Temperature Alarm
1 min.
15 min.
Yes
Probe Failure see 3.2
1 min.
15 min.
No
Door Open
1 min.
15 min.
No
Wrong Power
0 min.
none
Yes
Low Battery*
1 min.
8 hours
No
Low BUS Battery (optional)
1 min.
15 min.
No
Hot Condenser
1 min.
none
No
High Stage Failure
0 min.
15 min.
Yes
Micro Board Failure
0 min.
15 min.
Yes
All alarm delays and ringback times are ±30 seconds. * The automatic battery test runs immediately on power-up, then every 8 hours thereafter.
Thermo Scientific
Model 900 and 5900 Series
3-1
Section 3 Alarms
3-2
High Stage System Failure
The "high stage system failure" condition is created when the high stage compressor and fans run for 30 minutes and are not capable of cooling the interstage heat exchanger to the proper temperature. Under this condition, the high stage compressor and fans will turn off after 30 minutes and an audible and visual alarm will occur. The audible alarm can be silenced and will ring back every 15 minutes.
Probe Failure Alarm
The microprocessor in Model 900 and 5900 Series freezers continually scans all probes including the control probe, heat exchanger probe and condenser probe to ensure that they are operating properly. Should an error be detected, the "Probe Failure" alarm will occur as described above. If an error is detected with the control probe, the high and low stage compressors will run continuously. As a result, the cabinet temperature will decrease until it reaches the lowest temperature that the refrigeration system can maintain. If an error is detected with the heat exchanger probe, the freezer will cycle properly at its temperature set point using a 5 minute step start between the high and low stage compressors. If an error is detected with the condenser probe, there is no impact on the performance of the freezer; however, the hot condenser alarm may also occur. Contact the Technical Services department or your local distributor.
Model 900 and 5900 Series
Thermo Scientific