Farrar Scientific 4000-LC Series User manual
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4000-LC Series
23 cubic feet/659 liters
CONTROLLED RATE UPRIGHT FREEZER
-80C TO +40C
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ReadThisInstructionManual.
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.
When plugged in, there is high voltage present on terminals inside the machine
space. Proper care must be taken if the side panel is removed to perform any kind
of maintenance.
The material in this manual is for information purposes only. The contents and the product
it describes are 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 off and locked off to
prevent possible injury
Always dissipate high or low temperatures, especially inside of the control space
before performing any maintenance on the unit.
Always use the proper protective equipment (clothing, gloves, goggles, etc.)
xAlways dissipate extreme cold or heat and wear protective clothing.
xAlways follow good hygiene practices.
xEach individual is responsible for his or her own safety.
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4000-LC Series
Rate 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. 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
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1.0 Receiving
1.0
Preliminary Inspection
This item was thoroughly inspected and carefully packed prior to shipment and all necessary
precautions were taken to ensure safe arrival. Immediately upon receipt, before the unit is
moved from the receiving area, carefully examine the shipment for loss or damage. Unpack the
shipment and inspect both interior and exterior for any in-transit damage.
1.1
Visible Loss or Damage
If any loss or damage is discovered, note any discrepancies on the delivery receipt and call the
delivering carrier and request that their representative perform an inspection. Do not discard
any of the packing material and do not move the shipment from the receiving area.
2.0 Introduction:
The4000ͲLCseriesbyFarrarScientific,Inc.isacontrolledratefreezerwhichisdesignedtofreeze
orthawproductquicklyoratacontrolledrate.Thecontrolledratefreezeroperatesusingspecific
rampandsoakprofilestailoredtothecustomerproductrequirements.Thecontrollercanbe
configuredtorampdownandupintemperatureandholdthesettemperatureforaspecified
time.Theunitincorporatesscrollrefrigerationcompressors,hotgasandelectricresistance
heaterstomaintaintemperaturecontrol.
3.0 Specifications:
a.
Size External: 75”W x 38”F-B x 80”H (190.2 x 96 x 2029 cm)
b.
Material External: Galvanized steel painted with Powdura Hybrid powder coat. Color:
beige.
c.
Size Internal: 34”W x 27”F-B x 43”H (86.4 x 69.8 x 109 cm)
d.
Material Internal: 304 Stainless Steel, including ducts, plenum and shelves.
e.
Inner door frame gasket: PVC
f.
Outer door frame gasket: Silicon
g.
Door interior panel: Galvanized steel painted with Powdura Hybrid powder coat. Color: white.
h.
Control enclosure: Cold rolled steel, stainless steel, aluminum powder coated black, drain
tube stainless. Evaporator fan motor mount aluminum.
i.
Net weight: 1010 lbs. (458kg)
j.
Shipping weight: 1597 lbs. (724.4kg)
k.
Internal air exchanges: 1/second
l.
Temp range: +40C to -80C
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m.
Control IDEC ramp and soak controller
n.
Control method: Proportional hot gas and resistance heat
o.
Refrigeration: Cascade scroll compressors 5hp and 3.5hp
p.
Heat: 2600 Watts
q.
Shelves: Quantity 2, adjustable on .595” centers plus bottom of chamber
r.
Power requirement- North America: 208-230 Volt, 3 phase, 31 amps, 40 amp circuit
required. Hubbell Locking Plug, Hubbell part number: CS8365C 50A rated, 250VAC,
3P4W. Requires Receptacle Hubbell part number: CS8369
s.
Power requirement- Europe/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 (29.5C) 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)
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4.0 Setup/ Installation:
1.
Roll the unit into place 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.
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.
S
p
rin
g
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5.
Screw 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)
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7.
Place the evaporator pan under the drain tube.
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8.
Install (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.
9.
Place the shelves on the clips with the down flange facing the door
opening. (see photo below)
Shelfdownflange
ShelfClip
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10.
Two chamber (0.875” (2.22 cm)) access ports are
provided; one on the rear of the cabinet and one on the
left side. These ports may be used for customer
provided chamber or sample 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 mounting plate.
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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” (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
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Sample Probe Connection and Use
The unit control has the ability to read a 100-ohm RTD probe inserted into a
product sample. The probe assembly has a bulk 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
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11.
North America Electrical Plug: The unit comes installed with a Hubbell
Locking Plug, Hubbell part number: CS8365C. Plug the unit into the
matching receptacle Hubbell part number: CS8369 (not provided). The
plug is 50A rated, 250VAC, 3P4W. 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.
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 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.
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12.
4102/4105 – Water cooled condenser only. Inlet and Outlet chilled or tower water
connections are located at the rear of the 4102/4105, each connection is ¾” MPT
(Male Pipe Tread) (refer to the Chamber Layout drawing at the end of the manual
for connection locations).
a) We recommend the use of industrial ¾” flexible hose grade with a
minimum 8 feet (2.5 meter) in length. The use of flexible hose for the
water inlet and outlet allows easy movement of equipment during
service and troubleshooting.
Hard piping of equipment is not recommended.
We strongly recommend installation of ¾” ball valve at 4102/4105 inlet (chilled or
water tower), 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 and check for leaks at all connections.
c) Verify water pressure is adequate for equipment operation, along with
nominal flow and temperature requirements as follow:
Tower water: ч85°F(29.5°C).ш20PSIdifferential(1.4bar)
Water flow rate at maximum load = 7gpm(26.5L/min)
Water flow rate at average load = 4.5gpm(17L/min)
Chilled water: ч45°F(7.5°C).ш20PSI(1.4bar)
Water flow rate at maximum load = 3.5gpm(13.2L/min)
Water flow rate at average load = 2.0gpm(7.6L/min)
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5.0 Control System:
The unit consists of heating, cooling components, fans, and control
components. The major cooling components include a compressor (heat
moving component), condenser (heat rejection part), evaporator (heat
absorption part) and expansion valve (refrigerant flow control devices).
Heating is accomplished with the use of resistance heaters imbedded in
the evaporator assembly. Controls consists of a circulation fan, a PLC
ramping controller, RTD temperature sensors, stepper 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 OPERATION:
All unit operation is performed using the panel mounted touch screen display.
3. Basic Operation:
After unit setup, plug the power cord(s) into the properly sized receptacles.
The panel mounted display will turn on with the Home screen being displayed.
The present interior chamber temperature will be displayed.
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a. Home Screen
Go to the listed Screen
Manage Profiles Pressing this icon will navigate to the screen which will allow editing all
profiles.
Manual set point This icon will display the screen which will allow operating the
chamber at any desired temperature within its operational range.
System Health This icon will display the health 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 typically be under
log-in security protection and should only be accessed by
trained, service personnel. The operation of these screens is
described in a separate Service Manual.
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Note: Operator privileges or higher will be required to make
changes to any of the controller settings. The access will
return to view only if the 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
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b1. Run Profile – Enter
Batch File Name
Use this Pop-up screen to enter the batch file name, using 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.
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c. Run Profile – Stop
This screen will allow the user to stop the 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
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