Farrar Scientific 4000-LC Series, Instruction Manual

Page 1: ...4000ͲLC Series D4580880Ͳ01 Page 1 of 61 4000 LC Series 23 cubic feet 659 liters CONTROLLED RATE UPRIGHT FREEZER 80C TO 40C ...

Page 2: ...4000ͲLC Series D4580880Ͳ01 Page 2 of 61 ...

Page 3: ...re subject to change without notice Bio Freezer USA makes no representa tions or warranties with respect to this manual In no event shall Bio Freezer USA be held liable for any damages direct or incidental arising out of or related to the use of this manual Important operating and or maintenance instructions Read the accompanying text carefully Equipment being maintained or serviced must be turned...

Page 4: ...p Installation 5 Control System 6 Operation 7 Modifying or Creating a Profile 8 Sensor Validation 9 Alarm and Dry Contacts 10 Downloading Files from Unit 11 Controlling the Unit remotely using Ethernet 12 Changing System Settings Time Date IP Address 13 Troubleshooting 14 General Maintenance 15 Dimensions and Farrar Scientific contact information ...

Page 5: ...d rate The controlled rate freezer operates using specific ramp and soak profiles tailored to the customer product requirements The controller can be configured to ramp down and up in temperature and hold the set temperature for a specified time The unit incorporates scroll refrigeration compressors hot gas and electric resistance heaters to maintain temperature control 3 0 Specifications a Size E...

Page 6: ... China 400 Volt 3 phase wye connected 24 amps 30 amp fuses required and IEC 60309 6H 30 Amp 200 415V receptacle t Thermal room load Air cooled system 36 860 BTU Hr 11kW maximum during chamber warm up Water cooled system 1706 BTU 0 5 kW maximum u Drain External with heated evaporator pan powered from the cabinet v Water Supply for water cooled condenser models 4102 LC 4105 LC Tower water at 85F 29 ...

Page 7: ...nce from the back and sides for air flow and door opening clearance 2 Remove the foam wrapped 2 shelves 10 shelf clips and the evaporator pan from the unit interior and unwrap 3 Remove the 4 spring feet from the packaging and install on the evaporator 4 bottom projections of the evaporator pan small end first see photo below 4 Chamber drain tubing Spring ...

Page 8: ... the chamber drain tube with duckbill onto the threaded cabinet drain connector 6 Connect the supplied electrical cord to the evaporator pan receptacle and plug the other end in to the dedicated receptacle on the rear of the cabinet see photo below ...

Page 9: ...4000ͲLC Series D4580880Ͳ01 Page 9 of 61 7 Place the evaporator pan under the drain tube ...

Page 10: ...f clips in the duct sheet for each shelf 2 front and 2 in rear at the desired height Spacing is approximately 0 5 1 3 cm for each shelf 9 Place the shelves on the clips with the down flange facing the door opening see photo below Shelf down flange Shelf Clip ...

Page 11: ...mple monitoring The ports are filled with insulation and both ends are plugged to reduce moisture infiltration After monitoring sensors are installed replace the insulation and seal the port inside and outside of the cabinet Refer to the Cabinet Layout Drawing at the end of the manual for port locations Interior view sensor mounting plate Temperature Sensor Mount Remove 4 screws to remove sensor m...

Page 12: ... 0 125 to 0 250 3 2 mm to 6 35 mm diameter sensors with a minimum length of 3 0 76 2 mm in length Reinstall the sensor mount with the sensor tip pointing down Chamber temperature sensor 100 ohm RTD Customer installed sensor location Factory monitoring thermocouple sensor ...

Page 13: ...lk head connector which is plugged into the top of the internal chamber area This allows the sample probe to remain embedded within the frozen sample This probe reading can be used as part of a profile to achieve a more definite product temperature NOTE if the sample probe is not installed or fails an error message will appear on any screen in which the sample probe is utilized Sample Probe ...

Page 14: ...ompressors If the unit does not turn on no indicator lights when the power switch is turned on the first thing to do is switch 2 of the phase legs in the receptacle or power panel European Chinese Plug Connect the unit to an IEC 60309 6H 30 Amp 200 415V receptacle such as an ABL Sursum F52S33A Note The rate chamber is powered by three phase and the refrigeration compressors are required to operate...

Page 15: ... along with strainer and pressure gauge for trouble shooting and equipment testing purpose The ball valve needs to be accessible during trouble shooting of equipment and can also be used for testing and servicing equipment 4102 4105 unit Apply Teflon tape to 4102 4105 inlet and outlet connection and tighten b After each hose connection has been firmly tightened slowly turn on water supply to unit ...

Page 16: ...pper motor control hot gas control solid state relay and miscellaneous other hardware 6 0 Operation 1 POWER CONTROL Electrical power is provided via a power cord Internally power passes through a 3 pole main circuit breaker which is accessible inside the main control enclosure The only user accessible means of power disconnection is by unplugging the power cord from the wall receptacle 2 UNIT OPER...

Page 17: ...alth screen which is used for temperature probe calibration viewing alarm log and managing user accounts Unit Information This icon will display the general information concerning the unit such as typical serial label information software revisions and support contact information Technical This icon will allow access to the technical and service functions of the unit Note these functions will typi...

Page 18: ...control is left unattended for more than 5 minutes b Run Profile Start This screen will allow the user to run the selected profile The text will indicate if the profile is waiting to run or is running RETURN TO HOME SCREEN START PROFILE running This will cause the pop up screen Enter Batch File Name to appear GO TO either the profile status detail screen or view the profile trend graph ...

Page 19: ...g the on screen keypad This name will be used to create the data logging file which will save a csv format record of the file in memory The file name will have the format filename_yymmdd csv START PROFILE running This will cause the selected profile to start running CANCEL Will clear the file name and return to the Run Profile Screen ...

Page 20: ...he selected profile The text will indicate if the profile is waiting to run or is running RETURN TO HOME SCREEN STOP PROFILE After a confirmation pop up screen this will immediately cause the selected profile to stop running GO TO either the profile status detail screen or view the profile trend graph ...

Page 21: ...ill show the details of the currently running profile It will show what step is running and describe what the step is RETURN TO HOME SCREEN STOP PROFILE After a confirmation pop up screen this will immediately cause the selected profile to stop running View the profile trend graph ...

Page 22: ...f the temperature trend of the currently running profile The red line is the chamber temperature The green line is the product sample temperature if installed Both the horizontal and vertical scales of the graph can be changed by pressing the CHANGE GRAPH SETTINGS E1 Trend Graph Settings ...

Page 23: ...D4580880Ͳ01 Page 23 of 61 f Running Defrost start This screen will allow the operator to start a defrost cycle The defrost cycle will continue until the evaporator coil temperature warms to 20 C g Running Defrost stop ...

Page 24: ...ies D4580880Ͳ01 Page 24 of 61 This screen will allow the operator to stop a defrost cycle The defrost cycle will stop immediately h Manage Profiles This screen will allow the operator to view the selected profile ...

Page 25: ... will display the step by step listing of the selected profile From this screen individual steps can be edited or the profile can be restored to factory defaults To view additional steps press the View More Steps icon There are a total of 20 steps available per profile ...

Page 26: ...1 Page 26 of 61 j Edit profile step This screen will allow the operator to edit a profile step k Editing step values When editing a numerical value in a step a numeric keypad will drop down to use for entering the desired value ...

Page 27: ... D4580880Ͳ01 Page 27 of 61 l Changing step type The function of any step can be changed using the Change Step Type Screen Press the check mark next to the desired Step Type Then press Save m Reset Profile to Default ...

Page 28: ...actory setting n Manual Set Point Operation Selecting Go To Manual Set Point Operation on the Home Screen will send the user to this screen This screen will allow the operator to have the chamber move to the temperature entered in the Temp Set Point field and maintain that temperature until the operation is stopped o Manual Set Point Operation ...

Page 29: ...n press the Start Manual Set Point Operation button to cause the chamber to change to that temperature p View Alarm Log Selecting the View Alarm Log on the Health screen will take the user to the Alarm Log screen This screen will display all alarms that have occurred on this unit It will display date and time of when the alarm occurred as well as if and when it was cleared ...

Page 30: ...hey will then have to enter their personal password to log in as that user Note that only users who potentially have access to the selected function will have their name appear on the list Note also that any valid log in will only serve to accept that person as being the current user The user will have to press the selected function a second time to navigate or perform that selected action There a...

Page 31: ... access levels can exercise In addition to the Operator security level which allows the user to run any profile there are also security levels which grant access to run each individual profile These security levels are designated Profile n Op where the n will designate which profile is accessible n would be replaced with 1 through 6 to indicate which profile is accessible For example access to Pro...

Page 32: ... page will bring the user to this screen This screen shows the general unit information related to electrical power refrigeration types and amounts and the design operating pressure limits This screen also will list the unit serial number date of manufacture and the software version of the controls ...

Page 33: ... sample These three factory programmed profiles can be edited by the customer to suit their needs In addition to the three factory profiles there are three additional profiles available for the customer to create any profile that is needed Each profile may have up to 20 steps Pressing the STOP PROFILE button at any time will cancel any process that is currently running disable all refrigeration sy...

Page 34: ...omatically shut down and an alarm message will be displayed on the display 8 0 Sensor Calibration The chamber and sample temperature probes can be calibrated by selecting the Health icon on the Home Screen and navigating to either the Chamber Calibration or Sample Calibration screens NOTE If the sample probe is not connected an error message will appear on all screens which utilize the sample prob...

Page 35: ...adjust the calibration of the installed chamber temperature probe Touch the window by the Desired Probe Value text and a numeric entry pad will appear Use this keypad to enter the desired temperature The screen will calculate and display how much your entry is offset from the reading the PLC is measuring ...

Page 36: ...ust the calibration of the optional product sample temperature probe Touch the window by the Desired Probe Value text and a numeric entry pad will appear Use this keypad to enter the desired temperature The screen will calculate and display how much your entry is offset from the reading the PLC is measuring ...

Page 37: ...to figure 9 2 Figure 9 2 Remote contact terminal box with cover removed Terminals 1 5 are dry contact connections They share a common connection The signals are 1 General Alarm Contacts close when any alarm condition is occurring The contacts will open when the alarm condition ends 2 Profile Complete Contacts close when a profile is started Contacts will open when the profile is ended by the custo...

Page 38: ...perature Linear Scaling is 0 VDC 100 C 10 VDC 100 C Terminals 9 and 10 are a 0 10VDC retransmit signal for the product probe temperature Linear Scaling is 0 VDC 100 C 10 VDC 100 C Door open alarm horn and strobe In the event of a door opening while a profile or defrost cycle is running there is a horn and strobe light installed on the top of the unit that will activate and remote contact terminals...

Page 39: ... This application is included on the same memory device as the operation manual which was included with this product This program can also be provided by your technical support contact To download historical data for previously run profile batches do the following 1 Connect the Ethernet port of your computer to the RJ 45 jack located on the rear of the unit next to the remote alarms contact box ...

Page 40: ...000ͲLC Series D4580880Ͳ01 Page 40 of 61 2 Open the Data File Manager application on your computer 3 Select HMI and Ethernet on pop up screen The default IP address is 192 168 3 231 Then click on Connect ...

Page 41: ...e the following screen will appear 5 In the left hand window expand the HG5G 4G 3G V file folder structure by clicking on the arrow by the top level name Then double click on the HGDATA01 folder to expand the right hand window which will show the file folders available on the SD memory card ...

Page 42: ...80880Ͳ01 Page 42 of 61 6 To view the list of Profile run data logs double click on the DATALOG folder Every profile that has been run will be listed in the right hand window Scroll up and down to see all available files ...

Page 43: ...elect Upload File or Folder The application will ask for your user name and password before allowing you to download a file Note that this will require an Administrator level log in 8 After the log in is accepted a screen will appear which will allow you to select where you wish to upload the file to Select the path you wish to upload the file to then click on OK ...

Page 44: ... 10 The downloaded file will be in comma separated values CSV format This can readily be imported into a Windows Excel file or other programs that accept CSV formatting The file will contain Chamber and Sample Temperatures at listed date and time intervals A sample output file is shown below ...

Page 45: ...ouchscreen display with a date time stamp included These files are organized by date so that all actions occurring in a day will be contained in a single file The process of downloading an Operation Log file is similar to the Datalog file download process described above Select the OPERATIOLOG folder within Data File Manager and proceed The file name format is OPLOGA_yymmdd ...

Page 46: ...ation Log file is shown below 13 In a similar manner an alarm log file can be downloaded Select the ALARMLOG folder in Data File Manager and proceed as above to download an alarm log file Alarm log file names have the format ALMHTA_yymmdd Alarm Log files are organized as one file per day These files are also in CSV format ...

Page 47: ...SHOULD BE TAKEN TO ENSURE THAT ALL EQUIPMENT AND PERSONNEL ARE IN A SAFE POSTION AND ARE AWARE OF THE IMPENDING REMOTE OPERATION Hazards 1 Connect the local computer or network device to the unit using an Ethernet cable Cat 5 or better connected to the RJ 45 connector located on the rear of the unit next to the remote alarm contacts box ...

Page 48: ...ss of the unit in the web browser address bar The default IP address of the unit is 192 168 3 231 After the connection is made the unit will prompt you for a username and password to log in Note that this will require a Supervisor or higher security level log in to access the remote operation of the unit ...

Page 49: ...ffect as touching the HMI on the unit 5 Note that having remote control of the unit DOES NOT disable the local front panel control of the unit It will still be possible to operate the unit locally Any changes made locally on the HMI will be shown on your remote computer screen and vice versa 6 If you wish to relinquish remote control of the unit but still want to monitor the unit s HMI simply clic...

Page 50: ... Changing System Settings 1 Press the upper left corner of any screen on the Display hold for at least 5 seconds 2 A pop up menu will appear On the pop up menu touch System Mode System Mode Device Monitor Adjust Brightness Press Hold Maintenance X ...

Page 51: ...will appear You must have an Administrator level log in to proceed 4 On the System Mode Top Page press Main Menu SYSTEM MODE TOP PAGE RUN OFFLINE MAIN MENU MAC Address 00 03 7B 09 08 4F IP Address 192 168 3 231 2021 APRIL 08 THURS 11 52 15 ENG JPN BRIGHTNESS 28 ...

Page 52: ...desired and time Then Press Save Return to Main Menu tab Main Menu Initial Setting Clock Setting Offline Run System Information File Manager Top Page Self Diagnosis 6 TO CHANGE THE IP ADDRESS x On the Main Menu select Initial Setting tab x On the Initial Setting Menu press Communication I F Main Menu Init Set System Operation Initialize Ext Device O I Link Communication I F ...

Page 53: ... Address page use the keypad to enter the desired IP address Then press Save x Note that the chosen IP address should be within the 192 168 3 xxx subnet to allow proper communication with the PLC CPU If this is not acceptable contact Farrar Tech Support x To return to normal operation from any hidden screen press Main Menu Main Menu Initial Set Comm I F Ether IP Add IP Address 192 168 3 231 Subnet...

Page 54: ...s D4580880Ͳ01 Page 54 of 61 x Then on the Main Menu page press Run Main Menu Initial Setting Clock Setting Offline Run System Information File Manager Top Page Self Diagnosis x The Display returns to the Home Screen ...

Page 55: ...right corner of the electrical controls c Check that all other circuit breakers are on 2 Display is on but shows an error screen stating there is a PHASE MONITOR FAILURE a On initial startup check all 3 phases The rate chamber monitors for the correct phase sequence Switch 2 of the phase wires at the receptacle or power panel b A loss of power of any phase can also cause this error Reaching inside...

Page 56: ...ching inside of the cabinet while the unit is energized can be dangerous Always unplug the unit and lockout the power supply before performing maintenance inside of the unit 4 Unit not warming at normal rate a Verify a warming profile is selected and running b Verify temperature control set point is above actual chamber temperature Warming step in a profile c Verify door is closed The door switch ...

Page 57: ... isopropyl alcohol NOTE All moving parts have been permanently lubricated and will generally require no maintenance Cleaning the condenser Air cooled only Models 4002 LC 4005 LC For air cooled units monthly cleaning of the condenser will aid the heat transfer characteristics of the refrigeration system and increase its efficiency Dust dirt and lint will tend to accumulate on the fins of the conden...

Page 58: ...of the ice and wipe out any water standing in the bottom of the cabinet 5 If there is freezer odor wash the interior and exterior with a solution of laboratory detergent and warm water Rinse with distilled water 6 Close the doors restart the freezer Evaporator Inspection The evaporator should be inspected every six 6 months This is a visual inspection Complete the following steps 1 Turn off the fr...

Page 59: ...and operational inspection complete the following steps 1 Turn off power to the freezer 2 Remove side panel cover 20 screws 3 Manually flush the valve and piping before and after installing repairing or replacing a valve to remove filings chips or other foreign matter Manual flushing does not affect valve adjustment To flush the valve insert screwdrivers under both sides of the valve spring guide ...

Page 60: ...4000ͲLC Series D4580880Ͳ01 Page 60 of 61 15 0 Dimensions ...

Page 61: ...contacting Farrar Scientific Inc Please have the following information readily available Model Number Serial Number Date of Purchase Purchase Order Contact Information for Farrar Scientific Inc Farrar Scientific Inc 30765 State Route 7 Marietta Ohio 45750 Phone 740 374 8300 www farrarscientific com ...