Forma Model 900 and 5900 Series -86C ULT Upright Freezer Operating and Maintenance Manual Rev 11

Preface

Important installer and user information: A redundant temperature sensing device has been included in this ULT freezer. This device is a type “T” thermocouple. For convenient access, the thermocouple (Figure 1-3) terminates in an interconnect jack (Figure 1-5) behind the base front cover. (May be located differently in chests. See Section 1.) It is strongly recommended that this thermocouple be attached to a redundant 24 hour 7 day monitoring system with alarm capabilities. Connecting the sensor to a monitoring and alarm system separate from the freezer provides the utmost in product safety, should the integral system fail. s Models Covered (Painted Interiors)

Models Covered (SS Interiors)

Packing List

Capacity (cu ft)

Voltage

Model

Catalog No.

902

13

230/50

5902

902SS

13

230/50

903

903

13

120/60

5903

903SS

13

120/60

909

909

13

230/60

5909

909SS

13

230/60

904

904

17

120/60

5904

904SS

17

120/60

905

905

17

230/50

5905

905SS

17

230/50

910

910

17

230/60

5910

910SS

17

230/60

906

906

23

230/50

5906

906SS

23

230/50

956

956

23

120/60

5956

956SS

23

120/60

957

957

23

230/60

5957

957SS

23

230/60

907

907

28

230/50

5907

907SS

28

230/50

908

908

28

230/60

5908

908SS

28

230/60

Model

Catalog No.

902

Capacity Voltage (cu ft)

Part No. Description

Quantity

122005

Key

2 (4 for DD)

380520

Neoprene Cap

2

510016

¼-20 x 5-½” Bolt

2

195763

Retaining Clip

1

370563

Remote Alarm Connector

1

Double Door (DD) Units

Double Door (DD) Units 991

991

13

230/50

5991

991SS

13

230/50

992

992

13

120/60

5992

992SS

13

120/60

986

986

13

230/60

5986

986SS

13

230/60

993

993

17

120/60

5993

993SS

17

120/60

994

994

17

230/50

5994

994SS

17

230/50

988

988

17

230/60

5988

988SS

17

230/60

990

990

23

120/60

5990

990SS

23

120/60

995

995

23

230/50

5995

995SS

23

230/50

989

989

23

230/60

5989

989SS

23

230/60

MANUAL NUMBER 7090902 11

40688

7/27/16

Removed key ring from packing list

ccs

10

31230/FR-2880

6/16/16

Enhanced base - expl part dwg - pages 7-9 & 7-10

ccs

9

40497/FR-2843

5/12/16

Updated refrigeration & electrical schematics - Schurter switch

ccs

8

40472/FR-2855

3/9/16

Updated 902 electrical schematic and start relay enclosure drawing - Zettler

ccs

7

40544

12/9/15

BUS information (preventive maintenance and BUS control panel and operation)

ccs

Thermo Scientific

Model 900 and 5900 Series

i

Preface

CAUTION Contains Parts and Assemblies Susceptible to Damage by Electrostatic Discharge (ESD)

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. s

Caution All internal adjustments and maintenance must be performed by qualified service personnel. s

Material in this manual is for information purposes only. The contents and the product it describes are subject to change without notice. Thermo Fisher Scientific makes no representations or warranties with respect to this manual. In no event shall Thermo be held liable for any damages, direct or incidental, arising out of or related to the use of this manual.

The -86C Freezers (see page i for specific list of models) described in this manual are high performance units which can be used for research and in situations that directly support medical applications. When these products are used to support a medical application, it is an accessory to a medical device and is therefore considered as a medical device in its own right by the regulatory body (e.g. FDA). This product is intended for use: • As cold storage in research use. • As a medical device for diagnostic use (storage of samples not intended to be re-introduced to human body). Registration: This medical application is considered a Class I medical device by the FDA. This product is classified as product code – JRM, regulation number 862.2050 and is considered a Class 1 device, 510(K) exempt.

©2014 Thermo Fisher Scientific. All rights reserved.

ii

Model 900 and 5900 Series

Thermo Scientific

Preface

Important operating and/or maintenance instructions. Read the accompanying text carefully.

Potential electrical hazards. Only qualified persons should perform procedures associated with this symbol.

Equipment being maintained or serviced must be turned off and locked off to prevent possible injury.

Extreme temperature hazards, hot or cold. Use special handling equipment or wear special, protective clothing.

WEEE Compliance: Thermo Fisher Scientific has contracted with companies for recycling/disposal in each EU Member State. For further information, send an email to [email protected].

4

Always use the proper protective equipment (clothing, gloves, goggles, etc.)

4 Always dissipate extreme cold or heat and wear protective clothing. 4 Always follow good hygiene practices. 4 Each individual is responsible for his or her own safety.

Thermo Scientific

Model 900 and 5900 Series

iii

Preface

Do You Need Information or Assistance on Thermo Scientific Products? If you do, please contact us 8:00 a.m. to 6:00 p.m. (Eastern Time) at: 1-740-373-4763 1-800-438-4851 1-877-213-8051 http://www.thermofisher.com [email protected] www.unitylabservices.com

Direct Toll Free, U.S. and Canada FAX Internet Worldwide Web Home Page Tech Support Email Address Certified Service Web Page

Our Sales Support staff can provide information on pricing and give you quotations. We can take your order and provide delivery information on major equipment items or make arrangements to have your local sales representative contact you. Our products are listed on the Internet and we can be contacted through our Internet home page. Our Service Support staff can supply technical information about proper setup, operation or troubleshooting of your equipment. We can fill your needs for spare or replacement parts or provide you with on-site service. We can also provide you with a quotation on our Extended Warranty for your Thermo Scientific products. Whatever Thermo Scientific products you need or use, we will be happy to discuss your applications. If you are experiencing technical problems, working together, we will help you locate the problem and, chances are, correct it yourself...over the telephone without a service call. When more extensive service is necessary, we will assist you with direct factory trained technicians or a qualified service organization for on-the-spot repair. If your service need is covered by the warranty, we will arrange for the unit to be repaired at our expense and to your satisfaction. Regardless of your needs, our professional telephone technicians are available to assist you Monday through Friday from 8:00 a.m. to 6:00 p.m. Eastern Time. Please contact us by telephone or fax. If you wish to write, our mailing address is: Thermo Fisher Scientific (Asheville) LLC 401 Millcreek Road, Box 649 Marietta, OH 45750 International customers, please contact your local Thermo Scientific distributor.

iv

Model 900 and 5900 Series

Thermo Scientific

Table of Contents

Thermo Scientific

Section 1

Installation and Start-up...1-1 Control Panel Keys, Displays, Indicators...1-4 Operation of the Keypad...1-5 Install Freezer...1-5 Choose Location...1-5 Install Wall Bumpers...1-6 Install Shelves...1-6 RS-232 Communications...1-6 Remote Alarm Contacts...1-7 Attach Power Cord...1-8 Connect Unit to Electrical Power...1-8 Run Mode...1-8 Freezer Start-Up...1-9 Set Operating Temperature...1-9 Set High Temperature Alarm...1-10 Set Low Temperature Alarm...1-10

Section 2

Calibrate...2-1 Calibrate Control Probe...2-1

Section 3

Alarms...3-1 High Stage System Failure...3-2 Probe Failure Alarm...3-2 Alarm Error Charts...3-3

Section 4

Maintenance...4-1 Clean Cabinet Exterior...4-1 Clean Air Filter...4-1 Clean Condenser...4-1 Clean Water-cooled Condenser...4-2 Prepare Unit for Storage...4-2 Long Term Storage with Water-cooled Condenser...4-3 Defrost Chamber...4-3 Clean Door Gasket...4-4 Vacuum Relief Port...4-4 Check Battery(s)...4-5 Replace Battery(s)...4-5 PREVENTIVE MAINTENANCE...4-6

Model 900 and 5900 Series

v

Table of Contents

vi

Section 5

Factory Installed Options...5-1 Back Up System (BUS)...5-1 Install Vent Stack, Solenoid and Injection Assembly...5-1 Install Temperature Probe...5-3 Connect Probe/Solenoid Harness...5-4 BUS Control Panel...5-5 Configure Optional BUS (Back-Up System)...5-6 Set Optional BUS Set Point...5-6 Test BUS Operation...5-7 Clean Vent Stack...5-7 Disconnect Fitting Asm. and Transfer Hose...5-7 Chart Recorder...5-7 Installing the Chart Paper...5-8 Change Recorder Temperature Range...5-8 Recorder Calibration...5-8 Water-cooled Condenser...5-9 Water Connections...5-11 Five Inner Door Option...5-11

Section 6

Specifications...6-1 Single Door Units...6-1 Double Door Units...6-3

Section 7

Spare Parts...7 - 1

Section 8

Refrigeration Schematics...8 - 1

Section 9

Electrical Schematics...9 - 1

Section 10

Warranty...10 - 1

Appendix

Handling Liquid Nitrogen...A - 1 Handling Liquid CO2...B - 1 First Aid...C - 1

Model 900 and 5900 Series

Thermo Scientific

Section 1 Installation and Start-up

Control Panel

Optional Back Up System Controls Temperature Recorder (Optional)

Figure 1-1. Freezer Front View Components

Thermo Scientific

•

Control panel - keypad, displays and indicators

•

BUS (Optional Back Up System) control panel

•

Optional temperature recorder or datalogger

Model 900 and 5900 Series

1-1

Section 1 Installation and Start-Up

Wall Bumper (pre-tapped holes)

Optional Back-up System Connections RS-232 or RS-485 Interface Power Switch (mains disconnect) Remote Alarm Contacts

Power Inlet

Figure 1-2. Freezer Rear View Components •

Remote alarm contacts

•

Power inlet for power cord connection

•

Optional BUS connections for probe and solenoid

•

RS-232 (default) or RS-485 interface

•

Power switch (mains disconnect)

Shelf Bracket Optional Miscellaneous Accessories Probe Optional - Recorder Probe/Datalogger Probe Sealant (Caution: This is a critical seal. Seal must be maintained.)

Control RTD/Redundant Type T Thermocouple Probe

Figure 1-3. Chamber Probe(s)

1-2

Model 900 and 5900 Series

Thermo Scientific

Section 1 Installation and Start-Up

Vacuum Relief Port

Chamber Probe Cover

Figure 1-4. Vacuum Relief and Probe Cover Location •

Vacuum relief port - pressure equalization port

•

Probe cover - houses control, optional recorder, datalogger, or optional miscellaneous accessory probes

Battery power switch

To remove filter

Thermocouple interconnect jack Battery mounting bracket

O

Freezer battery and optional BUS battery

Figure 1-5. Battery(s) location and switch

Thermo Scientific

•

Battery mounting bracket(s)

•

Battery power switch (freezer and BUS)

•

Freezer battery

•

Optional BUS battery

•

Freezer filter location

Model 900 and 5900 Series

1-3

Section 1 Installation and Start-Up

Control Panel Keys, Displays, Indicators

Temperature Display

Mode Key

Alarm Silence Alarm Indicator Key Panel

Up and Down Arrows

Enter Key

Figure 1-6. Control Panel

1-4

Model 900 and 5900 Series

•

Temperature Display - Displays temperature in degrees Celsius.

•

Mode Select Switch - Used to select Run, Set Temperature, Set High Alarm, Set Low Alarm, Calibrate, Backup.

•

Alarm Indicator - Light pulses on/off during an alarm condition of the cabinet.

•

Silence - Silences the audible alarm. See Section 4 for alarm ringback times.

•

Alarm Panel - indicates the current alarm condition.

•

Up and Down Arrows - Increases or decreases values, toggles between choices.

•

Enter - Stores the value into memory

Thermo Scientific

Section 1 Installation and Start-Up

Operation of the Keypad

The Model 900 and 5900 Series freezer has five basic modes which allow freezer setup and operation. Press the Mode key to scroll through the mode selections. Up Arrow: Increases or toggles the parameter value. Enter: Must press Enter key to save to memory all changed values. Down Arrow: Decreases or toggles the parameter value. Silence Key: Press to silence the audible alarm. See Section 4 for alarm ringback times.

Install Freezer

Note If tipped more than 45°, allow the unit to sit upright for 24 hours before start up. s To remove the freezer from the pallet, use a 1/2" wrench to remove all the bolts securing the shipping bracket to the pallet. Remove the shipping bracket. Remove the ramp boards from the pallet and place the slotted end over the ramp brackets on the pallet. The support blocks on the ramps will be facing down. Before moving the freezer, make sure the casters are unlocked and moving freely. Align the caster with the ramp boards. Use adequate personnel to roll the freezer off the pallet.

Choose Location

The freezer can be easily pushed to the desired approved location, described below. If necessary, the doors and lower front panel may be opened to move the unit through tight openings. When the freezer is in position, set the front caster brakes. Note The freezer must not be moved with the product load inside. s Note For proper ventilation and airflow, a minimum clearance of 5” at the rear and top and a clearance of 8” on the side of the freezer is required. Allow adequate space in the front of the freezer for door opening. s Locate the freezer on a firm, level surface in an area with an ambient temperature between 18°C and 32°C. Provide ample room to reach the mains disconnect switch (power switch) located on the rear of the freezer.

Thermo Scientific

Model 900 and 5900 Series

1-5

Section 1 Installation and Start-Up

Install Wall Bumpers

The parts bag, located inside the cabinet, contains the following parts. Table 1-1. Parts bag Quantity

Stock #

Description

Purpose

2

510016

1/4-20 x 5-1/2” Bolt

Wall Bumper

2

380520

Neoprene Cap

Cap Protector

Install the bolts into the pre-tapped holes on the back of the compressor section. Install a neoprene cap on each bolt. Refer to Figure 1-2 for the locations of the pre-tapped holes.

Install Shelves

Install the shelf clips into the shelf pilasters (front and back) at the desired shelf level. Install the shelves in the cabinet onto the clips. Note Maximum shelf load is 100 lbs (45.4 kg) per shelf. s Note On units having the optional 5 inner door option, refer to the instructions accompanying the inner door kit. s

RS-232 Communications

The Model 900 Series freezer has a data communications interface. The factory default setting is RS-232. The wiring identification for the interface is shown in Figure 1-7. One nine pin, sub "D" style connector is located on the back of the freezer. See Figure 1-2 for the location of the Figure 1-7. RS-232 Interface connector on the freezer. The freezer transmits temperature information every 60 minutes. A standard DB9 serial extension cable can be used to connect the freezer to a serial device. Some serial devices may require a null modem adapter. Data format: Baud...1200 Data bits...8 (7 bit ASCII with leading zero) Start bits...1 Stop bits...2 Parity...none The data transfer sequence is transmitted in the following format. X refers to numerical temperature data. (NUL) (-) XXX (SP) C (SP) (Error Message) (SP) (LF) (CR) (EOT) (SP)

1-6

Model 900 and 5900 Series

Thermo Scientific

Section 1 Installation and Start-Up

RS-232 Communications (continued)

In the event of a CNTRLFAIL, Er07, or the control probe is out of range error, the numerical temperature data (XXX) in the transmission would be replaced by T_ERR. If no alarm condition exists, spaces will be sent. A total of 20 characters will be sent. SP - Space LF - Line feed CR - Carriage return EOT - End of text (4) NUL - Null character (00) If an alarm condition does exist, “Error Message” in the protocol will be replaced by the following: UNDERTEMP (temperature above the low alarm setpoint) OVERTEMP (temperature below the high alarm setpoint) PWRFAIL (AC power failure) CNTRLFAIL (Control probe failure) Er07 (micro failure) HSHX FAIL (Heat exchanger failure) HOT COND (Hot condenser)

Remote Alarm Contacts

IMPORTANT USER INFORMATION CAUTION! Stored product should be protected by a redundant 24 hour/day monitoring system with alarm capability. An interconnect jack and thermocouple are installed for centralized monitoring, should on-board system fail.

See Figure 1-2 for the location of the remote alarm contacts. The remote alarm connector is located in the parts bag provided with the manual. It must be installed if connecting the freezer to an alarm system. After installing the wiring from the alarm system to the connector, install the connector to the freezer microboard and secure with the two screws provided. The remote alarm provides a NO (normally open) output, a NC normally closed) output and COM (common). The contacts will trip on a power outage and high temperature or low temperature alarms. They will also trip on high stage, control probe or microboard failures. Figure 1-8 shows the remote contacts in the alarm state.

Figure 1-8. Remote Alarm Contacts

Thermo Scientific

Model 900 and 5900 Series

1-7

Section 1 Installation and Start-Up

Attach Power Cord

Insert the power cord into the power inlet module. Place the retaining bracket (P/N 195763) over the connector. Tighten retaining screws to secure.

Figure 1-9. Power Cord Connection

Connect Unit to Electrical Power

Caution See the serial tag on the side of the unit for electrical specifications or refer to the electrical schematics in this manual. s Caution If the factory installed option water-cooled condenser is present, do not turn the freezer on without water connected and flowing. Damage to the refrigeration system could occur within 5 minutes if water is not connected and flowing on unit start-up. Refer to Section 5. s The freezer should be operated on a dedicated grounded service. Check the voltage rating on the serial tag of the unit and compare it with the outlet voltage. Then, with the power switch turned off, plug the line cord into the wall outlet. First, turn on the freezer power switch. Then open the lower front door by grasping the bottom left corner. Locate the battery switch (Figure 1-5) and turn it to Standby mode ( ). During initial freezer start-up, the system battery may require charging and the Low Battery indicator may illuminate. Caution Ensure the battery switch is turned to Standby mode ( ). The rechargeable batteries require 36 hours to charge at initial start-up. A “Low Battery” alarm may occur until the batteries are fully charged. Should a power failure occur during the initial start-up period, the electronics will have limited operation. s

Run Mode

Run mode is the default mode for the freezer. This mode displays the cabinet temperature on the temperature display under normal operating conditions. In addition, the Run mode allows display of the high stage heat exchange temperature. This information scrolls by pressing the up or down arrow keys. The display returns to the operating temperature in 10 seconds if no keys are pressed.

1-8

Model 900 and 5900 Series

Thermo Scientific

Section 1 Installation and Start-Up

Freezer Start-Up

With the freezer properly installed and connected to power, system set points can be entered. The following set points can be entered in Settings mode: Control temperature, high temperature alarm set point, low temperature alarm set point, and (optional) BUS set point. Default settings are shown in the table below. Table 1-2. Default Settings Default Settings

Temperature

Control Set Point

-80°C

High Temperature Alarm

-70°C

Low Temperature Alarm

-90°C

Optional BUS Set Point

-60°C

Note If the set point is changed and the low temp and high temp alarms are set 10° from the set point, the alarm set points will be adjusted automatically to maintain a distance of at least 10° from set point. s Caution If the factory installed option water-cooled condenser is present, do not turn the freezer on without water connected and flowing. Damage to the refrigeration system could occur within 5 minutes if water is not connected and flowing on unit start-up. Refer to Section 5. s

Set Operating Temperature

Model 900 and 5900 Series freezers have an operating temperature range of -50°C to -86°C, depending on ambient temperature. The freezer is shipped from the factory with a temperature set point of -80°C. To change the operating temperature set point: 1. Press the Mode key until the Set Temperature indicator lights. 2. Press the up/down arrow key until the desired temperature set point is displayed. 3. Press Enter to save the set point. 4. Press the Mode key until the Run indicator lights for Run mode If no keys are pressed, the freezer will automatically return to RUN mode after 5 minutes. Note If the set point is changed and the low temperature and high temperature alarms are set 10° from the set point, the alarm set points will be adjusted automatically to maintain a distance of at least 10° from set point. s

Thermo Scientific

Model 900 and 5900 Series

1-9

Section 1 Installation and Start-Up

Set High Temperature Alarm

The high temperature alarm will activate an audible/visual warning when the freezer chamber temperature has reached or exceeded the high temperature alarm set point. To set the high temperature alarm set point: 1. Press the Mode key until the Set High Alarm indicator lights. 2. Press the up or down arrow key until the desired high temperature alarm set point is displayed. 3. Press Enter to save the setting. 4. Press the Mode key until the Run indicator lights for Run mode If no control keys are pressed, the freezer will automatically return to RUN mode after 5 minutes. Note The high alarm set point must be set at least 5°C from the control set point. s Note At initial start-up, the high temperature alarm is disabled until the cabinet reaches set point or 12 hours elapse. s

Set Low Temperature Alarm

The low temperature alarm will activate an audible/visual warning when the freezer chamber temperature has reached or decrease below the low temperature alarm set point. To set the low temperature alarm set point: 1. Press the Mode key until the Set Low Alarm indicator lights. 2. Press the up or down arrow key until the desired low temperature alarm set point is displayed. 3. Press Enter to save the setting. 4. Press the Mode key until the Run indicator lights for Run mode If no control keys are pressed, the freezer will automatically return to RUN mode after 5 minutes. Note The low alarm set point must be set at least 5°C from the control set point. s

1-10

Model 900 and 5900 Series

Thermo Scientific

Section 2 Calibrate Once the freezer has stabilized, the control probe may need to be calibrated. Calibration frequency is dependent on use, ambient conditions and accuracy required. A good laboratory practice would require at least an annual calibration check. On new installations, all parameters should be checked after the stabilization period. Caution Before making any calibration or adjustments to the unit, it is imperative that all reference instruments be properly calibrated. s

Calibrate Control Probe

Plug a type T thermocouple reader into the receptacle located inside the lower door (see Figure 1-5). Compare the control temperature set point to the temperature of the measuring device. 1. Press the Mode key until the Calibrate indicator lights. 2. Press up/down arrow to match the display to calibrated instrument. 3. Press Enter to store calibration. 4. Press the Mode key to return to Run mode.

Temperature Stabilization Periods

Startup - Allow 12 hours for the temperature in the cabinet to stabilize before proceeding. Already Operating - Allow at least 2 hours after the display reaches set point for temperature to stabilize before proceeding. During calibration, the temperature display will not be available. s If no keys are pressed for approximately five minutes while in calibration mode, the system will reset to Run mode.

Thermo Scientific

Model 900 and 5900 Series

2-1

Section 3 Alarms The Model 900 and 5900 Series freezer alarms are displayed on the freezer control panel. When an alarm is active, the indicator next to the alarm description will light and there will be an audible alarm. Press the Silence key to disable the audible alarm for the ringback period. The visual alarm will continue until the freezer returns to a normal condition. The alarms are momentary alarms only. When an alarm condition occurs and then returns to normal, the freezer automatically clears the alarm condition. Table 3-1. Alarm Indicators Description

Delay

Ringback

Relay

Power Failure

1 min.

15 min.

Yes

High Temperature Alarm

1 min.

15 min.

Yes

Low Temperature Alarm

1 min.

15 min.

Yes

Probe Failure see 3.2

1 min.

15 min.

No

Door Open

1 min.

15 min.

No

Wrong Power

0 min.

none

Yes

Low Battery*

1 min.

8 hours

No

Low BUS Battery (optional)

1 min.

15 min.

No

Hot Condenser

1 min.

none

No

High Stage Failure

0 min.

15 min.

Yes

Micro Board Failure

0 min.

15 min.

Yes

All alarm delays and ringback times are ±30 seconds. * The automatic battery test runs immediately on power-up, then every 8 hours thereafter.

Thermo Scientific

Model 900 and 5900 Series

3-1

Section 3 Alarms

3-2

High Stage System Failure

The "high stage system failure" condition is created when the high stage compressor and fans run for 30 minutes and are not capable of cooling the interstage heat exchanger to the proper temperature. Under this condition, the high stage compressor and fans will turn off after 30 minutes and an audible and visual alarm will occur. The audible alarm can be silenced and will ring back every 15 minutes.

Probe Failure Alarm

The microprocessor in Model 900 and 5900 Series freezers continually scans all probes including the control probe, heat exchanger probe and condenser probe to ensure that they are operating properly. Should an error be detected, the "Probe Failure" alarm will occur as described above. If an error is detected with the control probe, the high and low stage compressors will run continuously. As a result, the cabinet temperature will decrease until it reaches the lowest temperature that the refrigeration system can maintain. If an error is detected with the heat exchanger probe, the freezer will cycle properly at its temperature set point using a 5 minute step start between the high and low stage compressors. If an error is detected with the condenser probe, there is no impact on the performance of the freezer; however, the hot condenser alarm may also occur. Contact the Technical Services department or your local distributor.

Model 900 and 5900 Series

Thermo Scientific