Forma Scientific 3158 User manual

Forma Scientific, Inc.
P.O. Box 649
Marietta, Ohio 45750
Telephone: [phone]
Telefax: [phone]
________________________________________
Model: 3158
Single Chamber
Water Jacketed Incubator
Manual No. 7003158
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.
MANUAL ADDENDUM
Re: Incubator CO2Control
CAUTION!
If the incubator sustains a power failure long enough to affect temperature and in turn affect
humidity, then the CO2readout will be incorrect. The unit will return to NORMAL,
indicating correct chamber conditions.
NOTE: PLEASE ALLOW ADEQUATE TIME FOR THE UNIT TO STABILIZE. (Short
OFF and ON power failures will not adversely affect the chamber operation.)

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. 7003158
0 6/82 Original Manual
REV ECN DATE DESCRIPTION

Forma Scientific, Inc. ____________________________________________________
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
small box containing the following accessories is packed inside the incubator:
STOCK # DESCRIPTION QTY. PURPOSE
380284 3.8" Hose x 1/4 MPT Adapter 1 Fill & Drain
190028 Decontamination Kit 2 Replace Parts
180001 Polypropylene Funnel 1 Fill & Drain
72017 Vinyl Tubing 3/8" ID 6' Fill & Drain
ALSO PACKED WITHIN EACH INCUBATOR
224200 Stainless Steel Shelves 6
505072 Shelf Brackets 12
3113210 Stainless Blower Channel 1
3113220 Stainless Duct Sheet Left 1
3113230 Stainless Duct Sheet Right 1

Forma Scientific, Inc. ____________________________________________________
Table of Contents
Section 1 - Introduction
1.1 The Water Jacket: Key Features
1.1 Auxiliary Equipment
Section 2 - Specifications
Section 3 - Operation
3.1 Operation Overview
3.2 Humidification and CO2(IMPORTANT!)
3.3 Control Panel

Forma Scientific, Inc. ____________________________________________________
Section 4 - Installation and Start-Up
4.1 Location
4.2 Preliminary Disinfecting
4.3 Installing the Duct Sheets
4.4 Installing the Shelves
4.5 Leveling
4.6 Connecting to Power
4.7 Connecting the CO2Supply
4.8 Preparing the Incubator for Filling
4.9 Filling the Water Jacket
4.10 Filling the Humidity Reservoir or Pan
4.11 Setting the Chamber Temperature
4.12 Setting the Overtemp Safety Thermostat
4.13 Zeroing the CO2Controller
4.14 Setting the CO2Content
Section 5 - Routine Maintenance
5.1 Using the Decontamination Kit
5.2 Disinfecting the Incubator Interior
5.3 Cleaning the Cabinet Exterior
5.4 Draining the Water Jacket
5.5 Changing the CO2Filter
5.6 A Word About CO2Test Instruments
5.7 Overview of the FYRITE CO2Analyzer
5.8 FYRITE Operating Precautions
5.9 Operating the FYRITE
5.10 Checking the FYRITE Fluid Strength
5.11 Raising/Lowering the FYRITE Fluid Level

Forma Scientific, Inc. ____________________________________________________
Section 6 - Service (For Qualified Personnel Only)
6.1 General Troubleshooting
6.2 Use of the Troubleshooting Flowcharts
6.3 CO2Control Calibration
6.4 37C Control Calibration
6.5 Replacing the CO2Sensor
6.6 Replacing the Chamber Heater
6.7 Replacing the Door Heater
6.8 Replacing the Triac
6.9 Replacing the CO2Solenoid
6.10 Replacing the Temperature Control
6.11 Replacing the Pilot Lights
6.12 Replacing the Circuit Breaker
6.13 Replacing the Power Switch
6.14 Replacing the Thermistor
6.15 Replacing the Blower Motor
Parts List, Supplements, Schematics
Warranty Information

Forma Scientific, Inc. ____________________________________________________
SECTION 1 - INTRODUCTION
1.1 THE WATER JACKET: KEY FEATURES
Forma’s water jacket design represents the best combination of economy,
accuracy and reliability available in today’s technology. Some of the salient
features include:
• A door heater which adjusts automatically to ambient conditions,
providing a condensate-free inner door for unhampered viewing of the
product in the chamber without unnecessary door openings, which
temporarily disturb temperature, humidity, and CO2control.
• Ultra-flat, vibration-free shelves to provide optimal culturing conditions.
• Direct-set CO2, temperature, and alarm setpoints.
• Tamper-proof controls to prevent unauthorized or accidental adjustments.
• Digital readout of temperature and CO2levels in the chamber surrounding
the product.
• A sealed chamber to minimize CO2consumption.
• A sealed water jacket to minimize water evaporation.
The water jacket incubator is designed for ease of serviceability 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 of a particular control module.
• Self-diagnostic switches in the control modules to aid in troubleshooting
the system and localizing problems.

Forma Scientific, Inc. ____________________________________________________
The design of the water jacket also allows for ease in disinfecting or autoclaving
with a minimum of unit downtime.
• There are 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 are easily removable
without tools for cleaning and disinfecting the entire interior.
• A blower wheel that is disposable and easily replaced.
Careful consideration has been given to the importance of product protection
through the addition of:
• An Add Water audible 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 are activated when the CO2
percentage in the chamber deviates 1% above or below the CO2control
setpoint.
• An overtemperature alarm that is activated when the chamber temperature
rises above the control setpoint.
1.2 AUXILIARY EQUIPMENT
1. Stainless Steel Shelf
The perforated shelf is square for easy installation. 22 shelf capacity. Minimum
order of 1 shelf. Catalog # 224200
2. Shelf Channels
For mounting extra shelves and a humidity pan. Two needed per shelf or pan.
Minimum order of 1. Catalog # 505072
3. Tissue Culture Shelves
These 11" x 16" stainless steel shelves for culture dishes are designed for
stacking to increase incubator storage space. Minimum order of 6 shelves.
Catalog # 500171

Forma Scientific, Inc. ____________________________________________________
4. Multiplex Strip Recorder
This easy-to-install, self-contained strip recorder keeps a permanent record of
both temperature and CO2. Catalog # 197012
5. Extra Recorder Chart Paper
A one-month supply of chart paper (1 roll) for the multiplex recorder.
Catalog # 180029
6. FYRITE CO2Analyzer Kit
For checking the CO2(0-20%) level in the chamber. Connects to the gas
sample port on the control panel. Kit comes complete with aspirator, sampling
tube, and carrying case. Catalog # 220012
7. Extra FYRITE Fluid
For replacing FYRITE tester fluid. Three bottles per carton.
Catalog # 220051
8. Digital Thermometer
Hand-held, the size of a pocket calculator, features clear liquid crystal readout
of temperature from -99.9°C to +99.9°C. Ideal for general laboratory use.
Catalog # 853227
9. Two Stage Pressure Regulator
Controls CO2cylinder gas pressure. First stage reduces tank pressure to pre-set
intermediate level. Second stage reduces pressure to recommended incubator
inlet pressure. Permits stable CO2flow on high or low demand through the
entire cylinder supply. Catalog # 965010
10. CO2Gas Guard
For use with automatic CO2incubators only. Protects dual tank CO2supply by
automatically switching to another tank when one supply is exhausted. Audible
alarm warns of tank depletion; Reset button silences the alarm. Manual tank
switchover included. Model # 3030
11. Replacement CO2Filter
Disposable 99.97% microbiological filter to replace the inline CO2filter when
it becomes clogged. Catalog # 770001

Forma Scientific, Inc. ____________________________________________________
12. Disinfection Kit
Includes parts needed for improved disinfection of the incubator. Includes
disposable blower wheel, O-ring for the CO2sensor and blower shaft seal.
Catalog # 190028
13. Laboratory Disinfectant
For use in and around the laboratory. Ideal for cleaning and disinfecting
incubators, bio-freezers, glassware washers, baths, circulators, and other
equipment. Protects against contamination, reduces chances of infection.
AMPHYL spray absorbs odors, minimizes contamination. Spraying action
reaches hard-to-reach places. 12 (14 oz.) aerosol cans per case.
Catalog # 170002
O-SYL Disinfectant Detergent. A combination cleaner and disinfectant with a
broad spectrum anti-microbial action. 6 (1 gal.) bottles per case.
Catalog # 170001
ROCCAL II Germicidal Sanitizing Agent. Bactericidal, kills mildew, prevents
growth of fungi and bacteria in the water jacket. 4 (1 gal.) bottles per case.
Catalog # 170003
14. Humidity Pan
This humidity pan rests on the bottom shelf channels and is easily removable
for cleaning. Order an extra set of 2 shelf channels for mounting.
Catalog # 237001
15. Hygrometer
For measuring chamber humidity. This instrument has a 4" dial and a range of
0 to 100% RH. Catalog # 155010
13. Glass Thermometer
For independently measuring chamber temperature. Range from 0°C to 100°C.
Catalog # 285722

Forma Scientific, Inc. ____________________________________________________
SECTION 2 - SPECIFICATIONS
Capacity
Chamber Capacity 5.7 cu. ft. (0.16 cu. m.)
Water Jacket Volume 10.5 gal. (39.7 liters)
Humidity Reservoir Capacity 1.46 gal. (5.5 liters)
Humidity Pan Capacity 5.28 qt. (5 liters)
Weights
Net (approximately) 180 lbs. (81.6kg)
Net Operational
(approximately) 267.5 lbs. (121.3kg)
Shipping (nominal)
Motor 270 lbs. (122kg)
Dimensions
Exterior 24.6"W x 41.9"H x 23.8"F-B
(62.5 cm x 106.4 cm x 60.4 cm)
Interior 18.6"W x 26.8"H x 18.8"F-B
(47.2 cm x 68.1 cm x 47.8 cm)
Construction
Interior 20 ga. stainless steel, type 304, 2B finish
Exterior 18 ga. cold rolled steel
Insulation 1-1/2" fiberglass
Inner Door Gasket Silicone
Outer Door Gasket Four sided molded magnetic vinyl
Finish Polyurethane enamel, Bristol Grey and
Windsor Blue trim

Forma Scientific, Inc. ____________________________________________________
Shelves
Capacity 22 (6 provided)
20 with use of optional humidity pan
Dimensions 17.75"W x 17.75" F-B (45.2 cm x 45.2 cm)
Construction 18 ga. perforated stainless steel, type 304
Surface Area 2.2 sq. ft. (0.2 sq. m) per shelf
Maximum 48.2 sq. ft. (1.36 sq. m)
Flatness ±0.032" off horizontal plane
Clearance Adjustable on 1” centers
Alarm/Monitor Module
Sensor Thermistor
Sensitivity ±0.1°C
Readout LCD
Setpoint Digital with screwdriver adjust
Accuracy ±0.2°C
Readability 0.1°C
Alarm Setability 0.1°C
CO2 Module
Sensitivity ±0.1% CO2
Supply Voltage ±15V
Sensor Matched thermistors
Controller Thermal conductivity
Setpoint Digital with screwdriver adjust
Readout LCD
Readability 0.1% CO2
Setability 0.1% CO2
Alarm Differential and Delay ±1.0% (nominal) for longer than
approximately 4 minutes.
Temperature Control
Range 0°C to +60°C
Sensor Thermistor
Controller Proportional, zero switching
Sensitivity ±0.05°C

Forma Scientific, Inc. ____________________________________________________
Heaters
Chamber 260 Watts
Door 5 Watts continuous, 120 Watts cycled
Top 6 Watts
Blower
CFM 7.5
Wheel Material Polypropylene
Motor 1/200 HP, 1700 RPM, 4 pole,
externally mounted, internally removable
Fittings
Fill/Drain Port ¼” FPT
Access Port 1.25" (3.17cm), plugged
CO2Connection ¼” serrated fitting, ¼” I.D. tubing
Sample Port ¼” OD, ¼” ID tubing
Electrical Characteristics
Main 90-130 Volts, 50/60Hz, 1PH, 4 FLA
Circuit Breaker 5 Amps
Power Switch 2 Pole
Line Cord 6’, Hospital grade
Performance Data:
Temperature
Control Tolerance ±0.02°C at +37°C in 22.2°C ambient
Range +5°C above ambient to +50°C
Uniformity ±0.2°C at 37°C
Recovery Rate
after 10 second door opening *Within 2 minutes, ±0.5°C
Recovery Rate
after 20 second door opening *Within 10 minutes, ±0.5°C
Heat-Up Time
from ambient to 37°C 10 hours
* - to within ½°C

Forma Scientific, Inc. ____________________________________________________
CO2
Control Tolerance Better than ±0.1%
Range 0 to 20%
Consumption @ 5% CO21.7 liters/hour
+7.2 liters/15 second door opening
Recovery Rate
after 10 second door opening **Within 5 minutes
Recovery Rate
after 20 second door opening **Within 10 minutes
Humidification
Range 98% RH @ +37°C
Recovery Rate
after 10 second door opening ***Within 25 minutes
Recovery Rate
after 20 second door opening ***Within 30 minutes
Energy Consumption
@ 37°C in a 25°C ambient 100 Watts per hour/chamber
** to 4.5% CO2(setpoint 5% CO2)
*** to 97% rH

Forma Scientific, Inc. ____________________________________________________
SECTION 3 – OPERATION OVERVIEW
3.1 OPERATION (See Figure 3-1)
The water jacket is filled with approximately 10.5 gallons (39.7 liters) of
water through the fill port located on the front of the unit. The water is then
warmed by the chamber heater, providing very stable heating of the incubator
chamber. Not only does the water stay at a constant temperature with a
minimum of heater on-time, but it also acts as insulation from ambient
temperature conditions.
Temperature control is maintained by a proportional, zero-switching device,
which provides temperature uniformity throughout the chamber. A separate and
independent overtemperature controller assures product safety by assuming
control at the overtemp setpoint if the primary controller malfunctions. Should
an overtemp condition develop, the monitor alarm system will alert the
operator that a malfunction has occurred.
An internal blower gently circulates the air in the chamber to prevent CO2
stratification while minimizing culture desiccation.
3.2 HUMIDIFICATION AND CO2(IMPORTANT!)
Forma has selected the thermal conductivity method of measuring CO2, and
when properly calibrated, the automatic CO2system will provide stable CO2
control on a long-term basis. The thermal conductivity of the incubator
atmosphere is affected by not only the quantity of CO2present, but also by the
humidity level in the chamber. Since CO2control is desired, it is important that
the absolute humidity be held constant so any change in thermal conductivity is
caused only by a change in the CO2concentration. Inadequate humidification
can cause the incubator humidity to fluctuate with ambient atmospheric
changes and can affect the CO2calibration by as much as 1.5%. A special pan
that is easy to remove for cleaning can be ordered from Forma (See Section 1).
This pan, with the water level maintained between the Add and Full lines, will
provide adequate humidification in the incubator.

Forma Scientific, Inc. ____________________________________________________
It should be noted that temperature changes of themselves have little effect on
CO2calibration, but they do cause large changes in the absolute humidity, and
these changes are reflected in changes in the CO2calibration. If either the
temperature or humidity setpoints are changed, the CO2control should be
zeroed for the new condition(s).
Operation of
Water Jacketed Incubator
Figure 3-1

Forma Scientific, Inc. ____________________________________________________
Incubator Controls
Figure 3-2

Forma Scientific, Inc. ____________________________________________________
3.3 CONTROL PANEL (See Figure 3-2)
1) Fill Port and Vent
The fill/drain fitting has been located on the front of the unit to facilitate filling
and draining of the water jacket without having to move the unit. When water
enters the water jacket during filling, the air that was present in the jacket exits
through the vent. Under no circumstances should the vent be plugged.
2) Power Switch and Pilot Light
The main power switch controls the ON/OFF power to the unit. The power
pilot light is activated when the power switch is on and the unit is receiving
power.
3) Circuit Breaker (Reset)
The 5 amp circuit breaker for the incubator (labeled Reset) can be pushed to
reset the incubator power supply within a few seconds after the breaker has
tripped. If it trips a second time, the unit should be checked by a qualified
electrician.
4) Variable/37C Switch, Temp Control and Heater Pilot Light
When the Variable/37C switch is set to the 37C (up) position, chamber
temperature will automatically be maintained at +37°C. If necessary, the 37C
control can be calibrated using the calibration screw located at the lower left
side of the temperature control dial. See Section 6.4 to calibrate the 37C
setting.
When the Variable/37C switch is set to the Variable (down) position, control
is assumed by the temperature control potentiometer. The numbers (0 to 60)
around the control knob indicate approximate setpoint values in degrees
Centigrade. Any value between +5°C above ambient temperature and 50°C
may be selected. The heater pilot light will be activated whenever the heater is
energized.
5) Gas Sample Port
A sample port for checking CO2percentage by independent means (e.g.
FYRITE or similar CO2measuring device). See Section 6.7-6.9 for details on
the proper use of the FYRITE. Important! The Sample Port should never be
capped as it serves as the vent for the incubator chamber.

Forma Scientific, Inc. ____________________________________________________
6) Setpoint Adjustment Tool
A small screwdriver, located directly above the sample port, has been
provided for setting the CO2and overtemp setpoints. Pull out on the knob to
release the screwdriver.
3.4 CO2MODULE (Refer to Figure 3-2)
7) CO2Power Switch
The CO2power switch controls electrical power to the CO2system, and it
must be On when the incubator is to be operated with CO2. The switch should
be turned On as soon as power is applied to the unit to allow the CO2system to
warm up.
8) CO2Controller and Digital Display
The LCD digital readout on the CO2module continually displays the percent
of CO2in the chamber. The setpoint is displayed when the CO2SET/SILENCE
button is pushed.
The CO2setpoint is changed by pushing the CO2SET/SILENCE button and
rotating the CO2setscrew to the desired percentage.
9) Audible CO2Alarm and Pilot Light
The audible CO2alarm and pilot light are activated when the percent CO2
deviates from setpoint by ±1% (nominal) for longer than approximately four
minutes.
10) Set/Silence Push Button
When pushed, the SET/SILENCE button will silence the CO2alarm and de-
energize the alarm light. The alarm will remain de-activated until another alarm
occurs. This button must be pushed to set or display the CO2setpoint.
11) Alarm Disable Switch
Note: It is necessary to pull the CO2module out slightly to gain access to the
alarm disable switch.
When the alarm switch is in the DISABLE position, the CO2alarm is
completely disabled. When the switch is set to the NORMAL position, the
alarm system is operative and can be silenced by pressing the SET/SILENCE
button.