Forma Scientific 3158 User manual

Forma Scientific, Inc.
P.O. Box 649
Marietta, Ohio 45750
Telephone: [phone]
Telefax: [phone]
________________________________________
Models:
Single Chamber 3158, 3164, 3154, 3166
Dual Chamber 3326, 3336, 3354
Water Jacketed Incubator
Manual No. 7063158
Important!
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.

Forma Scientific, Inc.
NOTE:
The material in this manual is for information purposes only. The contents and
the product it describes are subject to change without notice. Forma Scientific, Inc.
makes no representations or warranties with respect to this manual. In no event shall
Forma Scientific, Inc. be held liable for any damages, direct or incidental, arising out
of or related to the use of this manual.
MANUAL NO. 7063158
- N/A 8/9/96 Add gas guard drawings/parts list per B. Purvis
0 --- 7/17/96 Updated calib. Procedures, Section 7 heg
0 IN-2009 11/15/95 Release 5, added CE Mark
REV ECN DATE DESCRIPTION

Forma Scientific, Inc.
GENERAL SAFETY NOTES
The Occupational Safety and Health Administration (O.S.H.A.) has revised Section
1910-147, The Control Of Hazardous Energy (Lockout/Tagout).
Hazardous energy may be: electric, air, hydraulic, water, steam, gravity, spring & all other
equally hazardous energy.
This revised regulation, states that you will de-energize all potential sources of energy
(may be more than one energy source) prior to performing service or maintenance on any
equipment. It also states that a lock shall be placed on the de-energized control, along
with a verified test (use of a voltmeter or other equipment) to insure no accidental starts.
If you are not familiar with this regulation, review the O.S.H.A. Regulation, Section
1910-147.
In field service, full compliance with this regulation is difficult at best.
Troubleshooting must often be performed with hazardous energy applied; therefore
extreme caution must be followed during these troubleshooting steps. Only Qualified
Personnel Must Perform This Work. This phase of the repair work must be coordinated
through the customer's facilities maintenance department or designated person.
When performing service or maintenance as an outside contractor/worker, follow the
Outside Work Force's Lockout/Tagout system. Be alert for new types of lockout/tagout
devices.
√Always use the proper protective equipment (clothing, gloves, goggles etc.).
√Always dissipate extreme cold or heat, or wear protective clothing.
√Always follow good hygiene practices.
√Each individual is responsible for his/her own safety.
For your safety adhere to all DANGER and CAUTION statements.
Danger: This word is used to call attention to immediate hazards of
equipment or conditions which, if not avoided, could result in personal
injury, loss of life or property damage.
Caution: This word is used to call attention to potential hazards of
equipment or conditions which, if not avoided, could
result in personal injury, loss of life or property damage.

Forma Scientific, Inc.
Table of Contents
Page
Section 1 - Receiving
1.1 Preliminary Inspection ......................................................................... 1-1
1.2 Visible Loss or Damage ....................................................................... 1-1
1.3 Responsibility for Shipping Damage .................................................... 1-1
Section 2 - Unpacking List
2.1 Unpacking List..................................................................................... 2-1
Section 3 - Introduction
3.1 The Water Jacket: Key Features .......................................................... 3-1
Section 4 - Installation and Start-Up
4.1 Location............................................................................................... 4-1
4.2 Preliminary Disinfecting ...................................................................... 4-1
4.3 Installing the #6 Neoprene Stopper (Access Port) ................................ 4-2
4.4 Installing the Shelf Brackets and Cam Latch to the Duct Sheets........... 4-2
a. Installing the Shelf Brackets......................................................... 4-2
b. Installing the Cam Latch Assembly.............................................. 4-2
4.5 Installing the Duct Sheets..................................................................... 4-4
4.6 Installing the Shelves ........................................................................... 4-4
4.7 Leveling............................................................................................... 4-4
4.8 Connecting the Incubator to a Power Source ........................................ 4-5
4.9 Preparing the Incubator for Filling ....................................................... 4-5
4.10 Filling the Water Jacket ...................................................................... 4-7
a. Funnel Method............................................................................. 4-7
b. Tap Fill Method ........................................................................... 4-8
4.11 Connecting the Optional Gas Guard ................................................... 4-9

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4.12 Connecting the Gas Supply without the Gas Guard ............................. 4-10
4.13 Filling the Humidity Reservoir or Pan................................................. 4-11
4.14 Setting the Chamber Temperature ....................................................... 4-12
4.15 Setting the Over Temp Safety Thermostat ........................................... 4-13
4.16 Zeroing the CO2Controller................................................................. 4-14
4.17 Setting the CO2Content .................................................................... 4-15
Section 5 - Operation
5.1 Operation ............................................................................................. 5-1
5.2 Overview of Humidification and CO2................................................. 5-1
5.3 Control Panel ....................................................................................... 5-2
a. Fill Fitting and Vent Hole ............................................................ 5-2
b. Power Switch and Pilot Light....................................................... 5-3
c. Circuit Breaker............................................................................. 5-3
d. Variable/37°C Switch, Temp Control and Heater Pilot Light ....... 5-3
e. Gas Sample Port........................................................................... 5-4
f. Setpoint Adjustment Tool............................................................. 5-4
5.4 (Factory-Installed Option) Gas Guard Stock #190410 ......................... 5-4
a. Control Switch ............................................................................. 5-5
b. Silence Switch ............................................................................. 5-5
c. Gas Depletion Alarm.................................................................... 5-5
d. Active Tank Indicating Lights...................................................... 5-5
e. Pressure Low Indicating Lights .................................................... 5-6
5.5 CO2Module ........................................................................................ 5-6
a. CO2Power Switch ....................................................................... 5-6
b. CO2Controller and Digital Display............................................. 5-7
c. Audible CO2Alarm and Pilot Light ............................................. 5-7
d. SET/SILENCE Push Button......................................................... 5-7
e. Alarm Disable Switch .................................................................. 5-7
f. CO2Inject Light.......................................................................... 5-8
g. CO2Zero Adjustment .................................................................. 5-8
5.6 Alarm/Monitor Module ........................................................................ 5-8
a. Over Temperature Controller and SET/SILENCE Button............. 5-8

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b. Over Temperature Alarm and Pilot Light ..................................... 5-9
c. Add Water Pilot Light and Audible Alarm ................................... 5-9
5.7 Remote Alarm Relay System................................................................ 5-9
5.8 Recorder Output................................................................................... 5-11
Section 6 - Routine Maintenance
6.1 Installing the Decontamination Kit....................................................... 6-1
6.2 Disinfecting the Incubator Interior ....................................................... 6-3
6.3 Cleaning the Cabinet Exterior .............................................................. 6-4
6.4 Draining the Water Jacket .................................................................... 6-4
6.5 Changing the CO2Filter ...................................................................... 6-5
6.6 CO2Test Instruments .......................................................................... 6-5
Section 7 - Service (For Qualified Personnel Only)
7.1 General Troubleshooting...................................................................... 7-1
7.2 CO2Control Module Calibration ......................................................... 7-4
a. Minor CO2Calibration ................................................................ 7-4
b. Complete CO2Control Calibration.............................................. 7-5
7.3 37C° Control Calibration ..................................................................... 7-9
7.4 Calibrating the Temperature Monitor ................................................... 7-9
7.5 Replacing the CO2Sensor ................................................................... 7-10
7.6 Replacing the Triac .............................................................................. 7-10
7.7 Replacing the CO2Solenoid ................................................................ 7-11
7.8 Replacing the Temperature Control...................................................... 7-11
7.9 Replacing the Pilot Lights.................................................................... 7-12
7.10 Replacing the Thermistor ................................................................... 7-12
7.11 Replacing the 0.3 Amp Fuse................................................................ 7-12
7.12 Replacing the Blower Motor ............................................................... 7-13
a. Single Units ................................................................................ 7-13
b. Stacked Units.............................................................................. 7-14

Forma Scientific, Inc.
Section 8 - Specifications
Section 9 - Auxiliary Equipment
Section 10 - Parts List
Section 11 - Schematics
Section 12 - Warranty Information

Forma Scientific, Inc.
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1-1
SECTION 1 - RECEIVING
1.1 PRELIMINARY INSPECTION
This incubator was thoroughly inspected and carefully packed prior to shipment and all
reasonable precautions were taken to ensure safe arrival of the merchandise at its
destination. 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.
Failure to adequately describe such evidence of loss or damage may result in the carrier
refusing to honor a damage claim. Immediately call the delivering carrier and request that
their representative perform an inspection. Do not discard any of the packing material and
under no circumstances move the shipment from the receiving area.
1.3 RESPONSIBILITY FOR SHIPPING DAMAGE
For products shipped F.O.B. Marietta, Ohio, the responsibility of Forma Scientific,
Inc. ends when the merchandise is loaded onto the carrier's vehicle. On F.O.B.
Destination shipments, Forma Scientific's and the carrier's responsibility ends when your
Receiving Department personnel sign a free and clear delivery receipt.
Whenever possible, Forma Scientific, Inc. will assist in settling claims for loss or in-
transit damage.

Forma Scientific, Inc.
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2-1
SECTION 2 - UNPACKING LIST
2.1 UNPACKING LIST
Remove the packing box from the incubator. If the unit is to be moved by fork lift,
leave the incubator on the skid until it has been moved to its designated location. A
plastic bag containing the following accessories is packed inside the incubator:
Qty. Stock # Description Purpose
1 190028 Decontamination Kit Maintenance
1 180001 Polypropylene Funnel Fill & Drain
3' 246011 Vinyl Tubing 3/8" ID Fill & Drain
6' 246010 Vinyl Tubing 3/16" ID CO2 Connection
1 285057 Extender Card Maintenance & Calibration
Also packed with each incubator:
Qty. Stock # Description
24 23052 Stainless Steel Wing Nuts (#10-32)
20 55000 Stainless Steel Screws (Truss Head #10-32" x 5/8")
1121034 Cam Latch (Nylon)
1127019 Stainless Steel Spacer (1/4" Diameter x 9/16")
1550017 Stainless Steel Screw (Truss Head #8-32" x 1")
123051 Stainless Steel Wing Nut (#8-32)
5224140 Stainless Steel Shelves
1600034 Snapper Hose Clamp (.375")
43113234 Shelf Brackets
13113224 Stainless Duct Channel, Top
13113222 Stainless Duct Sheet, Left
13113223 Stainless Duct Sheet, Right
1130038 #6 Neoprene Stopper
1190388 Telephone Line Cord, 12'
1190392 Modular RJ-11 Jack
17053158 Instruction Manual

Forma Scientific, Inc.
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3-1
SECTION 3 - INTRODUCTION
3.1 THE WATER JACKET: KEY FEATURES
The Forma Scientific Model 3158 water jacketed incubator is designed to meet the
stringent requirements of today's modern laboratory and is a combination of economy,
accuracy and reliability.
The Model 3158 Incubator features:
•Ultra-flat, vibration-free shelves to provide optimum culturing
conditions.
•Direct-set CO2, temperature, and over temperature alarm set points..
•Digital readout of temperature and CO2levels in the chamber.
•A sealed chamber to minimize CO2consumption.
•A sealed water jacket to minimize water evaporation.
The 3158 water jacket incubator is designed for easy and convenient servicing by
providing:
•Front access to all components so that the unit need not be moved for
service, repair, or routine maintenance.
•A slide-out control panel for easy access to electrical components.
•Plug-in CO2, and Temperature/Alarm modules to facilitate servicing or
replacement.
•Self-diagnostic switches in the control modules to aid in
troubleshooting the system and localizing problems.
•Minimal unit down-time to disinfect the water jacket.

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3-2
•No cracks or crevices in, or around, the chamber walls to harbor
hidden or hard-to-reach bacterial growth.
•Stainless steel shelves, shelf channels and duct sheets which are easily
removed without tools for cleaning and disinfecting the entire interior.
•A blower wheel which is disposable and easily replaced.
•An improved water jacket drain and fill system.
Careful consideration has been given to the importance of product protection through
the addition of:
•An audible Add Water alarm and pilot light to alert the operator when
the water level in the water jacket has become too low for efficient
operation.
•Audible and visual CO2alarms which activate when the CO2content
in the chamber deviates 1% above or below the CO2control setpoint.
•An Over temperature Alarm which activates when the chamber temperature rises
above the control setpoint.
•An Add Water and Over temperature silence with 30 minute ring back.
•Remote alarm contacts for Over Temperature, Add Water, Power Failure and CO2
deviation.

Forma Scientific, Inc.
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4-1
SECTION 4 - INSTALLATION AND START-UP
4.1 LOCATION
Locate the incubator on a firm, level surface capable of supporting the unit.
Approximate weight with water: Single Chamber = 357 lbs (162 kg)
Dual Chamber = 714 lbs (324 kg)
The incubator should be placed in an area of the laboratory away from any centrifuges,
sonicators, doors, windows and air-conditioning or heating ductwork that might produce
drafts. To help prevent microbial contamination, the incubator should not be located in
areas of high personnel traffic.
Adequate room must be provided behind the incubator for connections of electrical,
gas and other equipment. Also, since gases are emitted from the rear of the incubator, the
unit should not be installed in an unvented recess or in a poorly ventilated room.
Caution: To prevent injury to personnel and/or damage to equipment, lock inner
glass door and secure outer door before tipping unit to adjust the leveling
feet. Do not attempt to tilt the incubator without assistance while
adjusting the leveling feet.
4.2 PRELIMINARY DISINFECTING
Before installing the duct sheets and the shelves, remove the clear plastic film from the
shelf brackets and duct sheets. Forma Scientific, Inc. recommends disinfecting all interior
surfaces (including both door gaskets). Rinse the surfaces with sterile distilled water (50K
Ohm to 1 Meg Ohm). Also disinfect the CO2sensor and the blower wheel, taking care
not to saturate the sensor.
The duct sheets and shelves must be washed with the same disinfectant solution and
rinsed with sterile distilled water prior to their installation in the chamber. Repeat rinsing
until you are satisfied that all of the disinfectant-detergent has been removed. Proceed
with the installation as noted. Refer to Section 6.2 of this manual.

Forma Scientific, Inc.
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4-2
4.3 INSTALLING THE #6 NEOPRENE STOPPER (ACCESS PORT)
Open the incubator outer door and inner glass door. Locate the opening in the top left
corner of the interior chamber. Place the beveled end of the stopper in the opening.
4.4 INSTALLING THE SHELF BRACKETS AND CAM LATCH
ASSEMBLY TO THE DUCT SHEETS (Refer to Figure 4-1)
A plastic coating has been applied on the duct sheets and shelf brackets to protect the
finish during shipping and handling. This plastic coating must be peeled off before the
protected parts are installed.
a. Shelf Brackets
1. Locate the plastic bag containing the #10-32 x 5/8" truss head screws and wing nuts
(20).
2. With the duct sheet in a vertical position, align and mount the shelf brackets to the
unflanged side of the duct sheets. Wing nuts go on the flanged side.
b. Cam Latch Assembly
1. Locate the bag containing (2) #8-32 x 1" stainless steel truss head screws, (2) #8-32
wing nuts, (2) stainless steel spacers and (2) cam latches (nylon).
2. Place stainless steel spacer (sleeve) over the #8-32 x 1" screw and insert it into the
opening of the cam latch.
3. Locate the five (5) small adjustment holes at the top of each duct sheet.
4. Place the cam latch on the inside (or unflanged side) of duct sheet and insert screw
with spacer sleeve through the middle hole of the five hole adjustment. If the duct
sheets appear to be too tight or too loose, the cam latch assembly may be re-
positioned up or down one hole for proper alignment.
5. Secure screw on flanged side of duct sheet with #8-32 wing nut.
6. Repeat these procedures for the other duct sheet.

Forma Scientific, Inc.
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4-3
Installing the Shelf Brackets and Duct Sheets
Figure 4-1

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4-4
4.5 INSTALLING THE DUCT SHEETS (Refer to Figure 4-1)
Note: The left duct sheet has large notches in both top and bottom edges. The right duct sheet
has a single notch in the top edge only.
1. Carefully put the right duct sheet into the incubator chamber with the flanges toward
the wall.
2. Put the left duct sheet into the chamber, with the square notch at the top and the
flanges toward the wall. Allow the top of the left-side duct sheet to lie diagonally
across the chamber, resting upon the right-side duct sheet.
3. Hook the top channel into the top opening of the right duct sheet. The top channel
must be positioned so that the brass CO2sample tube (mounted in the ceiling of the
incubator) is aligned with the notched out area on the right rear side of the top
channel. The round opening will align with the blower wheel when it is slid into
place.
4. While supporting the blower channel, slide the left duct sheet up until it is vertical,
making sure that the blower channel lines up into the slot on both duct sheets.
5. Turn cam latch to a vertical position (up against bottom side of top channel) to
secure. If duct sheets appear to be too tight or too loose, upon installation, the cam
latch assembly may be re-positioned up or down one hole for proper alignment.
4.6 INSTALLING THE SHELVES
The shelves may be placed at any level in the chamber. Slide the shelf into the shelf
bracket at the desired level.
4.7 LEVELING
Check the level of the unit by placing a bubble-type gauge on one of the shelves. Turn
the hex nut located on the leveling leg clockwise to lengthen the leveling leg, or raise the
unit. Turning the hex nut counterclockwise will shorten the leg, or lower the unit. Be sure
to level the incubator before filling the water jacket.
Caution: To prevent injury to personnel and/or damage to equipment, lock inner
glass door and secure outer door before tipping unit to adjust leveling
feet. Do not attempt to tilt the incubator without assistance while
adjusting the leveling feet.

Forma Scientific, Inc.
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4-5
4.8 CONNECTING THE INCUBATOR TO A POWER SOURCE
With the incubator power switch OFF, connect the unit to an adequate power source.
Refer to the serial tag located on the back of the unit or see Section 8.10 of this manual
for specific power requirements.
Note: Forma Scientific, Inc. recommends that the incubator be connected to a separate
electrical circuit.
4.9 PREPARING THE INCUBATOR FOR FILLING
450 ML of rust inhibitor was placed in the water jacket before the incubator was
shipped. The rust inhibitor mixes with the distilled water during filling and provides a
protective coating on the interior of the water jacket.
The fill fitting is used to fill the water jacket without having to move the incubator.
The fill fitting is located on the center front of the unit, directly above the door. Refer to
Figure 4-3.
The vent hole, located adjacent to the fill fitting allows the air displaced by water
entering the jacket to escape. It also prevents distortion of the chamber by allowing air to
escape as the unit expands and contracts during heating and cooling.
Caution: Do not plug this vent. A plugged vent will damage the water jacket
chamber.
1. Remove the plastic protective cap from the fill fitting. Check to see that the vent hole
located adjacent to the fill fitting is not covered or plugged.
2. Remove the protective metal cover from the drain fitting and valve and make sure the
valve is closed (turned to the vertical position). Refer to Figure 4-4 for drain and
drain valve location.
3. Set the TEMP SELECT switch to the variable position (down) and turn the temp
control knob completely counterclockwise to keep the heater from coming on before
the water jacket is filled. Refer to Figure 4-2 and Figure 4-3 for component locations.

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4-6
4. Turn the incubator power switch ON. The ADD WATER warning light and audible
alarm will come on. Pressing the SET/SILENCE button on the alarm panel will
silence the audible alarm
5. Remove the adjusting screwdriver from the control panel. The black knob is the
handle of the adjusting screwdriver. Refer to Figure 4-2.
6. Push the SET/SILENCE button on the Monitor Alarm Module, and adjust the over
temp alarm setpoint to a setting 2° or 3° above the intended operating temperature.
(Refer to Section 4.14)
Electric Power and Temperature Control Module
Figure 4-2
7. Press the CO2SET/SILENCE button and rotate the CO2set screw until the display
reads 00.0. (Refer to Figure 4-7 for locations of the SET/SILENCE button and set
screw.)

Forma Scientific, Inc.
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4-7
4.10 FILLING THE WATER JACKET
There are two methods of filling the water-jacket.
a. Funnel Fill Method
b. Tap Fill Method
Caution: Purity of the distilled water used in the water jacket and humidifier must
be within the 50K ohm to 1 Meg ohm range to protect and prolong the life
of the stainless steel water jacket. The use of tap water or distilled water
outside of the specified range will decrease the operating life of the unit
and will void the warranty.
Water Jacket Fill Fitting and Vent Hole
Figure 4-3
a. Funnel Fill Method (Refer to Figure 4-3)
A funnel and vinyl tubing are contained in the accessories bag included with each
incubator.
1. Verify that the water jacket drain valve on the bottom of the incubator frame is
closed. The valve is located behind a protective metal cover and will require two
screws to be removed. The valve is closed when the valve knob is turned vertical.
Refer to the illustration in Figure 4-4.

Forma Scientific, Inc.
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4-8
2. Attach the funnel into one end of the 3/8" I.D. vinyl tubing.
3. Remove the plastic protective cap from the fill fitting.
4. Attach the free end of the funnel tubing to the fill fitting.
5. Hold funnel above the level of the fill fitting and pour the water into the funnel until
the ADD WATER alarm light goes out. The water jacket holds about 13 gallons (49
liters) of water.
6. Add one additional quart (one liter) of distilled water. The incubator is now properly
filled.
7. Remove the tubing from the fill fitting and replace the plastic protective cap.
Note: Water seepage may occur from vent hole when chamber temperature increases.
Figure 4-4
Incubator Base with Water Jacket Drain and Valve
b. Tap Fill Method (Refer to Figure 4-3)
Three feet of 3/8" ID vinyl tubing is provided in the accessories bag included with
each incubator. If the distilled water outlet is more than three feet from the incubator,
more tubing and a connector will be required.
1. Verify that the water jacket drain valve on the bottom of the incubator frame is
closed. The valve is located behind a protective metal cover and will require two
screws to be removed. The valve is closed when the valve knob is turned vertical.
Refer to the illustration in Figure 4-4.

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4-9
2. Remove the plastic protective cap from the fill fitting.
3. Connect the 3/8" I.D. vinyl tubing between the fitting and the distilled water tap.
4. Open the tap until water flows steadily into the water jacket.
Caution: A high rate of flow and high pressure can cause distortion to incubator
chamber walls.
5. Turn the water off immediately when the ADD WATER alarm light goes out.
6. Using the funnel, add an additional quart (one liter) of distilled water.
7. Remove vinyl tubing and reinstall the plastic protective cap.
4.11 CONNECTING THE OPTIONAL GAS GUARD (Refer to Figure 4-5)
a. Connecting the Outlet of the Gas Guard to the Incubator's Gas Inlet
Before connecting the gas supply tanks, connect a piece of supply tubing between the
outlet fitting and the gas inlet(s) on the back of the incubator. If both chambers are to be
monitored by the gas guard both inlets need to be connected. The gas outlet is located
between Tank 1 and Tank 2 inlet fittings. Check the connections for leaks.
b. Connecting The CO2Supply Tanks
Note: Output pressure from the tanks must be regulated with a dual stage pressure
gauge set at 15 PSIG. Liquid substances must be supplied in tanks without
siphon tubes to ensure that only gas enters the incubator.
The high pressure gauge should have an indicating range of 0 to 2000 PSIG to monitor
tank pressure. The low pressure gauge should have an indicating range of 0 to 30 PSIG to
monitor actual input pressure to the incubator injection system. A suitable two-stage
pressure regulator is available from Forma Scientific, Inc., Stock #965010.
Supply pressure lower than 13.5 PSIG will cause improper operation of the gas guard
and may cause the occurrence of nuisance alarms. Pressure higher than 15 PSI will
damage the CO2control system.