SRI27 SRI27-2 BOD INCUBATORS
BOD INCUBATORS SRI27 SRI27-2 Previously designated LI27 LI27-2 Installation and Operations Manual REV 04/2014 4861651 Sheldon Manufacturing Inc. P.O. Box 627 Cornelius, Oregon 97113 EMAIL: tech@Shellab.com INTERNET: http://www.Shellab.com/~Shellab 1-800-322-4897 (503) 640-3000 FAX (503) 640-1366 TABLE OF CONTENTS SECTION 1.0 RECEIVING AND INSPECTION SECTION 2.0 INSTALLATION SECTION 3.0 GRAPHIC SYMBOLS SECTION 4.0 CONTROLS OVERVIEW SECTION 5.0 OPERATION SECTION 6.0 MAINTENANCE SECTION 7.0 TROUBLESHOOTING SECTION 8.0 PARTS LIST UNIT SPECIFICATIONS SCHEMATICS These units are general purpose Biochemical Oxygen Demand (BOD) incubators for professional, industrial or educational use where the preparation or testing of materials is done at approximately atmospheric pressure and no flammable, volatile or combustible materials are being heated. These units are not intended for hazardous or household locations or use. 2 1 Section RECEIVING AND INSPECTION Your satisfaction and safety require a complete understanding of this unit. Read the instructions thoroughly and be sure all operators are given adequate training before attempting to put the unit in service. NOTE: This equipment must be used only for its intended application; any alterations or modifications will void your warranty. 1.1 Inspection: The carrier, when accepting shipment, also accepts responsibility for safe delivery and is liable for loss or damage. On delivery, inspect for visible exterior damage, note and describe on the freight bill any damage found and enter your claim on the form supplied by the carrier. 1.2 Inspect for concealed loss or damage on the unit itself, both interior and exterior. If necessary, the carrier will arrange for official inspection to substantiate your claim. 1.3 Return Shipment: Save the shipping crate until you are sure all is well. If for any reason you must return the unit, first contact your Customer Service representative for authorization. Supply data plate information including model number and serial number. For information on where to contact Customer Service, please see the manual cover. 1.4 Accessories: Verify that all of the equipment indicated on the packing slip is included with the unit. Carefully inspect all packaging before discarding. The unit is supplied with six (6) shelves, one (1) Condensate Pan (with bracket), and four (4) casters. WARNING: Never use this unit for the growth, cultivation, incubation or storage of fruit flies (drosophila melanogaster). This unit is not designed for use with fruit flies. Improper use of this unit, including use with fruit flies, will void any warranty. Other units are specifically manufactured for fruit fly application, and you should consult your dealer or the manufacturer in order to identify another model suitable for your application. 3 2 Section INSTALLATION This unit should remain upright for 24 hours prior to operating to allow the oil in the refrigeration compressor to settle. Local city, county or other ordinances may govern the use of this equipment. If you have any questions about local requirements please contact the appropriate local agency. Installation may be performed by the end user. Under normal circumstances this unit is intended for use indoors, at room temperatures between 10 and 32C, at no greater than 75% Relative Humidity ( at 25C ) and with a supply voltage that does not vary by more than 10%. Customer Service should be contacted for operating conditions outside of these limits. 2.1 Power Source: Before connecting the unit to the power source, the electrical supply circuit must conform to all national and local electrical codes. The power source must match the cycle and ampere requirements as noted on the data plate located on the side of the incubator. This unit is intended for 50/60 HZ application. VOLTAGE SHOULD NOT VARY BY MORE THAN 10% FROM THE DATA PLATE RATING. A separate circuit is recommended to prevent possible loss of product due to the overloading or failure of other equipment on the same circuit. 2.2 Location: When selecting a site for the incubator, consider all conditions that may affect performance, such as extreme heat from radiators, stoves, ovens, autoclaves, etc. Avoid direct sun, fast moving air currents, heating and cooling ducts, and high traffic areas. To ensure air circulation around the unit, allow a minimum of 20cm (8”) between incubator and any walls or partitions that may obstruct free airflow. Allow a minimum of 30cm (12”) for top clearance of the unit. 2.3 Lifting and Handling: These units are heavy and care should be taken to use appropriate lifting devices that are sufficiently rated for these loads. Units should only be lifted from their bottom surfaces. Doors, handles and knobs are not adequate for lifting or stabilization. The unit should be completely restrained from tipping during lifting or transport. All moving parts, such as shelves and trays should be removed and doors need to be positively locked in the closed position during transfer to prevent shifting and damage. 2.4 Leveling: The unit must sit level. If leveling feet are used, turn the feet counter-clockwise to raise the level. If casters are used, repeat the same process. Before moving the unit, both casters and leveling feet must be screwed all the way in to prevent bending and damage. 2.5 Cleaning: The unit chamber should be cleaned and disinfected prior to use. Remove all of the interior parts, if assembled, and clean thoroughly, including all corners using a suitable disinfectant that is appropriate to your application. DO NOT use spray cleaners that might leak through openings and cracks and get on electrical components, or that may contain solvents that will harm coatings. DO NOT use chlorine-based bleaches or abrasives as they will damage metal interior. Regular periodic cleaning is required. Special care should be taken when cleaning around sensing heads to prevent damage. WARNING: Never clean the unit with alcohol or flammable cleaners with the unit connected to the electrical supply. Always disconnect the unit from the electrical service when cleaning and assure all volatile or flammable cleaners are evaporated and dry before reattaching the unit to the power supply. 4 2.6 Installing Condensate Evaporator: This unit is supplied with an electric Condensate Evaporator Pan. On units with casters, install mounting bracket on the back of the unit and slide condensate pan onto the bracket. Then, install the drain tube so water will drain into pan. Plug the supplied power cord into the condensate pan and plug other end into outlet on the control box on top of the unit marked “Vaporizer.” On units without casters, install supplied spring on bottom of condensate pan and set on floor in back of unit. Condensate Evaporator Pan Mounting Bracket Power Cord Units without casters (install springs) Units with Casters (mount bracket) Important Note: When loading shelves with product, allow space between rows of product for proper air circulation and do not load product to block back wall. Leave at least 2” of air space between product and ball wall. 5 3 Section GRAPHIC SYMBOLS Your incubator is provided with a display of graphic symbols on the control panel which are designed to help identify the use and function of the adjustable components. 1. Indicates that you should consult your manual for further description and discussion of a control or user item. 2. Indicates “Temperature” 3. Indicates “Overtemperature” 4. C Indicates “Degrees Centigrade” 5. Indicates “AC Power” 6. Indicates “Manual Adjustment” 7. Indicates “Potential Shock Hazard” behind partition 8. Indicates “Earth Ground” 9. Indicates “Unit should be recycled” (Not disposed of in land-fill) 6 4 Section CONTROLS OVERVIEW 4.1 Power Switch: The main power I/O (on/off) switch controls all power to the unit and must be in the I/ON position before any systems are operational. 4.2 Main Temperature Control: The Main Temperature Control is a Watlow EZ-Zone PM Control. It is a PID Programmable Ramp and Soak with Event Outputs. It consists of an upper and lower display, EZ Button, Advance Button, Infinite Button, and UP and DOWN Arrow Button. This Control is for maintaining a constant process temperature and running a defrost schedule, if desired. We highly recommend that you read the Watlow EZ-Zone PM Manual for detailed information on the control. 4.3 Heating Light: This pilot lamp is ON when the unit is heating up to set point and is blinking when controlling temperature at set point. 4.4 Low Limit Thermostat: Is located in the top of the Control Box behind the Control Panel on the left hand side. It has been factory calibrated to 1°C and should not need any adjustments. 4.5 Defrost: Defrost System is tied in with the Main Temperature Control as an Event Output. To set up a defrost schedule will be explained under the Maintenance Section. 4.6 Overtemperature Thermostat: This controller is marked SET OVERTEMPERATURE and is equipped with an adjustment knob and a graduated dial from 1 to 10. Completely independent of the Main Temperature Controller, the Overtemperature Thermostat guards against any failure of the Main Temperature Controller which would allow temperature to rise past set point. If temperature rises to the Overtemperature set point, the Thermostat takes control of the heating element and allows continued use of the incubator until the problem can be resolved, or service can be arranged. It is not recommended that the unit be allowed to operate for an extended period of time using only the Thermostat as temperature uniformity will suffer. 4.7 Over Temp Light: This pilot light comes on when the Overtemperature Thermostat has been activated. Under normal operating conditions this light should never come on. 4.8 Circuit Breaker: Located in the back of the Control Box behind the Control Panel on the left side. Circuit Breaker protects against short circuits within the unit. If Circuit Breaker is tripped, the unit will shut down. Before resetting Circuit Breaker, the cause should be determined and corrected. 7 5 Section OPERATION The refrigeration system, heater, and air circulating fan are used in conjunction with the temperature control circuit to achieve sensitive temperature control. The thermostat sensor located in the air stream senses any temperature deviation from the control point, and heat is provided to maintain desired temperature. The circulating fan provides even air distribution throughout the chamber and assures temperature uniformity. Regardless if the temperature maintained, the compressor operates continuously. This constant operation minimizes component failure which is more frequently associated with a cycle type operation. Note that a factory set Low-Limit Thermostat will shut off the compressor when temperatures reach 1C. 5.1 The power supply must match the unit’s requirements listed on the data plate located on the side of the incubator. 5.2 Plug the service cord into the power supply and turn the Power Switch to the ON position. Turn the Overtemperature Thermostat to its maximum position, clockwise using a coin or flat edged tool. 5.3 Place a certified reference thermometer (not supplied) in the center of the chamber. Be certain the thermostat is not touching any shelving or chamber walls. Taping the thermometer to a petri dish raises it off the shelf and keeps the scale in view. Placing the reference thermometer in the chamber at this stage of operation will allow for calibrating the control with out the loss of processing time. 5.4 Loading Procedure: Adequate spacing should be allowed between items whenever possible. Proper spacing will allow maximum air circulation, which is necessary for temperature uniformity. 5.5 Set Main Temperature: The Temperature control has two (2) displays (Upper and Lower). The Upper display is the Process Temperature and the Bottom Display is the Process Set Point. To change Set Point, push UP Arrow to raise or push DOWN Arrow to lower Process Set Point. After desired Process Set Point is reached, allow 24 hours for unit to stabilize. 5.6 Calibrating Main Temperature Control: It is recommended that calibration is done once the unit is installed in its working environment. Once unit has been stable for several hours, compare process display with reference thermometer. After comparing the two figures out the calibration offset by subtracting the reference thermometer reading to the display reading. If the reference is greater than the display, it will be a positive number. If the reference is smaller than the display, it will be a negative number. EXAMPLE: REFERENCE THERMOMETER 22°C 18°C PROCESS DISPLAY 20°C 20°C OFFSET CAL 2 -2 Once the Offset Calibration Number is established, it can then be entered into the control. To enter into the control, push and hold both UP and DOWN Arrow Button simultaneously for three (3) seconds or until A1 appears in the Upper Display and Oper appears in the Lower Display. Then, push the Advance Key repeatedly unit I.CA appears in the Bottom Display and a number value in the Upper Display. This number 8 value can be changed by using the UP or DOWN Arrow Buttons. Change the number value to the Offset Calibration Number established earlier. If it is a negative number, you subtract. If it is a positive number, you add. Once the Offset Calibration Number is entered, push the Infinite Button repeatedly to exit to Home Page. (Process Temperature Display Top and Set Point Display Bottom.) 5.7 Set Overtemperture Thermostat: The Overtemperature Thermostat should be initially set to its maximum position to allow the unit to stabilize. Once the temperature is stabile at the desired set point, turn the Thermostat counterclockwise until the OVER TEMP light turns on. Next turn the Thermostat clockwise just until the pilot lamp turns off. This will set the Overtemperature set point at approximately 1C above the Main Temperature set point. 5.8 Low Temperature Control: This control is factory set and should NOT be adjusted. It is pre-set at 1C and is an added feature that keeps samples from freezing. 5.9 High Temperature Control: This control is a Bimetallic Thermostat that is rated at 50C and is not settable. 5.10 Accessory Outlet: There is an electrical outlet inside the chamber for use with equipment not exceeding one (1) amp. Note that equipment in the chamber may provide additional heat that could affect the temperature range of the incubator. It is recommended that testing be done with the incubator and any additional equipment to insure that the desired operating conditions can be met. CAUTION: When operating at normal conditions, this incubator is capable of damaging certain accessory equipment. Make certain that accessory equipment is capable of operating under the conditions you intend to run your incubator. 5.11 Auto Tuning: Automatically changes PID Parameters to make the control run more stable at Set Point. To execute an Auto Tune, push the Advance Button repeatedly until AUtI appears in the Bottom Display and no in the Top. Change no to yES by pushing the UP or DOWN Arrow Button and push the Infinite Button once to Return to Home Page is reached. The control will start flashing AttN in the Bottom display and tUnI in the Top Display. When it stops flashing, Auto Tuning is complete. 9 6 Section MAINTENANCE The design of the chamber is such that periodic maintenance is kept to a minimum. NO lubrication or adjustments of components is needed. If the incubator is used frequently at temperatures below ambient room temperature or in any manner that increases moisture build-up within the chamber, a frequent defrosting schedule is recommended. 6.1 Defrosting: Frost can build up on the evaporator coils do to too much moisture entering the chamber. The unit should be defrosted and cleaned on a regular basis. There are two (2) methods to defrost: Manual and Running. A defrost schedule program can be programmed into the control. 6.1.1 Manual Defrost: This process will need to be done at a time when the incubator will not be in use for several hours. Push both UP and DOWN Arrows simultaneously for three (3) seconds or until AI appears in the Top Display and OPEr in the Bottom Display. Push the UP and DOWN Arrow until P.StA appears in the Top Display. Now push the Advance Button repeatedly until Ent 1 appears in the Bottom Display and OFF in the Top Display. Use the UP and DOWN Arrow Button to change OFF to ON and push the Infinite Button repeatedly to return to Home Page. After returning to Home Page, a small number “2” should be illuminated on the right side of the control. This represents that EVENT OUTPUT 1 is active and the compressor is now shut off (no cooling). Turn the Process Set Point up to 40°C and leave the door ajar about 3-4 inches and run for several hours. After all the ice is melted and water evaporated, close the door and reset Process Set Point to the desired Set Point. Repeat the same process as above to turn the EntI to the OFF state. After returning to Home Page, the number “2” light should be off making EVENT OUTPUT 1 inactive (compressor running). Allow unit to stabilize and then it will be ready to use. 6.1.2 Defrost Scheduled Program: A Defrost Schedule Program can be set up through the Main Temperature Control. The Control is set up at the factory to run an eleven (11) hour fifty (50) minute compressor run time and a ten (10) minute compressor off time. When running the program, the compressor will shut down for ten (10) minutes and cause a temperature spike to occur inside the chamber for approximately thirty (30) minutes. Depending on what the process Set Point dictates how drastic of a temperature spike occurs. At 20°C, it will be a 2°C temperature rise. If these temperature spikes are unacceptable, then use the Manual Defrost Method. To start the program, first enter the desired Process Set Point. Then, push the EZ Button. A small RAMP Symbol will illuminate on the right hand side of the control to indicate the program is running. To stop the program, push the EZ Button again and the Ramp Symbol will disappear and the program will stop. Do not stop the program while it is in the defrost mode. The defrost mode is indicated by the Number “2” illuminated on the right hand side of the control. Stopping the program while in this condition will make the control stay in this condition (compressor not running). If program was stopped while in the Defrost Cycle, go to the Manual Defrost Section to reset the EVENT OUTPUT 1 (Ent 1) to the OFF position. (compressor running) 10 6.1.3 Changing Defrost Schedule Times: The Defrost Schedule comes from the factory set for eleven (11) hours, fifty (50) minutes compressor run time and ten (10) minutes off time. These times can be altered to best fit your process. Keep in mind that the longer the compressor run time, the longer compressor off time need to be and the greater the temperature spike will occur. Do not set the Compressor Off Time Cycle less than five (5) minutes because it could damage the compressor by trying to start before the pressure can equalize in the refrigeration system. To change the time, push and hold the Advance Button for three (3) seconds (or until P1 appears in the Top Display and Prof in the Bottom Display). Push Advance Button again and P1 will appear in the Bottom Display and “1” in the Top Display. (P1 and 1 represent STEP 1 in PROFILE 1.) Push the advance Button again and SoAh will appear in the Top Display and StyP in Bottom Display. (Represents Soaking Set Point.) Push Advance Button again and hoUr will appear in the Bottom Display. This is where the amount of hours is entered for Compressor Run Time. Enter the amount of hours that is desired by pressing the UP and DOWN Arrow Button and then push the Advance Button. Min will appear in the Bottom Display. Enter the amount of minutes desired by pressing the UP and DOWN Arrow Button and push the Advance Button. SEC will appear in the Bottom Display. Enter the amount of seconds desired by pressing the UP and DOWN Arrow Button and then push the Infinite Button. (P1 will appear in the Bottom Display and 1 in the Top Display.) Use the Up Arrow Button and change the 1 to 2. Push the Advance Button and SoAh will appear in the Top Display and StyP in the Bottom Display. Push the Advance Button again and hoUr will appear in the Bottom Display. (This is where the Compressor Off Time is selected.) Repeat the process from above to set the Compressor Off Time and then push the Infinite Button repeatedly to get back to Home Page. To start program, push the EZ Button. The Watlow EZ Zone PM Control is capable of numerous individual types of profiles. Refer to Watlow EZ-Zone PM Manual for further detailed information or call Tech Support on the front cover. 6.2 Cleaning: Clean the incubator with a mild soap and water solution, rinse clean with water and wipe dry with a soft cloth. 6.3 Disinfecting: Disinfect the incubator on a regular basis. Remove all of the interior parts and clean thoroughly, including all corners using a suitable disinfectant that is appropriate for your application. DO NOT use spray cleaners that might leak through openings and cracks and get on electrical components, or that may contain solvents that will harm the coatings. DO NOT use abrasives of any kind as they will damage the interior. Special care should be taken when cleaning around sensing heads to prevent damage and around the door gasket so as not to impair the positive seal. WARNING: Never clean the unit with alcohol or flammable cleaners with the unit connected to the electrical supply. Always disconnect the unit from the electrical service when cleaning and assure all volatile or flammable cleaners are evaporated and dry before reattaching the unit to the power supply 6.4 Compressor Compartment: Located on top of unit behind the Control Panel. The Condensing Unit should be cleaned every six (6) months to ensure proper refrigeration efficiency. Power should be disconnected when performing this procedure. 6.5 Electrical Components: There is no maintenance to electrical components. If the unit fails to operate correctly, refer to Troubleshooting Section or call Tech Support on front cover. 11 7 Section TROUBLESHOOTING When troubleshooting, always make a visual inspection of the incubator and control console to find loose or disconnected wires which may be source of the trouble. In the event the incubator does not operate properly, check the following before calling for service. PROBLEM Temperature Higher Than Set Point POSSIBLE CAUSE POSSIBLE SOLUTION 1. Unit in Defrost Mode. 1. Set to Normal Operating Mode (see Manual Defrost) 2. Compressor Not Running. 2. Check #1, then check if compressor is plugged into Control Box. 3. Unit Iced Up. 3. Perform a Manual Defrost Procedure. Temperature Lower Than Set Point 1. Over Temperature Set Too Low. 1. Set Over Temperature Thermostat Temperature Unstable 1. Unit Iced Up 1. Perform a Manual Defrost Procedure. 2. Blockage of Airflow. 2. Allow Air Space In and Around Load. 3. Erratic Changes in Ambient Conditions 3. Make Sure Unit is Not Near Heat Vents or Air Conditioning Vents. 1. Faulty Power Source 1. Check Power Source. 2. Tripped Circuit Breaker 2. Turn Power Off and Reset Circuit Breaker. If it Trips Again, Call Tech Support (on front cover). Unit Will Not Turn On Service If none of the suggestions listed above in the Troubleshooting guide have solved the problem Customer Service should be contacted for assistance. Call 1-800-322-4897, and have the model number, serial number and voltage (listed on the date plate on the side of the incubator) as your service representative will require it. 12 8 Section PARTS LIST Description SRI27 (LI27) 115V SRI27-2 (LI27-2) 220V BOD Defrost Heater Tubular Casters 4” w/break Circuit Breaker Condensate Vaporizer 115V Control Thermostat CPR 80°C Control Watlow PM EZ-Zone Convenience Outlet Defrost Relay Evap Coil Assy Complete TXV I/O (on/off) Switch Limit Disc Pilot Light, Green Pilot Light, Red Probe RTD Shelf 29 3/8” x 24 ¾” Shelf Clip Solid State Relay Transformer 2350576 9900627 1100500 9900622 1750862 1750833 6100525 7030536 9900609 7850532 1750834 4650554 4650553 6600520 9900624 9900625 7030533 N/A 2350576 9900627 1100500 9900622 1750862 1750833 6100531 7030536 9900609 7850532 1750834 4650554 4650553 6600520 9900624 9900625 7030533 8350521 13 UNIT SPECIFICATIONS All Models Shipping Weight 480 lbs 217.72 k Net Weight 296 lbs 134.26 k Exterior WxDxH (in) Dimensions 37 x 41 x 78 37 x 41 x 83 (w/casters) Exterior WxDxH (cm) Dimensions 93.98 x 104.14 x 198.12 93.98 x 104.14 x 210.82 (w/casters) Interior WxDxH (in) Dimensions Interior WxDxH (cm) Dimensions 30 x 29 x 54 76.20 x 73.66 x 137.16 Capacity 27 cubic feet .76 cubic meters Capacity 540 bottles Temperature Range 0C to 45C Temperature Uniformity +1.0C at 20C 14 Wire Diagram SRI27 (LI27) 120 Volt (9851087) BL K WHT CIRCUIT BREAKER 15A LIGHTED POWER SWITCH BL K WHT INTERIO R FANS BL K WHT BL K COMPRESSOR LOW LIMIT BL K WHT INTERIO R OUTLET R1 5 BL K 1 9 YE L WHT RELAY COMPRESSOR OUTLET BL K CONDENSATE PAN OUTLET JUMO OTP BL K OTP RED BL K 1 4 RED 2 1 2 50°C LIMIT ORN 3+ WHT HEATING GREEN WHT 4HEATER ELEMENTS BL K 22G BLK 22G RED BL K X1 L3 W1 X3 98 99 Y1 J3 CF WHT L2 L4 CD K2 K4 CE T1 T2 B5 9851087 S1 S2 D6 5/13/09 dlr rev 6/4/09 dlr rev 9/12/11rmh R1 R2 D5 WATLOW PM WHT RTD 13 BLU 14 R1 RELA Y COIL 15 SRI27-2 (LI27-2) 230 Volt (9851174) BL K WHT CIRCUIT BREAKER 15A LIGHTED POWER SWITCH BL K WHT BL K WHT BL K WHT INTERIO R FANS BL K COMPRESSOR LOW LIMIT BL K WHT R1 5 BL K 1 9 YE L WHT RELAY COMPRESSOR OUTLET BL K CONDENSATE PAN OUTLET JUMO OTP BL K OTP RED BL K 1 4 RED 2 1 2 50°C LIMIT ORN 3+ WHT HEATING GREEN WHT 4HEATER ELEMENT BL K 22G BLK 22G RED BL K 9851174 Rev a 9/12/11 rmh X1 L3 W1 X3 98 99 Y1 J3 CF WHT L2 L4 CD K2 K4 CE T1 T2 B5 S1 S2 D6 R1 R2 D5 WATLOW PM WHT RTD 13 BLU 14 R1 RELA Y COIL 16
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