Farrar Scientific 4000M Series, Instruction Manual

Page 1: ...4000 Series Page 1 of 41 3460006 17_serial series 5000000 4000M Series 23 cubic feet 659 liters CONTROLLED RATE UPRIGHT FREEZER 80C TO 40C ...

Page 2: ...4000 Series Page 2 of 41 3460006 17_serial series 5000000 ...

Page 3: ...escribes are subject to change without notice Farrar Scientific makes no representations or warranties with respect to this manual In no event shall Farrar Scientific 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 m...

Page 4: ...te Chamber Instruction Manual Contents 1 Receiving 2 Introduction 3 Specifications 4 Setup Installation 5 Control System 6 Operation 7 Modifying or Creating a Profile 8 Sensor Validation 9 Options 10 Trouble shooting 11 General Maintenance 12 Factory Default Watlow Settings ...

Page 5: ...ove the shipment from the receiving area 1 3 Responsibility for Shipping Damage For products shipped F O B Marietta Ohio the responsibility of Farrar Scientific ends when the merchandise is loaded onto the carrier s vehicle On F O B Destination shipments Farrar Scientific s and the carrier s responsibility ends when your Receiving Department personnel sign a free and clear delivery receipt 2 0 Int...

Page 6: ... second m Temp range 40C to 80C n Ambient Temperature Range 18C to 30C o Ambient Humidity Less than 75 RH p Control Watlow PM 8 ramp and soak controller q Control method Proportional hot gas and resistance heat r Refrigeration Cascade scroll compressors 5hp and 3 5hp s Heat 2600 Watts t Shelves Quantity 2 adjustable on 595 centers plus bottom of chamber u Power requirement North America 208 230 Vo...

Page 7: ...ondenser model 4102 4105 Tower water at 85F 29 5C and 20 psi differential 1 38 Bar Water flow rate at maximum load 7 0 gpm 26 5 liters min Water flow rate at average load 4 5 gpm 15 0 liters min Chilled water at 50F 10C and 20 psi differential 1 38 Bar Water flow rate at maximum load 3 5 gpm 13 3 liters min Water flow rate at average load 2 0 gpm 7 6 liters min ...

Page 8: ...ce near the required power connection Allow for 6 15 3 cm of clearance from the back and sides for air flow and door opening clearance If lifting the unit place lift forks under center of enclosure 3 Remove the foam wrapped 2 shelves 10 shelf clips and the evaporator pan from the unit interior and unwrap 4 Remove the 4 spring feet from the packaging and install on the evaporator 4 bottom projectio...

Page 9: ...t until it bottoms out Pivot p trap drain end up Place the evaporator pan under the drain outlet and pivot the p trap down into the evaporator pan see photo below 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 Cabinet drain connector ...

Page 10: ...ll 4 shelf 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 8 Place the shelves on the clips with the down flange facing the door opening see photo below Shelf down flange Shelf Clip ...

Page 11: ...ors 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 The sensor mount will accept 0 125 to 0 250 3 2 mm to 6 35 mm diameter sensors with a minimum length of 3 0 length Reinstall the sensor mount with the sensor tip poin...

Page 12: ...um F52S33A Note The rate chamber is powered by three phase and the refrigeration compressors are required to operate in a specific direction The unit incorporates a phase monitor to protect the compressors 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 11 4102 4105 Water cooled...

Page 13: ...tion and tighten each connection accordingly d After each hose connections have been firmly tightened slowly turn on water supply to unit and check for leaks at all connections e Verify water pressure is adequate for equipment operation along with nominal flow and temperature requirements as follow Tower water 85 F 29 5 C 20 PSI differential 1 4 bar Water flow rate at maximum load 7 gpm 26 5 L min...

Page 14: ...ll be off compressors will be in pump down mode only 1st stage refrigeration compressor will turn on and off automatically to remove refrigerant from the evaporator section of the refrigeration system 2 MODE SWITCH Selects the profile to be run when the CYCLE START button is pressed There are 3 user configurable and selectable temperature profiles that can be run 3 CYCLE COMLETE INDICATOR Flashing...

Page 15: ...1 Power Switch Indicator 2 Mode Switch Cycle Running Indicator 3 Cycle Complete Indicator 4 Watlow USB Configuration Port Connect using USB A to USB B cable supplied with unit 5 Start Pushbutton 6 Stop Pushbutton 7 EZ1 button for defrost 8 Watlow Ramp and Soak Controller ...

Page 16: ... temperature alarms are triggered Communications Indicator flashes when connected to a pc using the Watlow Configurator software Unit Operating Status off Unit is in standby state or Control Temperature Setpoint EZ1 Key to initiate Defrost Cycle when evaporator temperature is below 15C Output Indicators 1 Refrigeration Modulation lit when full refrigeration is requested otherwise may pulse on and ...

Page 17: ...YCLE STOP button must be pressed so that OFF is displayed and then a new profile can be initiated There is a cycle complete light that can be triggered as a visual indicator at any point in a profile If the option of remote contacts is installed on the unit this same signal is used to drive that signaling event In case of a power failure of over 5 minutes during a freeze or defrost profile the uni...

Page 18: ...is cool down time may vary Step 4 Turn the power switch to the on position If the evaporator coil has cooled sufficiently the error will have cleared and the unit can go back into normal operation If the error has not cleared turn the unit off and open the door to let the unit cool further 7 0 Modifying or Creating Profile Programming the 4000 series Rate Chamber There are two ways to interface wi...

Page 19: ...atlow com en resources and support Technical Library Software and Demos Once the software is installed double click on the EZ ZONE Configurator icon placed on your desktop during the installation process If you cannot find the icon follow the steps below to run the software 1 Move your mouse to the Start button 2 Place the mouse over All Programs 3 Navigate to the Watlow folder and then the sub fo...

Page 20: ...e available devices found on the network as shown below Searching Network for Devices Available Network Devices Displayed The PM8 is shown highlighted to bring greater clarity to the control in focus Any EZ ZONE device on the network will appear in this window and would be available for the purpose of configuration or monitoring simply click on the control of choice After doing so the screen below...

Page 21: ...wanted menus and parameters Once the focus is brought to an individual parameter single click of mouse as is the case for Analog Input 1 in the left column all that can be setup related to that parameter will appear in the center column The grayed out fields in the center column simply mean that this does not apply for the type of sensor selected As an example notice that when a thermocouple is se...

Page 22: ... above click the Finish button once again The screen below will than appear When saving the configuration note the location where the file will be placed saved in and enter the file name File name as well The default path for saved files follows Users Username My Documents Watlow EZ Zone Configurator Saved Configurations The user can save the file to any folder of choice All safety and operations ...

Page 23: ...et point of the air in the chamber or maintain a previously defined set point Each profile starts at that Profile s start step and ends with a step type that either turns the unit off or holds a specific temperature until a user interacts with the unit to stop operation The available step types that can be used with the 4000 series unit and example profiles are listed below Each step type has indi...

Page 24: ...Loop 2 18ºC Hours 0 Use these parameters to set the soak Minutes 10 time Seconds 0 Rate 0ºC Wait for Process Instance 1 Wait For Process 1 0ºC Wait Event 1 Off Wait Event 2 Off Day of Week Every Day Jump Step 1 Jump Count 1 End Type User Event 1 On Tied to internal outputs on the controller Event 2 Off Event 1 must be ON and Event 2 OFF for this step type Wait for Process This step type is used to...

Page 25: ...at will hold the previous steps set point until a user presses the CYCLE STOP button This step will only be used at the end of a profile Step Type Wait for Event Target Set Point Loop 1 40ºC Target Set Point Loop 2 18ºC Hours 0 Minutes 0 Seconds 0 Rate 0ºC Wait for Process Instance 1 Wait For Process 1 40ºC Wait Event 1 On Wait Event 2 Off Day of Week Every Day Jump Step 1 Jump Count 1 End Type Us...

Page 26: ... 1 18ºC Wait Event 1 Off Wait Event 2 Off Day of Week Sunday Jump Step 1 Jump Count 1 End Type Off Event 1 Off Event 1 and Event 2 must both be set to OFF in Event 2 Off this step type Unused Step This step type is completely skipped by a running profile All of the parameters will be greyed out except for the step type Step Type Unused Step ...

Page 27: ...ime are Target Set Point 1 Hours Minutes Seconds Event 1 and Event 2 All others are grayed out When selecting other Step Types other options selectable will be in dark characters Screen 5 Screen 5 description Profile 1 Step 1 is a time step and will ramp down to the 80C set point in 10 seconds Event 1 is on turning on the refrigeration liquid hot gas solenoid valves and turning on the profile runn...

Page 28: ...1 monitors the chamber temperature to reach the Wait for Process 1 temperature of 80C Event 1 is on which continues to activate the refrigeration liquid hot gas solenoid valves and profile running indicator on the mode switch Event 2 is off Note the only selectable options for this step are Wait for Process Instance Wait for Process 1 Event 1 and Event 2 ...

Page 29: ... Wait for Event monitors the Wait for Event 1 and 2 if either is on then the profile waits at that step until the stop button is pressed Event 1 is on which continues to activate the refrigeration liquid hot gas solenoid valves and profile running indicator on the mode switch Event 2 is on which activates the cycle complete indicator ...

Page 30: ...step 3 Event 1 must be On This turns on the compressor and internal circulation fan Event 2 must be Off Cycle Running indicator is on Profile 1 step 3 hold soak at 70C for 3 hour before continuing to step 4 Event 1 must be On This turns on the compressor and internal circulation fan Event 2 must be Off Cycle Running indicator is on Profile 1 step 4 Ramp set point in 10 Seconds from current display...

Page 31: ...on when modifying or creating a profile 37 total steps may be used The last step in a profile should be a wait event W E 1 this will allow the unit to hold the last step indefinitely until the stop button is pressed at which time all control functions will stop Step 38 40 are reserved for defrost the defrost profile From figure 5 2 the following keys will be used to create a profile 1 Infinity key...

Page 32: ...planation can be found in the supplied Watlow manual Overview of control system and usage of cabinet After the unit is turned on and a profile is selected the unit is ready to run the profile load the unit with product you wish to condition close and latch the door Press the start button When the start button is pressed the first items to occur are the liquid and hot gas solenoids energize along w...

Page 33: ...to the remote contact terminals Locate the terminal enclosure on the back of the control area near the power cord Remove the cover from the enclosure by removing the 4 Philips head screws Refer to figure 9 2 Refer to the below chart for the state of the at various operational states of the 4000 series unit 4000 Series Unit State Remote Running Contacts Contacts 1 2 Contacts 3 4 Contacts 5 6 Unit U...

Page 34: ... and strobe light installed on the top of the unit that will activate and remote contact terminals 5 6 will close See the chart below for further explanation 4000 series Unit State Door Open Alarm Contacts Door Position Strobe Horn State Contacts 5 6 NO Unit turned on In standby off state CLOSED OFF OPEN OPEN OFF OPEN Unit turned on Profile 1 Profile 2 or Profile 3 running CLOSED OFF OPEN OPEN ON ...

Page 35: ...60006 17_serial series 5000000 Door open alarm horn and strobe installation The door alarm electrical connection is located on top of the right side black control panel area Remove the protective cap from the connector and discard ...

Page 36: ...00 Insert the strobe alarm tower onto the connector The white lines on the connector and strobe should align Turn the strobe alarm tower clockwise until the white line on the connector aligns with the end or the arrow The tower is now locked to the connector ...

Page 37: ...hamber temperature upper display Cooling step in a profile c Verify door is closed The door switch turns off the internal circulation fan heat and refrigeration d If unit has been run repeatedly cold the evaporator may have iced up Initiate a defrost cycle e Check evaporator fan fuses F 1 F2 Reaching inside of the cabinet while the unit is energized can be dangerous Always unplug the unit and lock...

Page 38: ...ning the condenser Air cooled only 4002 4005 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 condensing unit This obstruction will affect the flow of air through the condenser thereby lowering the efficiency of the system a Remove c...

Page 39: ...rior 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 freezer 2 Open outer door 3 Remove evaporator cover plate 4 Visually inspect blower wheel and check blower wheel balance via tu...

Page 40: ... under both sides of the valve spring guide and lift upwards see figure 1 below 12 0 Factory Default Watlow Settings Included on the flash drive is a PDF copy of the factory loaded Watlow Configuration The file is in the Farrar Scientific Model 4002 Documentation folder on the flash drive All highlighted text needs to be verified in the unit configuration before operation of the equipment Not all ...

Page 41: ...SISTANCE Farrar Scientific products support team are ready to answer your questions In addition to technical support we offer various accessories extended warranty program and validation services Visit us at www farrarscientific com or Contact us at 740 374 8300 30765 State Route 7 Marietta OH 45750 Tel 740 374 8300 Fax 740 374 8310 ...