Farrar Scientific 4000M Series User manual

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4000M Series
23 cubic feet/659 liters
CONTROLLED RATE UPRIGHT FREEZER
-80C TO +40C

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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.
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. 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 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.)
 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.

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4000 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. Options
10. Trouble shooting
11. General Maintenance
12. Factory Default Watlow Settings

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1.0
Receiving
1.1
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.
1.2
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.
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 Introduction:
The 4000 Series Farrar Scientific controlled rate freezer is designed to freeze or thaw product
quickly or at a controlled 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.

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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.
This product is for Indoor Use Only.
e.
Material Internal: 304 Stainless Steel, including ducts, plenum and shelves.
f.
Inner door frame gasket: PVC
g.
Outer door frame gasket: Silicon
h.
Door interior panel: Galvanized steel painted with Powdura Hybrid powder coat. Color:
Beige
i.
Control enclosure: Cold rolled steel, stainless steel, aluminum powder coated
black, drain tube stainless. Evaporator fan motor mount aluminum.
j.
Net weight: 1010 lbs. (458kg)
k.
Shipping weight: 1597 lbs. (724.4kg)
l.
Internal air exchanges: 1/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 Volt, 3 phase, 31 amps, 40 amp
circuit required. Maximum mains supply fluctuation +/- 10%. Hubbell Locking
Plug, Hubbell part number: CS8365C 50A rated, 250VAC, 3P4W. Requires
Receptacle Hubbell part number: CS8369.
v.
Power requirement- Europe 400 Volt, 3 phase, wye connected, 24 amps. 30
amp fuses required. Maximum mains supply fluctuation +/- 10%. IEC 60309
(6H) 30 Amp 200/415V receptacle required.
w.
This unit is Overvoltage Category II
x.
This unit is Pollution degree 2
y.
Thermal room load:
Air cooled system: 36,860 BTU/Hr/11KWmaximum during chamber warm
up (maximum)
Water cooled system: 1706BTU/0.5KW (maximum)

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z.
Drain: External with heated evaporator pan, powered from the cabinet.
aa. Water Supply for water cooled condenser 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)

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4.0
Setup/ Installation:
1.
Note: The receptacle for this unit must be positioned such that this unit can be rolled on its
casters to achieve the following receptacle spacing: At least a 3 foot clearance in front of
the receptacle, with a 30” wide working space, and headroom at least the height of the
equipment.
2.
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. 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
projections of the evaporator pan (small end first). (see photo below)
5.
Condensate drain p-trap tubing.
Spring Feet
End to be inserted into
cabinet drain connector.
See next instruction
Condensate outlet

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Press the condensate drain p-trap into the right- angle cabinet drain connector under the
cabinet 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

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7.
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.
8.
Place the shelves on the clips with the down flange facing the door opening. (see
photo below)
Shelf down flange
Shelf Clip

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9.
Three chamber (0.875” (2.22 cm)) access ports are provided; two 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
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 pointing down.
Remove 4 screws to remove
sensor mounting plate.
Chamber temperature
sensor 100 ohm RTD
Customer installed
sensor location
Factory test
thermocouple sensor

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10.
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 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.
11.
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 are 1/2” FPT (Female Pipe Tread). For
the 4105, a 22mm, 1.5 adapter is provided (refer to the Chamber Layout drawing at the end of
the manual for connection locations).
a) We recommend the use of industrial ½” 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.

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b) We strongly recommend installation of ½” 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.
c) Connections to unit: Apply Teflon tape to inlet and outlet connection, 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)
Water flow rate at average load = 4.5 gpm (17 L/min)
Chilled water: ≤ 45°F (7.5°C). ≥ 20 PSI (1.4 bar)
Water flow rate at maximum load = 3.5 gpm (13.2 L/min)
Water flow rate at average load = 2.0 gpm (7.6 L/min)
Connection to
chamber
Connection from
water source

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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, Watlow Ez Zone® ramping controller, RTD temperature sensors, stepper
motor control hot gas control, solid state relay and misc. other hardware.
6.0
Operation:
Control panel:
1) POWER SWITCH
 Turns the unit ON and OFF
 When in the OFF position, internal control heater power will be OFF, evaporator fan will
be off, condensate evaporator pan will 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 indication light to signify the final step in a profile
4) USB CONFIGURATION PORT
 Female USB type B connector for interfacing with the Watlow controller to program
profile steps
 EZ-Zone Configurator is the Watlow provided software for direct interface
with the controller
5) CYCLE START PUSHBUTTON
 Used to start the temperature profile as selected by the MODE switch
6) CYCLE STOP PUSHBUTTON
 Stops all operations of the unit and returns to the OFF state
 All compressors, heat sources, and internal circulation fan will turn off
7) DEFROST BUTTON (EZ1)
 Soft key tied to the defrost function of the 4000 series unit

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Figure 6.1
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

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Control Description
Basic Operation:
After unit setup, turn the power switch to the ON position (Figure 6.1). The green power switch
will light, and the Watlow controller will light showing interior chamber temperature (top red display) and
current operating status (bottom red display). Please refer to Figure 6.2 for more details on the Watlow
Display.
User Selectable Profiles:
The unit is factory configured for 3 independent programmable temperature profiles, selectable
from the Mode Selection Switch. Pressing the cycle start button while the unit is in standby mode (OFF
displayed in the bottom green Watlow display area) will start the temperature profile that the Mode
Selection Switch is set to.
Profile Running Indicator
Chamber Temperature C
(Alarm and Error Codes
will display when over
-
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 off.
2. Heater modulation, lit or pulsing indicating heaters
are activating.
3. Evaporator over-temperature control, lit normally, off
in over temp condition set at 65 degree C. Returns to
normal when cabinet lowers to 60C and alarm is
manually cleared.
4. Control probe over-temperature control, lit normally,
and off in over temp condition. Set at 45 degree C.
Returns to normal when cabinet lowers to 43C and
alarm is manually cleared.
6. Evaporator coil temperature indicator
ON – Evaporator is above 15C
OFF
–
Evaporator is below 15C
Infinity Key
Up Arrow for Increasing Profile
Parameters
Advance Key
Figure 6.2
Down Arrow for Decreasing
Profile Parameters

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Factory default temperature profiles are programmed to control the unit chamber
temperature to set point (bottom green numerical display), and hold at that temperature until the Cycle
Stop button is pressed. Once Profile 1, 2 or 3 has reached its final temperature, the green cycle
complete indicator
will flash until the cycle stop button is pressed. Below are the set-points for each factory default profile.
Profile 1: -80˚C (Cycle complete light with begin flashing once chamber air temperature has
reached -80˚C)
Profile 2: -40˚C (Cycle complete light will begin flashing once chamber air temperature has
reached -40˚C)
Profile 3: +25˚C (Cycle complete light will begin flashing once chamber air temperature has
reached +25˚C)
Each of these default profiles is configured to reach the target set-point as fast as possible. The unit
can also perform controlled rate temperature ramp and soak processes over the course of several
minutes, or several days depending on the product need. (The configuration steps required for these
type of profiles is explained in the Profiling section.)
Pressing the CYCLE STOP button at any time will cancel any process that is currently running, disable
all refrigeration systems, and return the unit to the OFF state at any time.
A profile can only be started from the OFF state. Changing the position of the MODE switch, or
pressing the cycle start button while a temperature profile is running will be ignored. To switch from
one programmed profile to another, the CYCLE 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 unit will stop the
current profile and will need to be restarted. In cases where the power fails for less than 5 minutes the
profile will restart automatically. (This time can be changed, please contact Farrar Scientific for
assistance)
Defrosting the Evaporator Coil:
The defrost mode is also a profile. The steps for the defrost cycle are steps 38, 39 and 40. These
steps should never change from factory default!
A defrost of the evaporator coil is only required after the unit has completed a freeze cycle at a chamber
temperature at or below 5˚C, and all product has been removed from the control space. The purpose
of the defrost cycle is to remove any ice buildup on the surface of the evaporator coil to ensure reliable
and consistent unit operation.
Pressing the EZ-1 soft button, while the unit is in the OFF state, will initiate a defrost cycle of the
evaporator coil internal to the unit control space. This defrost cycle is internally controlled and will
automatically terminate when the evaporator coil has reached a temperature of 15˚C. If EZ-1 is
pressed while another profile is already running, or if the evaporator temperature is at or above 15˚C,
a defrost cycle will not occur.
As shown in Figure 6.2, a display of the number 6 on the bottom right side of the Watlow
display indicates that the evaporator temperature is at or above 15C.

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Control Security:
The Watlow control write security can be set to disable all functions from the Watlow controller front
panel. Please refer to the Watlow controller manual for detailed instructions. When write security is
set to the highest write security level (level 0), configuring of the control system and profiling must be
accomplished using the USB port supplied on the front of the control panel and the Watlow
Configurator® software with the supplied USB cable.
The Watlow Controller Support Tool on the included flashdrive or the included manual may be used
for a thorough understanding of the control system. The control used is Model PM8.
There are two over-temperature alarms programmed into the 4000 series unit. If the control probe
reaches a temperature above 45C, or if the evaporator reaches a temperature of 65C. In either case,
the unit will automatically shut down and an alarm message will be displayed across the front of the
Watlow controller. The following steps must be followed in order safely to clear these alarms.
Step 1: Press the “Cycle Stop” button on the control panel
Step 2: Turn the power switch to the off position
Step 3: Open the door on the front of the unit for at least 5 minutes. (This step is to cool down the
evaporator coil to below 60C, depending on ambient temperatures this 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 with the 4000 series main operations Watlow PM8 controller. The first
option is the use of the controllers front mounted keys to access operations menus. The second, and
recommended option, is to use a Windows computer and the Watlow provided software EZ-Zone
Configurator.
Installing and interfacing with the 4000 series using EZ-Zone Configurator 6
Two pieces of software need to be downloaded and installed on the windows computer to interface
with the Watlow controller inside of the 4000 series unit. Watlow EZ-Zone Configurator Version 6 and
the FTDI USB driver for the USB to RS485 conversion cable inside of 4000 series unit. The included
thumb drive has installation files for both of these pieces of software. Below are also links to download
the installation files from the internet.
Watlow EZ-Zone Configurator Version 6.1 Download:
http://www.watlow.com/products/Controllers/Software/EZ-ZONE-Configurator-Software
It is important to only use the most up to date version of EZ Zone configurator, Version 6.1 as of this
manuals printing. If an older version is used, programming parameters will not be loaded into the unit
correctly causing unwanted unit operation.

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Windows FTDI driver download:
http://www.ftdichip.com/Drivers/VCP.htm
It is important to only use the most up to date version of the FTDI USB driver, 2.12.28 as of this manuals
printing. If an older version is used, programming parameters will not be loaded into the unit correctly
causing unwanted unit operation.
The following is an excerpt from the Watlow EZ-Zone Users Guide on how to connect to the Watlow controller
using EZ-Zone Configurator.
Software Configuration
Using EZ-ZONE Configurator Software
To enable a user to configure the PM control using a personal computer (PC), Watlow has provided free
software for your use. If you have not yet obtained a copy of this software insert the CD (Controller Support
Tools) into your CD drive and install the software. Alternatively, if you are viewing this document electronically
and have a connection to the internet simply click on the link below and download the software from the
Watlow web site free of charge. http://www.watlow.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-folder "EZ-ZONE Configurator"
4. Click on EZ-ZONE Configurator to run.
The first screen that will appear is shown below.
If the PC is already physically connected to the EZ-ZONE PM control click the next button to go on-line.
Note:
When establishing communications from PC to the EZ-ZONE PM control an interface converter will be
required. The Standard Bus network uses EIA-485 as the interface. Most PCs today would require a USB
to EIA-485 converter. However, some PCs may still be equipped with EIA-232 ports, therefore an EIA-232
to EIA-485 converter would be required.
As can be seen in the above screen shot the software provides the user with the option of downloading a
previously saved configuration as well as the ability to create a configuration off-line to download later. The
screen shots that follow will take the user on-line.

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After clicking the next button above it is necessary to define the communications port that will be used on the
PC as shown below. Clicking on the drop down will allow the user to select the appropriate communications
port. This will be the port assigned to the EIA-485 to USB converter when it was connected to the PC. The
"Advanced" button allows the user to determine how many devices to look for on the network (1 to 17).
After clicking on the "Next" button, the software will scan the network for the zone addresses specified while
showing the progress made (as shown in the graphic below. When complete the software will display all of the
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 will appear. In the screen shot below notice that
the device part number is clearly displayed at the top of the page (yellow highlight added for emphasis). When
multiple EZ-ZONE devices are on the network it is important that the part number be noted prior to configuring
so as to avoid making unwanted configuration changes to another control. Looking closely at the left hand
column (Parameter Menus) notice that it displays all of the available menus and associated parameters within
the control.