Forma Scientific 3546 User manual

Forma Scientific, Inc.
P.O. Box 649
Marietta, Ohio 45750
U.S.A.
Telephone: [phone]
Telefax: [phone]
________________________________________
Models
3546 and 3548
Water Jacketed
Incubator
Operating Manual
Manual No. 7053546 Rev. 0
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.

Forma Scientific, Inc.
i
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. When contacting the factory regarding this
unit, have the model, serial number and date of purchase available.
MANUAL NO. 7053546
- 15817/IN-2210 12/18/96 Revised control panel wiring diagram rev 16 heg
- IN-2186 12/17/96 Revised control panel wiring diagram rev 15 heg
0 11/20/96 Updated to IEC 1010 specifications deg
REV ECR/ECN DATE DESCRIPTION

Forma Scientific, Inc.___________________________________________________Contents
iv
Table of Contents
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 - Installation and Start-Up
3.1 Location............................................................................................... 3-1
3.2 Preliminary Disinfecting ...................................................................... 3-1
3.3 Installing the #6 Neoprene Stopper (Access Port) ................................ 3-2
3.4 Installing the Shelf Brackets and Cam Latch to the Duct Sheets........... 3-2
Installing the Shelf Brackets ............................................................ 3-2
Installing the Cam Latch Assembly.................................................. 3-2
3.5 Installing the Duct Sheets..................................................................... 3-4
3.6 Installing the Shelves ........................................................................... 3-4
3.7 Leveling............................................................................................... 3-4
3.8 Connecting the Incubator to a Power Source ........................................ 3-5
3.9 Preparing the Incubator for Filling ....................................................... 3-5
3.10 Filling the Water Jacket ...................................................................... 3-7
Funnel Method................................................................................. 3-7
Tap Fill Method............................................................................... 3-8
3.11 Filling the Humidity Reservoir or Pan................................................. 3-9
3.12 Setting the Chamber Temperature ....................................................... 3-10
3.13 Setting the Overtemp Safety Thermostat ............................................. 3-10
3.14 Connecting the Optional Gas Guard .................................................... 3-12
a. Connecting the Gas Inlet ............................................................. 3-12
b. Connecting the CO2Tanks.......................................................... 3-12

Forma Scientific, Inc.___________________________________________________Contents
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3.15 Connecting the gas supply when not using the Gas Guard.................. 3-13
3.16 Zeroing the CO2Controller................................................................ 3-14
3.17 Setting the CO2Content .................................................................... 3-15
Section 4 - Operation
4.1 Operation ............................................................................................. 4-1
4.2 Overview of Humidification and CO2................................................. 4-1
4.3 Control Panel ....................................................................................... 4-3
Fill Fitting and Vent Hole................................................................ 4-3
Power Switch and Pilot Light .......................................................... 4-3
Circuit Breaker ................................................................................ 4-3
Variable/37°C Switch, Temp Control and Heater Pilot Light........... 4-4
Gas Sample Port .............................................................................. 4-4
Setpoint Adjustment Screwdriver .................................................... 4-4
4.4 CO2Module ........................................................................................ 4-4
CO2Power Switch........................................................................... 4-4
CO2Controller and Digital Display................................................. 4-4
Audible CO2Alarm and Pilot Light................................................. 4-5
Set/Silence Push Button................................................................... 4-5
Alarm Disable Switch...................................................................... 4-5
CO2Inject Light .............................................................................. 4-6
CO2Zero Adjustment ...................................................................... 4-6
4.5 Alarm/Monitor Module ........................................................................ 4-7
Overtemperature Controller and Push To Set Button ....................... 4-7
Overtemp Alarm and Pilot Light...................................................... 4-7
Add Water Pilot Light and Audible Alarm....................................... 4-7
4.6 Remote Alarm Relay System................................................................ 4-7
4.7 Recorder Output................................................................................... 4-8
4.8 (Optional) Gas Guard Stock #190410................................................... 4-8
Control Switch................................................................................. 4-10
Silence Switch ................................................................................. 4-10
Gas Depletion Alarm ....................................................................... 4-10
Active Tank Indicating Lights.......................................................... 4-10
Pressure Low Indicating Lights........................................................ 4-10
Start-Up Procedure .......................................................................... 4-10

Forma Scientific, Inc.___________________________________________________Contents
vi
Section 5 - Routine Maintenance
5.1 Installing The Decontamination Kit ..................................................... 5-1
5.2 Disinfecting the Incubator Interior ....................................................... 5-3
5.3 Cleaning the Cabinet Exterior .............................................................. 5-4
5.4 Draining the Water Jacket .................................................................... 5-4
5.5 Changing the CO2Filter ...................................................................... 5-5
5.6 CO2Test Instruments .......................................................................... 5-5
Section 6 - Service (Qualified Personnel Only)
6.1 General Troubleshooting...................................................................... 6-1
6.2 CO2Control Module Calibration ......................................................... 6-4
Stabilizing the Incubator.................................................................. 6-5
Adjusting the Zero Pot..................................................................... 6-5
Adjusting the Span Pot .................................................................... 6-6
Re-checking the Zero Adjustment.................................................... 6-7
Checking the CO2at the Desired Setpoint ....................................... 6-7
6.3 37°C Control Calibration ..................................................................... 6-8
6.4 Replacing the CO2Sensor ................................................................... 6-8
6.5 Replacing the Triac .............................................................................. 6-9
6.6 Replacing the CO2Solenoid ................................................................ 6-9
6.7 Replacing the Temperature Control...................................................... 6-10
6.8 Replacing the Pilot Lights.................................................................... 6-10
6.9 Replacing the Circuit Breaker .............................................................. 6-10
6.10 Replacing the Power Switch................................................................ 6-11
6.11 Replacing the Thermistor .................................................................... 6-11
6.12 Replacing the 0.3 Amp Fuse................................................................ 6-12
6.13 Replacing the Blower Motor ............................................................... 6-12
6.14 Fuse Chart.......................................................................................... 6-13
Section 7 - Features, Specifications and Accessories
7.1 Construction......................................................................................... 7-1
7.2 CO2Control Features .......................................................................... 7-1
7.3 Temperature Control ............................................................................ 7-2
7.4 Specifications/Accessories ................................................................... 7-3

Forma Scientific, Inc.___________________________________________________Contents
vii
Section 8 - Parts List
Section 9 - Schematics
Section 10 - Warranty Information

Forma Scientific, Inc.__________________________________________________Receiving
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.________________________________________________Unpacking
2-1
Section 2 - Unpacking List
2.1 Unpacking List
Remove packing box from 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 190247 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
20 55000 Stainless Steel Screws
(Truss Head #10-32" x
5/8")
Also packed with each incubator:
Qty. Stock # Description
24 23052 Stainless Steel Wing Nuts (#10-32)
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
17033546 Instruction Manual

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-1
Section 3 - Installation and Start-Up
3.1 Location
Locate the incubator on a firm, level surface capable of supporting the unit.
Approximate weight with water: 335 lbs (152 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 excessive 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.
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.
3.2 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.
For the complete disinfecting process, refer to Section 5.2 of this manual.

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-2
3.3 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.
3.4 Installing the Shelf Brackets and Cam Latch
Assembly to the Duct Sheets (Refer to Figure 3-1)
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.
Shelf Brackets
Locate the plastic bag containing the #10-32 x 5/8" truss head screws and wing nuts
(20 each).
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.
Cam Latch Assembly
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).
Place stainless steel spacer (sleeve) over the #8-32 x 1" screw and insert it into the
opening of the cam latch.
Locate the five (5) small adjustment holes at the top of each duct sheet.
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.
Secure screw on flanged side of duct sheet with #8-32 wing nut.
Repeat these procedures for the other duct sheet.

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-3
Installing the Shelf Bracketrs and Duct Sheets
Figure 3-1

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-4
3.5 Installing the Duct Sheets (Refer to Figure 3-1)
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.
Carefully put the right duct sheet into the incubator chamber with the flanges toward
the wall.
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.
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.
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.
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.
3.6 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.
3.7 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.
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.__________________________________________Installation/Start-up
3-5
3.8 Connecting the Incubator to a Power Source
With the incubator power switch OFF, plug the cord set into the receptacle on the back
of the unit. The cord set is the mains disconnect for the incubator. Connect the other end
of the cord set to an adequate power source. Refer to the serial tag located on the back of
the unit or see the Specification section or Electrical Schematics in the back of this
manual for specific power requirements.
Note: Forma Scientific, Inc. recommends that the incubator be connected to a
separate electrical circuit.
3.9 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.
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.
Do not plug this vent. A plugged vent will damage the
water jacket chamber.
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.
Remove the protective metal cover from the drain fitting and valve and make sure
the valve is closed (turned to the horizontal position). Refer to Figure 3-3 for drain
and drain valve location.
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 3-2 and Figure 3-4 for component locations.

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-6
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
Remove the adjusting screwdriver from the front of the control panel by pulling out
the black knob beneath the Sample Port. The black knob is the handle of the
adjusting screwdriver. Refer to Figure 4-2.
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 3.13)
Electric Power and Temperature Control Module
Figure 3-2

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-7
Press the CO2SET/SILENCE button and rotate the CO2set screw until the display
reads 00.0. (Refer to Figure 3-6 for locations of the SET/SILENCE button and set
screw.)
3.10 Filling the Water Jacket
There are two methods of filling the water-jacket.
a. Funnel Fill
b. Tap Fill
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.
a. Funnel Fill
A funnel and vinyl tubing are contained in the accessories bag included with each
incubator.
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 3-3.
Attach the funnel into one end of the 3/8" I.D. vinyl tubing.
Remove the plastic protective cap from the fill fitting.
Attach the free end of the funnel tubing to the fill fitting.
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.

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-8
Add one additional quart (one liter) of distilled water. The incubator is now properly
filled.
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 3-3
Incubator Base with Water Jacket Drain and Valve
b. Tap Fill Method
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.
A high rate of flow and high pressure from the water tap can
cause distortion to the incubator chamber walls.
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 3-3.
Remove the plastic protective cap from the fill fitting.
Connect the 3/8" I.D. vinyl tubing between the fitting and the distilled water tap.
Open the tap until water flows steadily into the water jacket.

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-9
Turn the water off immediately when the ADD WATER alarm light goes out.
Using the funnel, add an additional quart (one liter) of distilled water.
Remove vinyl tubing and reinstall the plastic protective cap.
3.11 Filling the Humidity Reservoir or Pan
Do not use plastic pans for humidification as they will have an unpredictable effect on
humidity and O2/CO2levels in the incubator. Use only the floor of the unit or the
optional stainless steel humidity pan.
Do not use de mineralized or de ionized water in the humidity reservoir or pan unless
it has been boiled immediately prior to use as it may be contaminated with bacteria.
Listed below are two recommended methods of providing elevated humidity in the
chamber.
Note: Frequent door openings will cause humidity loss from the chamber. Recovery time will
also be affected.
1. Reservoir
The reservoir in the bottom of the incubator may be filled with at least 3/4" of sterile
distilled (50K ohm to 1 Meg ohm) water.
2. Humidity Pan
The optional humidity pan (Forma Stock #237001) will hold about 6 quarts (5.8 liters)
of sterile distilled (50K ohm to 1 Meg ohm) water. Note: This pan may be autoclaved.
The best humidity and temperature response from the humidity pan is obtained when the
pan is placed directly on the incubator floor.
The water level in the humidity reservoir should be checked frequently. If a
disinfectant has been added to the water in the reservoir, it should be changed once a
week to help prevent microbial contamination. If a disinfectant has not been added to the
sterile distilled water, the water should be changed at least twice a week.
It is important that the water level in the reservoir or pan be kept relatively constant
as fluctuations or "dry-outs" will have an adverse effect on the humidity level and CO2
control in the chamber.

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-10
When installing the humidity pan, exercise care to
avoid tearing the inner door gasket.
3.12 Setting the Chamber Temperature (Refer to Figure 3-4)
Before the initial temperature setting is made, push in on the PUSH TO SET button on
the Alarm Monitor Module. Using the screwdriver on the control panel, turn the
OVERTEMP set screw until the display shows a temperature that is two to three degrees
above the desired operating setpoint. The overtemp safety may be reset after the chamber
temperature has stabilized at setpoint.
If a chamber temperature of 37°C is desired, set the Variable/37°C switch on the
Temperature Control panel to the 37°C (up) position. (Figure 3-2.)
If a value other than 37°C is desired, set the switch to the Variable position (down),
and set the temperature control knob to the desired setpoint. Any temperature between
5°C above ambient to 50°C may be selected.
3.13 Setting the Overtemp Safety Thermostat (See Figure 3-4)
Once the chamber temperature has stabilized (as indicated by the digital display), the
Over Temp Safety should be set as follows:
Push the SET/SILENCE button on the Alarm Monitor Module.
Using the screwdriver mounted on the control panel, turn the OVER TEMP set
screw until the desired over temp alarm point is shown on the digital display. The
over temp setpoint can be set within 0.1° of the operating setpoint, but it is
recommended that it not be set within 0.5 of setpoint.
Note: The Over Temp Safety should be checked quarterly to insure proper operation. To
check the over temp control, push the SET/SILENCE button on the Alarm Monitor
Module and turn the Set screw counterclockwise until the over temp safety light is lit.
Reset the Over Temp Safety after the test.

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-11
Temperature and Alarm Monitor Module
Figure 3-4

Forma Scientific, Inc.__________________________________________Installation/Start-up
3-12
Figure 3-5
Rear view of control panel,
Using the gas guard
1
3.14 Connecting the Optional Gas
Guard (Refer to Figure 3-5)
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 on the back of
the incubator. 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 nuisance alarms.
Pressure higher than 15 PSI will damage the
CO2control system.
Securely attach the gas lines from the
supply tank to the barbed fittings located on
the back of the unit. The fittings are labeled.
Check the connections for leaks.