Contherm Cat 1050 User manual

INSTRUCTION MANUAL
CAT 1050 –1400
STANDARD INCUBATORS
CONTHERM SCIENTIFIC LIMITED
P O BOX 30-605 LOWER HUTT 5040
TEL: (0064-4) 568 8034
FAX: (0064-4) 568 8095
EMAIL: contherm@xtra.co.nz

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WARRANTY STATEMENT
* * * * * * *
CONTHERM Scientific Company will guarantee CONTHERM equipment for
a period of twelve months from the date of installation against faulty
workmanship and fabricated materials. This guarantee covers the
replacement of component parts found to be defective and authorised
labour charges during this period.
Should a malfunction occur or condition develop beyond reasonable
acceptance the company will accept responsibility for returning the unit to
its factory specification at no cost to the Purchaser providing that the
operating instructions have been observed and the defect is due solely to
faulty design, material and workmanship. That the defective part be
returned, freight paid to the nearest sales service office. Units outside the
warranty period will be accepted and repairs will be covered under an
extension of the above for 90 days.
In remote installations where it is not possible for the company's or
agents' engineers to attend, authority may be given to allow the Purchaser
to arrange such service.
The Purchaser is required to remit the purchase price of the unit to the
supplier within the terms of that supplier's condition of sale. CONTHERM
Scientific Company will accept no liability or shall its agents for
consequent damage of any kind due to a malfunction or component
failure.
* * * * * * *

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STATEMENT of CONFORMITY
This CONTHERM cabinet conforms to the following standards:
Electrical Safety: Complies with AS/NZS3350:1:1994
EMC: Complies with EN 61326-1:1997

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CONTENTS
SECTION 1 Definition of Terms
SECTION 2 Introduction and Specifications
SECTION 3 Operating Instructions
SECTION 4 Theory of Operation
SECTION 5 Customer Troubleshooting and Maintenance
SECTION 6 Parts Lists for Spares and Accessories
IMPORTANT All electrical servicing must be carried out by
suitably qualified personnel only.

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SECTION 1 DEFINITION OF TERMS
For the purpose of our standard specifications the following definitions shall
apply:
a) WORKING SPACE
That portion of the internal space which is above the lowest shelf and
not less than 3cm from any wall (including roof).
b) CABINET TEMPERATURE
That temperature at the centre of the working space.
c) SPATIAL VARIATION
The difference between the midrange of all measured temperatures
obtained at one site and that at another site for those sites which give the
greatest difference.
d) TEMPORAL VARIATION
The maximum value of the temperature range obtained for the standard
site with the greatest range throughout the test interval.
e) TEMPERATURE OVERSHOOT
Any excess of actual over desired cabinet temperature during a heating
up period.
f) TEMPERATURE REPRODUCIBILITY
Temperature regained without alteration to controls.
g) TEST INTERVAL
Interval of time to which the steady state characteristics apply (Max 1
hour).
NB: All the above apply with an empty chamber.
For definitions and test methods refer: AS2853 : 1986 (and Appendices)

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SECTION 2 INTRODUCTION AND SPECIFICATIONS
The CONTHERM 1000 standard series range of incubators have been
expressly designed to give the widest choice of operating conditions consistent
with high reliability and low cost, the addition of a hi-resolution RTD control
system gives improved temperature performance over earlier models.
All specifications are quoted for a cabinet temperature of 37oC with an ambient
temperature of 20oC.
Construction - High quality stainless steel interior, full fibreglass insulation,
with non-jar magnetic door catch and corrosive resistant epoxy powder
coated exterior.
Safety - Fitted with an independent user adjustable Hi-Limit completely
separate from normal controls.
Convection - All units come with mechanical convection fan systems.
Electrical - All quoted at 37oC - ZP21 Micro-Controller mechanical
Convection.
-Designed to AS/NZS 3350.1.1994 220-250V AC M.E.N
EMC -Complies with EN 61326-1: 1997
PERFORMANCE:
a) Temperature:
Nominal Range Amb+2oC - 100.0oC
Temporal Variation +_ 0.2oC
Spatial Variation +_ 0.6oC
Initial Overshoot +2.0oC
Reproducibility +_0.4oC
Dial resolution 0.1oC
Operating Ambient 10oC - 35oC
Mains Voltage Range 220-250 AC 50Hz
b) Timer:
Timing range 1 minute - 99 hours 59 minutes
Timing Resolution 1 minute
NB: Timer does not start timing down UNTIL within 2.5oC of the
temperature SET POINT.

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SECTION 3 OPERATING INSTRUCTIONS
This appliance is NOT intended for use by young children or infirm persons
without supervision.
To set up unit for operation after unpacking and checking for damage proceed
as follows:
1) Install shelf runners: Fit lug into selected slot at rear of cabinet sidewall
and clip down into front slot to lock into place. Check heights of runners
are parallel.
2) Fit Shelves. Maximum shelf loading is 30Kg/shelf, maximum total for
cabinet is 100Kg.
3) Select a location handy to a 10amp electrical outlet.
4) Bench Units - Place on solid top with clearance underneath to allow
ventilation around entire cabinet.
5) Ensure a space of at least 150mm is allowed at the rear of the cabinet for
air circulation.
NB: Ensure ALL of the distinctly coloured cable ties (If fitted inside cabinet) are
REMOVED BEFORE operating the incubator.
NB: These cabinets are NOT suitable for operating with high humidity conditions
present inside. Humidity levels should be such that water does not condense on
the walls, floor or inside the outer door.
OPERATING CONTROLLER:
1) Plug cabinet into 220-250V Mains outlet.
2) Turn on main switch - The LED should show all 8888s then display the
current temperature in the cabinet. Do NOT press any buttons until after
the 8888’s have gone from the display.
3) Press and HOLD the temperature button (top) UNTIL the ‘SET’ LED
comes ON then RELEASE. The `SET' LED above the LED display
should now be ON!
4) While the ‘SET’ LED is On use the ‘UP’ & DOWN’ buttons to adjust the
SET POINT to the desired temperature.
5) WAIT for the display to return to normal; the ‘SET’ LED will then go off.

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6) The TIMER must now be set to run the cabinet - use the SAME method
as for the temperature EXCEPT press the ‘TIME’ button instead. To
obtain the special ‘[.]’ symbol for continuous operation, first adjust the
timer down until ‘0.00’ is reached, then press the down button once more
to get ‘99:59’ then the ‘up’ button to go 1 step above ‘99:59’ the special
‘[.]’ symbol should now be shown.
NB: the symbol ` [.] ' means run CONTINUOUSLY.
Setting the TIMER to 0.00 turns the cabinet OFF.
If the cabinet has TURNED OFF after the completion of a TIMED
operating period it is only necessary to PRESS and HOLD the
TIMER button until the ‘SET’ led comes on to REPEAT the TIMED run.
7) The cabinet will now attempt to obtain the SET POINT and control until
the TIMER runs out of time. The cabinet WILL NOT OPERATE if the
TIMER has been set to 0.00.
8) To look at the current TIME press the ‘TIME’ button for 2 seconds - the
amount of time left will nowbe displayed continuously.
To display the TEMPERATURE continuously - press the ‘TEMP’ button
for 2 seconds.
9) To CANCEL any Alarm (ie. 1- - - ) PRESS and HOLD the ‘TEMP’ button
until the ‘SET’ LED comes ON.
Ensure the mechanical user HI-LIMIT is set correctly as described in the
following section. The cabinet usually leaves the factory with the user HI-LIMIT
set fully anticlockwise, if left in this position the HI-LIMIT will not allowthe cabinet
to heat and control correctly.
FAN MOTOR
The fan motor may ‘PULSE’ when the ambient temperature is very close to the
set point temperature, this is due to the ‘Thermoguard’ mode of operation as the
controller attempts to lower the heating effect of the fan –a mechanical ‘pulse’
sound may also be heard.

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MECHANICAL HI-LIMIT MONITOR
The mechanical hi-limit is provided as a secondary safety device to protect the
cabinet from over temperature in the event of electronic controller failure.
To set the Mechanical Hi-Limit
Turn the Hi-Limit control FULLY CLOCKWISE.
Allow the cabinet to stabilise at the required operating temperature (for at least 1
hour), then turn the Hi-Limit control anti-clockwise until the MONITOR neon
comes on (or a slight 'click' is felt). Now turn the Hi-Limit control SLOWLY
CLOCKWISE until the MONITOR neon goes off (or a slight 'click' is felt), then
advance the Hi-limit clockwise 1-2 scale markings. This will set the Hi-Limit trip
point about 3 - 4oC above the current cabinet temperature.
WARNING: To prevent FIRE or SHOCK hazard, DO NOT expose this
product to rain or any type of moisture.
FOR YOUR SAFETY
To ensure safe operation the three-pin plug supplied must be inserted
ONLY into a standard three-pin power outlet that is effectively earthed
through the normal building wiring.
Extension cords are NOT recommended.
The fact that the equipment operates satisfactorily does NOT imply that
the power outlet is earthed and that the installation is completely safe. For
your safety, if in any doubt about the effective earthing of the power outlet,
consult a qualified electrician.
This appliance should be periodically tested according to the procedures
prescribed in AS/NZS 3760.
The basic safety checks and tests on electrical appliances required by AS/NZS
3760 are:
1. A visual check to ensure that there is no mechanical damage to
the supply cord, that controls etc. are in good working order and
that no parts are missing.
2. An earth continuity test.
3. An insulation resistance test.
In order to provide evidence of compliance, a label (signed and dated by the
person testing the equipment) may be placed on the tested appliance.

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ALARMS
All alarms are indicated by a number and three dashes on the LED display and
are accompanied by an audible alarm.
To CANCEL any Alarm (ie 1---) PRESS and HOLD the `TEMP’ button until the
‘SET’ LED comes ON.
ALARM MEANING
1--- This means the cabinet is OVER or UNDER temperature. If UNDER
temperature it could be due to the door being opened, otherwise
check the cabinet to determine if the Internal fan is still operating and that
the MECHANICAL Hi-Limit control is not interfering with normal
operation.
3--- Preset alarm - The cabinet has lost its control settings due to an internal
memory failure. Reset all control settings as desired and check the
calibration setting.
4--- This means that the TEMPERATURE sensing probe has failed (1000
RTD). The connections to the probe and the probe condition should be
investigated.
9--- This is a WATCHDOG alarm - The Electronic PCB has failed - Replace
the controller.

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CALIBRATION
Calibration should be carried out at 37.0oC or at the temperature of interest, with
the thermometer in the centre of the working chamber with the chamber empty.
The calibration temperature must be within the achievable operating range of
the incubator.
1) Place the Calibration Thermometer probe in the workspace centre, close
the door and set the controller for 37.0oC or the temperature of interest,
allowat least 1 hour to stabilise.
2) Read the temperature on the Calibration Thermometer.
3) To calibrate the cabinet -
a) Press and HOLD the `TEMP’ button until the ‘SET’ LED comes
ON and then release. The ‘SET’ led should now be ON.
b) WHILE the ‘SET’ led is ON: Press BOTH `UP' & `DOWN' buttons
TOGETHER - a beep will be heard and the word ` CAL' will
appear briefly on the LED display. Adjust the reading on the LED
display using the `UP' & `DOWN' buttons until it agrees with the
Calibration Thermometer.
NB: If when attempting to press BOTH buttons together, the
temperature SET POINT adjusts either up or down - it
means you are NOT pressing BOTH buttons at the SAME
TIME! - if the ‘SET’ led is still on you should attempt 3(b)
again, if the ‘SET’ led is OFF you should repeat from 3 (a).
c) WAIT for a further beep to occur, the LED display will briefly show
`----' and then the CALIBRATION CONSTANT, this will be a
number in the range 0.0 to 19.9. This figure SHOULD BE NOTED
as it may be used to return to this calibration setting. The LED will
then briefly show another ‘---‘ the controller will then resume its
role of normal operation.
NB: If a '[[[[' sign appears on the display the cabinet is
OUTSIDE its calibration display range and calibration should be
performed at a slightly higher temperature.
4) Allow to stabilise again - the temperature should now be correct. If NOT
repeat the procedure.
NB: The calibration can only be performed within limits, if the
calibration cannot be achieved a further fault exists.

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VERIFYING CABINET PERFORMANCE
There are two basic tests that may be carried out to verify cabinet performance.
NB: These tests MUST be carried out with the cabinet EMPTY and at the
specified ambient of +20oC.
TEMPORAL PERFORMANCE:
The cabinet should be set to operate at the Contherm specified calibration
conditions.
Temporal performance is tested by placing a suitable (calibrated) test probe in
the centre of the workspace and recording the readings for up to 1 hour AFTER
the cabinet has FULLY STABILISED.
The cabinet has fully stabilised when the average temperature is no longer
increasing or decreasing over time.
The result should be within the quoted specification.
This result is a function of the cabinet control system, sensor and airflow.
SPATIAL PERFORMANCE:
The cabinet should be set to operate at the Contherm specified calibration
conditions.
Check Spatial Variation @ 37oC
(Refer manual for specification, 8 points as per diagram)
[6R] [4C] [3R] TOP
[8C] [1C] [ ] CEN
[2F] [7C] [6F] BOT
(Where F=Front, C=Center, R=rear)
Spatial performance is tested by placing suitable (calibrated) test probes
(usually thermocouples) in the eight specified positions and recording the
readings for up to 1 hour AFTER the cabinet has FULLY STABILISED.
The cabinet has fully stabilised when the average temperature is no longer
increasing or decreasing over time.
The sensors must be no closer than 30mm to any wall or roof and must be
above the lowest shelf position by at least 30mm.
The result should be within the quoted specification.
This result is a function of the cabinet design and air distribution.
The spatial test must be performed with all doors, vents etc CLOSED and the
measuring sensors must be very closely matched at the specified temperature.

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CONTROL LAYOUT
3 4 1 2
7 6 8 5
1 Temperature adjustment button.
(Also used to adjust set points)
2 Time adjustment button.
(Also used to adjust set points)
3 LED Display - Gives readout of temperature in degrees centigrade OR
elapsed time in hours and minutes.
4 LED Indicators - Left LED indicates when the heating element is ON.
Right LED indicates when controller is in SET mode.
5 Refer "Caution" Instructions.
6 Mechanical Hi-limit set Adjustment Knob (No Scale).
7 Mains Switch and Circuit Breaker (6A) combined.
8 Hi-Limit Monitor Neon- will come on if power is being applied to heater
element while mechanical Hi-Limit is tripped.

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SECTION 4 THEORY OF OPERATION
This CONTHERM General Purpose Incubator uses a single chip
microprocessor electronic PID controller with a 1000Resistance RTD probe
as the temperature sensing element. The LED display gives a direct readout of
the SET POINT or Cabinet temperature in degrees centigrade.
The air inside the incubator is circulated by a small stirring MOTOR which draws
air in at the top of the chamber and discharges it down behind a false back to
the bottom, resulting in a vertical air flow.
The sheathed HEATING ELEMENT is located adjacent to the air rotor such that
the discharged air passes over the active portion of the element.
The chamber temperature is measured by a RTD SENSOR the resistance of
which increases with increasing air temperature. This change of resistance is
used by the ZP21 CONTROLLER to regulate the cabinet temperature to the
desired value.
Setting and Calibration of the chamber temperature is performed via the
adjustment buttons and is stored in non volatile memory. Settings will typically
be retained for up to 100 years even in the absence of power.
The type of cabinet (INCUBATOR, OVEN, C or MCP) is selected at the factory
by special button sequences during the power on period and stored in the non
volatile memory.
An internal glass door allows the contents to be viewed without disturbing the
internal temperature.

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SECTION 5 TROUBLESHOOTING AND MAINTENANCE
MAINTENANCE
The epoxy powder coated mild steel exterior is resistant to corrosion and
spillage’s and should be wiped with a damp cloth occasionally to maintain its
appearance.
The inside of the outer door is powder coated mild steel and is susceptible to
moisture. If left wet for long periods rust spots may occur.
The fan motor bearings do not require lubrication under normal conditions.
The stainless steel interior and shelves should be kept clean with a damp cloth.
Take care that the temperature probe is not damaged during cleaning of the
interior base.
Any spillage or breakage within the cabinet should be cleaned up immediately
with the cabinet switched off and unplugged at the mains.
NB: These cabinets are NOT suitable for operating with high humidity conditions
present inside. Humidity levels should be such that water does not condense on
the walls, floor or inside the outer door.
ROUTINE MAINTENANCE
Suggested to be checked Annually:
Check glass door gaskets for damage (cuts and splits), replace if necessary.
Check glass door(s) seal correctly onto gaskets, if split glass doors check
door alignment on centre seal, adjust door hinge if required.
Wipe out floor of cabinet to remove any water stains.
Check controller overlay for damage, replace if necessary.
Check basic cabinet control functions and that user hi-limit control is set
appropriately.

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ELECTRICAL SAFETY
This appliance should be tested for insulation and earthing continuity at regular
intervals according to AS/NZS 3760.
The basic safety checks and tests on electrical appliances required by AS/NZS
3760 are:
1. A visual check to ensure that there is no mechanical damage to
the supply cord, that controls etc. are in good working order and
that no parts are missing.
2. An earth continuity test.
3. An insulation resistance test.
In order to provide evidence of compliance, a label (signed and dated by the
person testing the equipment) may be placed on the tested appliance.
TROUBLESHOOTING:
A) CABINET COMPLETELY DEAD:
- Check wall socket and wall socket circuit breakers.
B) LARGE TEMPERATURE VARIATION IN CABINET, CONTROLLER
`HEATER' LED PULSING :
- Internal fan not operating (Check for air movement inside cabinet).
- Cabinet OVERLOADED with samples, remove some samples to allow
for better air movement.
- Look for HI-LIMIT Monitor neon coming on, if so indicates mechanical
Hi-Limit is set too low.
C) CABINET NOT CONTROLLING AT TEMPERATURE, ‘HEATER’ LED
NOT FLASHING :
- Check that the timer has been correctly set, if the timer is set to ‘0:00’
the cabinet will NOT operate.
The ZP21 PCB is equipped with a green "HEARTBEAT" LED adjacent to the
large buzzer. When the cabinet is operating this LED should be PULSING
about once per second. There are also TWO small glass fuses to protect the
PCB. REMOVE ALL power from the unit (By removing the mains plug)
BEFORE attempting to check these fuses.

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REMOVAL AND REPLACEMENT OF ZP21 CONTROLLER PCB
The following should only be carried out by suitably qualified electrical
personnel.
NB: ENSURE that power cord has been REMOVED from the wall socket
BEFORE attempting to remove the PCB.
a) Loosen the two black plastic fasteners holding the cabinet lid down by
turning anticlockwise so that the pop up. Lift the lid up at the front and
remove from cabinet.
b) Remove the two self tapping screws at either end of the control panel
and rotate the panel up so that it rests on the cabinet top.
c) ENSURE POWER CORD is REMOVED from wall socket then Unplug
socket from Controller PC Board. NOTE connections from side 10way
socket to sensor probe etc so that they can be correctly reinstalled, then
disconnect probe etc from socket.
d) Using suitable socket undo four 4mm securing nuts. Carefully NOTE
position and size of SPACERS
e) Remove PC Board.
List FULLY all fault details, carefully pack, return to Agent for repair.
ALWAYS supply contact details and FULL physical return address.
The refitting of the controller should be done in the reverse order as
above, taking care when reconnecting the sensor etc that they are
connected to the correct socket holes.
f) Carry out Insulation (use 500V insulation tester) and earth continuity
check BEFORE applying power to cabinet. (as per AS/NZS 3760 –In-
service safety inspection and testing of electrical equipment).
The basic safety checks and tests on electrical appliances required by
AS/NZS 3760 are:
1. A visual check to ensure that there is no mechanical damage to
the supply cord, that controls etc. are in good working order and
that no parts are missing.
2. An earth continuity test.
3. An insulation resistance test.
In order to provide evidence of compliance, a label (signed and dated by
the person testing the equipment) may be placed on the tested
appliance.
N.B: Check for loose wires that may have been missed, particularly the earth
wires.

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ELECTRICAL GP LAYOUT ZP21 1050 –1400 Drawing 550-59

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SECTION 6 PARTS LISTS AND SPARES
Shelves Cat 1050 GP1056
Cat 1100 GP1057
Cat 1150 GP1058
Cat 1200/1300/1400 GP1061
Shelf Support Brackets
(State Model when ordering) GP1064
Hinges:Glass Door GP1006
Glass door Catch
Fan Motor E.G.O GP1000
Elements Cat 1050/1100 300W ELEMEGO300
Cat 1150/1200 300W ELEMEGO300
Cat 1300/1400 600W ELEMEGO600
Temperature Sensor: 1000RTD GP1307
Hi-Limit Thermostat: Incubator GP1021
Hi-Limit Monitor Neon GP1033
Control Knob GP1324
Control Circuit Board: ZP21 GP1306
Mains Switch / Circuit breaker (6A)
Monitor Neon GP1073
Control Panel Overlay

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GLASS DOOR SIZES
(If purchasing independently)
H
W
5.0mm Toughened Clear Floated - All edges arased.
Cat.1050 374mm H x 432mm W
Cat.1100 495mm H x 507mm W
Cat.1150 571mm H x 587mm W
Cat.1200 636mm H x 700mm W
Cat.1300 462mm H x 700mm W 2off
Cat.1400 614mm H x 700mm W 2off
NOTE: If replacement doors are required hole placement and dimensions vary
on each size
When ordering a replacement glass door it is best to measure the original door
including any hole sizes and placement to ensure the new door will fit correctly.
This manual suits for next models
5
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