Cole Parmer 05012-20 Installation And Operational Manual

HORIZONTAL AIR FLOW

OVEN

MODEL: 05012-20, 05012-30

05012-40

INSTALLATION AND OPERATIONAL MANUAL

COLE-PARMER INSTRUMENT COMPANY_____________________________________________________________________

625 East Bunker Court, Vernon Hills, IL 60061 (847) 549-7600

•

FAX (847) 549-7676

SECTION 1.0

SECTION 2.0

SECTION 3.0

SECTION 4.0

SECTION 5.0

SECTION 6.0

SECTION 7.0

SECTION 8.0

SECTION 9.0

SECTION 10.0

TABLE OF CONTENTS

RECEIVING AND INSPECTION

GRAPHIC SYMBOLS

INSTALLATION

CONTROL OVERVIEW

PRECAUTIONS

CLEAN ROOM READY

INSTRUCTIONS, 05012-30,05012-40

OPERATION

MAINTENANCE

TROUBLESHOOTING

PARTS LIST

UNIT SPECIFICATIONS

SCHEMATICS

REV. 5/99

4861302

These units are 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.

Section

RECEIVING AND INSPECTION

1

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.

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.

any reason you must return the unit, first contact your customer representative for authorization. Supply nameplate data, including model number and serial number. Please see the manual cover for information on where to contact customer service.

1.4

Accessories: Verify that all of the equipment indicated on the packing slip is included with the unit. Carefully check all packaging before discarding. These units are equipped with 2 shelves, 8 shelf clips, and 4 leveling feet.

2.2

2.3

2.4

2.5

2.6

2.7

2.1

Section

2

GRAPHIC SYMBOLS

Your oven has been provided with a display of graphic symbols which should help in identifying the use and function of the available user adjustable components.

This symbol indicates that you should consult your manual for further description or discussion of a control or user item.

Indicates ÒAC PowerÓ

Indicates ÒManual ControlÓ

Indicates ÒTemperatureÓ

Indicates ÒOver Temperature SafetyÓ

Indicates ÒGroundÓ

Indicates ÒPotential Shock HazardÓ

Section

3

INSTALLATION

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 5

°

and 40

°

C, at no greater than 80% Relative Humidity (at 25

°

C) 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.

3.1

Power Source: The electrical supply circuit to the incubator must conform to all national and local electrical codes. Consult the incubatorÕs serial data plate for the voltage and ampere requirements before making connection. VOLTAGE

SHOULD NOT VARY MORE THAN 10% FROM THE DATA PLATE RATING.

This unit is intended for 50/60 Hz application. A separate circuit is recommended to prevent possible loss of product due to overloading or failure of other equipment on the same circuit. For installation of the units, the cord must be plugged directly into a grounded outlet, without the use of an extension cord.

3. 2 Lo ca tio n: In pe orm er all cond ion minimum of 5cm bet we en the unit an d walls or pa rtitions wh ich migh t obstru ct fr ee air flo w.

/ Ha dl g: T he se un it s are

lift d fr bot to m sur aces. Do a de qu at e for lift in g or sta bilizat io n . Th e unit sho uld be co m plet ely rest ra in ed fr om sho uld be re m oved an d do o rs nee d to be po sit ively locke d in the clo sed po sition d ur in g tra nsf er t o pre ve n t sh if t in g and d am a ge .

el T insta lle d an d the un it st an ding up rig ht , ea ch fo o t ca n be ra ise d by tu rn ing it in a cou nt er clo ckwise dir ectio n. Ad just the foo t at each co r ne r unt il th e un it st an d s level an d so lid wit h ou t rocking . If th e un it mu st be mo ve d, tu rn th e le velin g fee t all t he way clockwise t o p re ven t da m ag e while m o ving .

tme Whe n re m ovin g int er ior it em s fo r cle a ning or any ot he r rea so n , n ot e th a t yo u must, first rem ove the line r bot to m inser t bef o re rem o ving line r sid e inser ts. Th is re qu ire s a 8 /3 2 nut d r iver t o r em o ve t he ca p nut s. an : The un it ch am be r sho uld be cle an ed an d disin fe cte d pr ior to use .

Rem ove all of the in te rio r pa rt s, if asse mb led , and cle a n th o ro ug hly, in clu ding all cor ne rs usin a suit disinf ct t is ap ro

Reg ular pe rio dic cle an in g is re q uire d . Spe cia l car e sh o uld be ta ke n whe n cle an ing ma DO NOT USE chlorine-based bleaches or abrasive cleaners as this will damage the stainless steel interior. DO

NOT USE spray cleaners that might leak through openings and cracks and get on electrical parts or that may contain solvents that will harm the coatings. F or

M od els 050 12 - 30 a nd 05 01 2 -4 0 se e Sectio n 6 fo r f ur t he r in str uct io n.

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.

3 .7 Pla ce sh elve s in th e cha m be r as de sir ed .

Section

CONTROL PANEL OVERVIEW

4

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

High Limit Thermostat: This control is marked HIGH LIMIT and is equipped with an adjustable knob and a graduated dial from 0-10. It is independent of the

Main Controller and guards against any failure which would allow the temperature to rise past the Main Controllers set point. This allows continued operation of the oven until the problem can be corrected or service can be arranged. It is not recommended that the unit be operated for extended periods of time using only the Overtemperature Safety as the controller as temperature uniformity will suffer.

4.3

High Limit Activated: This pilot lamp will come on when the High Limit

Thermostat is activated and taken control of the heating element. Under normal operating conditions this pilot lamp should never be on.

4.4 Main Temperature Controller: This is a microprocessor based temperature /

Time Control with ramp and soak capabilities ( Watlow model 981 ).

4.5

Fuse: Located at the back of the unit next to the power cord, the fuse provides protection for the units electrical circuitry against power fluctuations. When blown, the fuses must be replaced before the unit can continue operation.

4.6

Power Exhaust Outlet: Located at the back of the unit next to the power cord, for easy installation of a power exhaust accessory. The 05012-30 does not come equipped with this feature.

Figure One

Section

5

PRECAUTIONS

5.1

This unit has been designed with vents from the chamber. In order to work effectively and safely, some precautions will need to be taken by the operator.

a.

In most applications, the exhaust damper will need to be open during drying or degassing for best results.

b. THIS OVEN IS NOT DESIGNED TO HANDLE COMBUSTIBLE GASSES,

AND IS NOT AN EXPLOSION PROOF OVEN. DO NOT PLACE

EXPLOSIVE, COMBUSTIBLE OR FLAMMABLE MATERIALS INTO THE

CHAMBER.

c.

Some of the out gassed byproducts may be hazardous or unpleasant to operating personnel. If this is the case, the exhaust should be positively ventilated to the outside and dealt with according to local regulations.

Contact your dealer about power exhausts.

5.2

Do not operate near noxious fumes.

5.3

Do not place sealed or filled containers in the oven chamber.

5.4

Do not cut or remove the ground prong from the power cord.

5.5

Do not use a 2-prong adapter plug.

5.6

Be sure that the power supply is as the same voltage as specified.

5.7

Disconnect the unit from its electrical source before proceeding to make any electrical repairs or replacement.

5.8

If a mercury thermometer is used and breakage should occur, all spilled mercury

MUST be completely removed from the chamber before continuing operation.

5.9

This oven is NOT designed for the use in Class I, II, or III locations as defined by the National electric Code.

5.10

This oven is not intended, nor can it be used, as a patient connected device.

Section

6

CLEAN ROOM READY INSTRUCTIONS

The 05012-30 and 05012-40 have been designed to operate at class 100 standards. It is not shipped clean room ready and the instructions below must be followed for proper installation. See Figures Two and Three.

6.1

BURN-IN OF THE HEPA FILTER

Before using this oven, it is important that the filter be Òburnt-inÓ properly. During burn-in, the Hepa filter will off gas. Because of this, the intake and exhaust port must be open with the exhaust port being ducted outside. A material safety data sheet is included with your operation literature for reference.

A. To burn in filter:

1.

Set oven at: 175

°

C for 1 hour;

220

°

C for 4 hours;

225

°

C for 1 hour;

250

° c for 1 hour.

2.

If operating temperature is higher than 250

°

C, continue the cycle of one (1) hour at 25

°

increments until the operating temperature is achieved.

B.

After burn-in, the interior must be disassembled and cleaned. Make sure unit is unplugged before disassembly. This requires an 8/32 nut driver to remove the cap nuts. Remove the bottom liner insert before removing the liner side inserts.

6.2

CONTROL AREA EXHAUST

As part of this design the control compartment is sealed and requires a minimum of 30 C.F.M. (Cubic Feet Per Minute) to be drawn from the control compartment exhaust port. This is required to limit control compartment temperature and maintain Class 100 integrity. If you are unable to exhaust the minimum 30

C.F.M. from the control compartment, then you must limit the maximum operating temperature to 280

°

C. Operation of the unit above 280

°

C, without required 30

C.F.M. control compartment exhaust will result in control degradation and

process failure. Not supplying the required 30 C.F.M. may also keep the unit from operating at class 100 specifications by allowing particulars from the control compartment to escape into the room.

Figure Two

05012-40 Intake/Exhaust

Figure 3

05012-30 Intake/Exhaust

Section

7

OPERATION

7.1

Power Supply: As mentioned is Section 3.1, be certain the power source matches the requirements listed on the data plate.

7.2

Turn the power switch to the I/ON position and turn the High Limit Thermostat to its maximum position, clockwise. This allows the setting of the Main

Temperature without interference of the High Limit..

7.3 Set Main Temperature Controller: This is explained in full detail in the enclosed

Watlow 982 users manual. A simplified 981 instruction sheet is included with the manual for your convenience. Please refer to the users manual and instruction sheet for operation and maintenance details.

7.4

Set High Limit Thermostat: Prior to setting the High Limit Control be certain the

Main Temperature Control has reached the input set point and has remained stable for several hours. This will insure that the High Limit is set at the proper temperature. As mentioned in step 7.2, the High Limit should be at maximum position. Now turn the Thermostat counterclockwise until the High Limit

Activated indicator light comes on. Next, turn the Thermostat clockwise just until the light turns off. Then turn the Thermostat two (2) of the smallest divisions on its scale past the point where the indicator light went out. The High Limit should now be set approximately 10

°

higher than the Main Temperature Controller.

Please note that the High Limit is a safety feature only. If the unit is allowed to operate using only the High Limit Thermostat, the temperature stability will suffer.

7.5

Power Exhaust Outlet: The power exhaust outlet is controlled by the Main temperature Controller. This is described in paragraphs 2 and 3 on the back page of the 981 simplified instructions and in the Watlow 982 users Manual. The

05012-30 does not come equipped with this feature.

Section

8

MAINTENANCE

Note: Disconnect the power cord from the power source before performing any service or maintenance on this unit.

basis. Use a disinfectant that is suitable for your application. DO NOT USE chlorine based bleaches or abrasive cleaners as this will damage the stainless steel interior. DO NOT USE spray cleaners that might leak through openings and cracks and get on electrical parts or that may contain solvents that will harm the coatings.

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.

8.2

Use care when cleaning the door gasket to prevent damage which could impair the positive door seal.

8.3

Storage: To prepare the unit for storage, remove all shelves and shelf clips. Be certain that the door is positively locked in the closed position. See Section 3.3,

Lifting/Handling, for proper transport procedures.

8.4

No maintenance is required on the electrical components. If the unit fails to operate as specified, please see the Troubleshooting guide, Section 9.0 before calling for service.

Section

TROUBLESHOOTING & SERVICE

9

FOR PERSONAL SAFETY, ALWAYS DISCONNECT THE POWER BEFORE

SERVICING. If the unit fails to operate as specified, review the following troubleshooting suggestions prior to calling customer service.

TEMPERATURE

Temp-

1

Temperature too high

1/ controller set too high-see your Watlow users manual

2/ controller failed on Ð call Customer Service

3/ wiring error Ð call Customer Service

Temp-

2

Chamber temp spikes over set point and then settles to set point

Temp-

3

Temperature too low

Recalibrate Ð see Watlow users manual

1/ high limit set too low Ð see section 7.4

2/ controller set too low Ð see Watlow users manual

3/ unit not recovered from door opening Ð wait for display to stop changing

4/ unit not recovered from power failure or being turned off Ð ovens will need several hours to warm up and stabilize

5/ element failure Ð call Customer Service

6/ controller failure Ð confirm with front panel lights that controller is calling for heat

7/ high limit failure Ð confirm with front panel lights that High Limit is operating correctly

8/ wiring problem Ð check all functions and compare wiring to owners manual - especially around any areas recently worked on

9/ loose connection Ð check shadow box for loose connections

Temp-

4

Unit will not heat over a temperature that is below set point

Temp-

5

Unit will not heat up at all

1/ confirm that blower motor is moving and that amperage and voltage match data plate Ð check blower motor motion in shadow box and feel for air movement in chamber

2/ confirm that set point is set high enough Ðturn High

Limitcounter clockwise and see if High Limit light comes on

3/ check connections to sensor

4/ check calibration Ð using independent reference thermometer, follow instructions in Watlow users manual

1/check amperage Ð amperage should be virtually at maximum rated (data plate) amperage

2/ do all controller functions work?

3/ is the High Limit set high enough? Ð for diagnostics, should be fully clockwise with the pilot light never on

4/ has the fuse/circuit breaker blown?

Temp-

6

Indicated chamber temperature unstable

1/ ±0.1 may be normal

2/ is blower motor working? Ð remove top panel and verify movement of blower motor in shadow box

3/ is ambient room temperature radically changing Ð either door opening or room airflow from heaters or air conditioning ? Ð stabilize ambient conditions

4/ it may happen if exhaust stack is 100% open or if power exhaust is cycling Ð adjust stack to at least _ closed

5/ sensor miss-located, damaged or wires may be damaged - check mounts for control and High Limit sensors, then trace wires between sensors and controls

6/ calibration sensitivity Ð call Customer Service

7/ high limit set too low Ð be sure that high limit is more than 5 degrees over desired set point; check if high limit pilot is on continuously; turn controller knob completely clockwise to see if problem solved then follow instructions in section 7.4 for correct setting

8/ electrical noise Ð remove nearby sources of RFI including motors, arcing relays or radio transmitters

9/ bad connection on temperature sensor or faulty sensor Ð check connectors for continuity and mechanical soundness while watching display for erratic behavior; check sensor and wiring for mechanical damage

Temp-

7

Temp-

8

Temp-

9

Temp-

10

Will not maintain set point

Display and actual reference thermometer donÕt match

1/ calibration error Ð see Watlow users manual

2/ temperature sensor failure Ð call Customer Service

3/ controller failure Ð call Customer Service

4/ allow at least two hours to stabilize

5/ verify that reference thermometer is certified

Can't adjust set points or calibration

1/ ASSURE THAT SET POINT IS AT LEAST 5

DEGREES OVER AMBIENT ROOM TEMPERATURE

2/ see if ambient is fluctuating

1/ turn entire unit off and on to reset

2/ if repeatedly happens, call Customer Service

Calibrated at one temperature, but not at another

10/ bad connections or faulty solid state relay Ð check connectors for mechanical soundness and look for corrosion around terminals or signs of arcing or other visible deterioration

This can be a normal condition when operating temperature varies widely. For maximum accuracy, calibration should be done at or as close to the set point temperature.

MECHANICAL

Mech-1 Door not sealing

Mech-2 Motor doesn't move

1/ check physical condition of gasket

2/ assure that gasket is in original location

Mech-3 Motor makes noise

1/ if shaft spins freely: check connections to motor and check voltage to motor;

2/ if shaft rubs or is frozen, relieve binding and retest

1/ If noise is from the motor, tap the top of motor shaft with ball peen hammer.

2/ If the sound gets worse, tap the other end of the shaft Ð avoiding touching the blower wheel.

3/ If there is no change, call Customer Service.

OTHER

Other-1 Controller on at all times - "locked-up"

Other-2 Controller timer resets on its own

1/ turn unit off and on to reset

2/ if cannot change any condition on the front panel, call Customer Service

1/ confirm that power from wall is consistent and within specs

2/ call Customer Service with serial number

Other-3 Front panel displays are off

Other-4 Unit or wall fuse/circuit breaker is blown

1/ Check for wire damage.

1/ check wall power source

2/ compare current draw and compare to specs on data plate

3/ see what other loads are on the wall circuit

Other-5 Unit will not turn on

1/ check wall power source

2/ check fuse/circuit breaker on unit or in wall

3/ see if unit is on, e.g., fan or heater, and just controller is off

4/ check all wiring connections, esp. around the on/off switch

Other-6 Unit is smoking Ðout of box

1/Put unit under vent and run at full power for one hour.

2/Models 1601 and 1605 follow special burn in procedures in section 6.0

Other

Ð7

Contamination in chamber

Other-8 Contamination in sample

1/ see cleaning procedure in operatorÕs manual

2/ develop and follow SOP for specific application; include definition of cleaning technique and maintenance schedule

1/ see ÒContamination in chamberÓ

2/ reduce air flow in chamber by dampening down inlet restrictor; be sure to verify adequate temperature uniformity at the reduced air flow

3/ protect open samples from areas of maximum air current, e.g., inlet air ducts

.

If this product should require service, contact your service representative. For information on where to reach customer service please see the front cover of this manual. Should return of the product be necessary, a return authorization number must be obtained and the product shipped, per instructions, to the indicated service center. If a return authorization number is not obtained the product will be returned back to the sender the same day it is received. To insure prompt handling, the return authorization number should be placed on the outside of the package and a detailed explanation of the return enclosed with the item.

PARTS LIST

Description

Adjustable Feet

Blower Motor

Control Relay

Convenience Outlet

Cooling Fan

EMI Filter - CE Complied Models

Fuse, 20 Amp ABC

Heating Element Ð 05012-20, 05012-40

Heating Element Ð 05012-30

Hepa Filter Assembly Ð 05012-30

Hepa Filter Assembly Ð 05012-40

High Limit Controller

High Limit Indicator Pilot Lamp

On/Off Switch

Power Cord

Power Relay

Shelf Clips

Temperature Probe

Watlow 981 Main Temp. Controller

Section

10

Part #

200129

4880512

102162

101483

210001

2800503

101341

120073

200114

X1000577

9990503

1750571

200020

103351

1800509

100064

200137

101827

1750540

UNIT SPECIFICATIONS

Weight

05012-20

05012-30

05012-40

Shipping

315

Call Customer

Service

315

Net

179

135

179

Dimensions

05012-20

05012-30

05012-40

Exterior

WxDxH (in.)

32X30.5X36.5

Interior

WxDxH (in.)

20X19X19

28.5X25.5X29.25

16.5X13.75X15

32X30.5X36.5

17X19X19

Capacity

05012-20

05012-30

05012-40

Cubic Feet

4.17

1.96

3.55

Temperature

05012-20

05012-30

05012-40

Range

Amb. +5-200

°

C

Max 350

°

C

Amb. +5-200

°

C

Max 350

°

C

Amb. +5-200

°

C

Max 350

°

C

Sensitivity

0.1

0.1

0.1

WIRE DIAGRAM