BENCHTOP CO2 INCUBATOR OPERATIONS MANUAL FOR MODELS 6014 6016 PO Box 715 Marietta, OH 45750 800-648-3042 740-373-6809 Fax 740-374-3760 www.caronproducts.com service@caronproducts.
Dear Valued Customer: Thank you for purchasing CARON Products & Services equipment. We appreciate your business and look forward to being your preferred supplier of controlled environment equipment products in the future. At CARON, we are committed to continuous quality improvement. Our goal is to supply our customers with highly reliable equipment at a fair price. In order to openly monitor our performance, we would appreciate your feedback on our products and services.
TABLE OF CONTENTS Section 1 – Warranty .................................................................................... 5 Section 2 – Equipment Overview ............................................................... 10 Section 3 – Installation ...............................................................................
Calibrating the Humidity Calibrating the CO2 Section 8 – Alarms ...................................................................................... 46 Alarm System Overview Changing Alarm Set-points Section 9 – Preventative Maintenance ...................................................... 47 Section 10 – Specifications ........................................................................ 48 Section 11 – Electrical Schematics ...........................................................
SECTION 1- WARRANTY INFORMATION CO2 INCUBATOR LIMITED WARRANTY Please review this section before requesting warranty service. At CARON, one of our primary goals is to provide customers with high levels of personal service and top quality products, delivered on time, backed by technical service and supported for the life of the product. Before contacting us for warranty service, please be aware that there are repairs that are not covered under warranty. WARRANTY DEFINED Caron Products & Services, Inc.
Force Majeure or Acts of God. This writing is a final and complete integration of the agreement between CARON and the customer. CARON makes no other warranties, express or implied, of merchantability, fitness for a particular purpose or otherwise, with respect to the goods sold under this agreement. This warranty cannot be altered unless CARON agrees to an alteration in writing and expressly stated herein shall be recognized to vary or modify this contract. Ohio Law governs this warranty.
EQUIPMENT INTERNATIONAL LIMITED WARRANTY Please review this section before requesting warranty service. At CARON, one of our primary goals is to provide customers with high levels of personal service and top quality products, delivered on time, backed by technical service and supported for the life of the product. Before contacting your distributor for warranty service, please be aware that there are repairs that are not covered under warranty. WARRANTY DEFINED Caron Products & Services, Inc.
This writing is a final and complete integration of the agreement between CARON and the customer. CARON makes no other warranties, express or implied, of merchantability, fitness for a particular purpose or otherwise, with respect to the goods sold under this agreement. This warranty cannot be altered unless CARON agrees to an alteration in writing and expressly stated herein shall be recognized to vary or modify this contract. Ohio Law governs this warranty. Caron Products & Services, Inc.
INTERNATIONAL SYMBOLS AND DEFINITIONS ? Help i Information Warning of hazardous area Warning of dangerous electric voltage Earth (ground) protective conductor WARNINGS Local government may require proper disposal 6014 & 6016 Operations Manual Rev C 2/14/12 Page 9 of 56
SECTION 2 – EQUIPMENT OVERVIEW Congratulations! You have just purchased the latest technology in incubators. Before using the equipment, familiarize yourself with key components of the product and thoroughly read this manual.
SECTION 2 – EQUIPMENT OVERVIEW -- CONTINUED Decon Switch & Light Temperature Controller Humidity Enable Switch Humidity Controller CO2 Enable Switch CO2 Controller Alarm Silence Switch Visual Alarm Indicator 6014 & 6016 Operations Manual Rev C 2/14/12 Page 11 of 56
SECTION 3 -- INSTALLATION Unpacking Your new unit has been thoroughly packaged to avoid shipping damage. However, the unit should be fully inspected upon arrival before signing for receipt. If the package has visual damage, notes should be made on the freight bill and signed by the delivery company. In the event of concealed damage after the unit is uncrated, keep the carton and packaging material.
Your new incubator was thoroughly cleaned prior to leaving the factory. It is recommended however, to disinfect all interior surfaces with a general purpose laboratory cleaning agent prior to using the product. After cleaning, dry all interior components with a sterile cloth as necessary. Installing the Port Stoppers The 6014 & 6016 have an access port built into the right side of the cabinet.
Stacking two Units The 6014 & 6016 are designed to allow two units to be stacked. When units are stacked they must be bolted together for safety. A stacking adaptor kit, STCK301 with instructions is available through CARON customer service. Failure to install the stacking adaptor kit can result in the top unit falling causing serious injury or death. Leveling the Unit Place a level on the middle shelf of the incubator. Adjust the cabinet leveling feet so the shelf is level.
The drain line relies on gravity to remove water from the incubator. The drain line must remain below the incubator to drain properly. Kinks or elevations in the drain line above the cabinet drain will not allow the incubator to drain. If a floor drain is not available, CARON offers a water recirculation system accessory (CRSY102) that acts as both a water supply and a drain for humidified incubators.
A water inlet fitting on the back of the unit and ¼” black tubing are provided to connect the water supply to the incubator. Connect an appropriate water supply to the fitting. Incoming line pressure should be regulated to not exceed 80 psi. If a Condensate Recirculator water recycling system was purchased as a water supply, refer to its user’s manual for proper installation of the water supply. Connecting a CO2 supply High concentrations of carbon dioxide can cause asphyxiation.
The unit requires a dedicated electrical outlet. See table below for model specific power required and connection. Model # -1 -2 -3 Power Requirements 115V, 60Hz, 12A FLA 230V, 60Hz, 8A FLA 230V, 50Hz, 6A FLA Plug Connection NEMA 5-15 NEMA 6-15 CEE 7/7 When the required electrical connection is available, plug the provided power cord into the unit and the electrical outlet.
SECTION 4 – ACCESSORY INSTALLATION Connecting Alarm Contacts (ALRM301) With the purchase of ALRM301, a set of terminals on the rear of the unit is provided to monitor temperature and humidity alarms. With the alarm contacts, the terminals provided allow for a NO (normally open) output, a NC (normally closed) and COM (common) connection. In the event of an alarm condition or power failure, the NO contact will close, and the NC contact will open.
Installing Carboy Water System (BOTL301) The optional 2.5 gallon carboy water system is preassembled and shipped inside the incubator. The four ¼” bolts required to mount the carboy to the unit will be mounted in the right hand side of the incubator. Remove the carboy assembly from inside the incubator and attach it to the incubator using the ¼” bolts.
Connecting Communications or Analog Outputs (DLUX303) With the purchase of DLUX303, the controllers are upgraded with additional features such as RS485 communications, and analog outputs. A set of terminals are provided to connect to RS485 communications and analog outputs. Analog Outputs DLUX303 provide analog outputs as either milliamps (0-20mA, 4-20mA) or voltage (05V, 1-5V, 0-10V, 0-20V) signal output that represents each of the displayed temperature, humidity and CO2 values.
Communications RS-485 communications are intended to communicate with a PC using ModBus RTU or Standard Bus. The maximum number of incubators connected to a single PC is limited to 247 controllers (Modbus) or 16 controllers (Standard Bus). Each incubator has 3 controllers. Connect shielded wires to the RS-485 Communications terminal blocks. Communications wires should be shielded and routed away from power wires. Maximum distance of total wire is 2000 feet.
Standard factory set up for chart speed is 7 day operation. Refer to the Chart Recorder’s User’s Manual provided with the recorder to change the chart speed settings for various chart speeds.
Installing the Stacking Kit (STCK301) Two incubators can be stacked using a stacking kit. The kit contains brackets and bolts to secure them together. Each incubator weighs in excess of 400 pounds. Ensure that sufficient resources are available to safely lift and move the product. Place the bottom incubator into its location. Using a lift or jack, place the other incubator on top. Bolt into place both brackets (back side, right & left) and secure the two together with 12 screws.
SECTION 5 – OPERATION With the incubator properly installed and the appropriate utilities connected, the power switch on the upper left of the control bezel can be turned on. Within a few minutes, the temperature and humidity will begin to approach set-points. Allow the unit to stabilize for 12 hours before use or prior to making any calibration adjustments.
Changing the Humidity Set-point If an alternative humidity set-point is required, the following steps can be taken: Actual Humidity Increase Humidity Set-point Enable Humidity Decrease Humidity Set-point Humidity Set-point Press the up arrow to increase the humidity set-point by 1% RH. Press the down arrow to decrease the humidity set-point by 1% RH. Pressing and holding either button will cause the set-point to scroll rapidly in either direction.
Changing the CO2 Set-point If an alternative CO2 set-point is required, the following steps can be taken: Actual CO2 Increase CO2 Set-point Enable CO2 Decrease CO2 Set-point CO2 Setpoint Press the up arrow to increase the CO2 set-point by 0.1% CO2. Press the down arrow to decrease the CO2 set-point by 0.1% CO2. Pressing and holding either button will cause the set-point to scroll rapidly in either direction.
Using the Decontamination Cycle The incubator is equipped with an automatic moist heat decontamination cycle. The purpose of the cycle is to eliminate common microbial contamination in your incubator and extend the time between manual cleaning cycles. CARON’s incubator is equipped with a controlled humidity system that eliminates standing water which is the primary source of contamination. The decontamination cycle is intended to be used as a reactive system to eliminate contamination.
9) Press the decon cycle switch located on the temperature controller panel. The yellow light will indicate the cycle is active. 10) The infrared CO2 sensor can be disinfected using isopropanol. cleaner on a soft clean cloth and wipe the sensor. Spray the Do not immerse the sensor in any type of cleaner as damage to the sensor may occur. With the decontamination cycle now active, the following automatic steps will occur: 1) The unit will heat the incubator to approximately 90C over a 2 hour period.
SECTION 6 – ACCESSORY OPERATION Using the Carboy Water System (BOTL301) To fill the carboy while attached to the incubator, unscrew the cap. Fill carboy with distilled or deionized water (see Connecting the Water Supply section for details). The carboy holds 2.5 liters. If the carboy must be removed in order to fill it up, first disconnect the tubing between the carboy and incubator by pressing the metal lever at the tubing connects / disconnects at the bottom of the carboy.
Operation of the Delux Controller System (DLUX303) The incubators can be purchased with upgraded controllers. The controllers have additional features of RS485 communications, analog outputs, and ramp & soak. RS485 Communications: The RS485 communications signals can be daisy chained from product to product and connected to a PC. Each controller on the network must be programmed with a unique address. Factory defaults for the controllers are addresses 1 for temperature, 2 for humidity, and 3 for CO2.
Analog Outputs: With DLUX303 controllers, there is an analog output signal for temperature and humidity which represents the actual incubator values. This allows the incubator to be connected to an in-house data acquisition or alarm system. The analog signal outputs are selectable as either voltage DC or milliamp. In both cases, the output is scalable from 0.0 to 20.0. Common settings are 0-1V, 0-5V, 1-5V, 0-10V, 0-20mA, and 4-20mA. The factory default settings are 0-5V.
Set the Scale Low value to correspond with the minimum value of the process output in electrical units. For 0-5V, set to 0. For 1-5V, set to 1. For 4-20mA, set to 4. Set the Scale High value to correspond with the maximum value of the process output in electrical units. For 0-5V, set to 5. For 1-5V, set to 5. For 4-20mA, set to 20. Set the Range Low value to the minimum temperature (or humidity or CO2) that will correspond with the Scale Low value (default is 0.0).
appropriate regulators are not available, contact CARON customer service to purchase them. Once the cylinder regulators are installed and adjusted on each tank, connect the outlet of the regulator on Tank 1 to the hose barb fitting labeled Tank 1 on the back of the unit. Repeat the process for Tank 2. Turn on the regulated gas supplies and check the connections closely for leaks. The power switch is used to turn on/off the operation of the product.
Operation of Front Mounted 6” Recorders (RCDR301, RCDR302) Built in 6” ink pen temperature and or humidity recorders can be purchased with CARON incubators. The recorders are shipped installed on the outer door of the incubator from the factory and require no installation. Changing the chart paper: Press and hold the “change chart” button on the recorder (#3) for approximately one second until the pen begins to move to the left of the chart and then release the button.
the two screws that hold the pen arm be loosened and the pen cartridge and metal pen arm be removed as an assembly. Unsnap the plastic "U" clip tab of the pen cartridge from the metal pen arm, remove and discard the old pen cartridge. Replace the new cartridge by opening the hinge and snapping it securely around the metal pen arm.
Recorder Calibration: If a calibration adjustment is required for a single pen recorder, use the left (#1) and right (#2) arrow push buttons on the recorder to calibrate (or move) the pen’s position on the chart to correspond to the temperature of the solution. The arrow buttons must be held for approximately five seconds before the pen will begin to move. For two pen recorders, you must first select the pen that you wish to calibrate.
Operation of Front Mounted 10” Recorders (RCDR303, RCDR304) Built in 10” thermal pen recorders can be purchased with CARON incubators. The recorders are shipped installed on the outer door of the incubator from the factory and require no further installation. Unlike ink pen recorders, the thermal recorders draw their own chart and control lines. The 10” recorders have been setup at the factory in the following configuration: 7 Day / 24 Hour / Temperature 0-100°C / Humidity 0-100% (for dual input recorders).
move off of the chart allowing you to place the recording chart paper onto the recorder. Press and release the Change Chart button to begin recording. Changing the Chart Paper: Press and hold the Change Chart button (#3) for approximately one (1) second until the pen begins to move off scale and then release the button. Note: The green LED light will flash fast while the thermal pen arm is moving off scale.
Recorder Calibration: If calibration is required for single input recorders, use the Left (#1) and Right (#2) arrow buttons on the recorder to calibrate the temperature being recorded on the chart to correspond to the temperature of the solution. The arrow buttons must be held for approximately eight (8) seconds before the pen begins to move. If calibration is required for dual input recorders, you must first select the input that you wish to calibrate.
Operation of Side Mounted Recorders (RCDR305, RCDR306) Side mounted Honeywell DR 4300 General Purpose Circular Chart Recorders are also available with CARON incubators. This chart recorder uses reliable microprocessor operation to generate dependable pen drawn analog traces on preprinted 10-inch (250 mm) charts. The two-pen model accepts inputs from a temperature sensor and a humidity sensor. The single-pen model records temperature only.
3. Lift the chart from the hub and locating pin and slide it from under the pens to remove it from the chart plate. 4. Slip the new chart under the pen lifter, pens and time index; and press the chart into place over the chart hub and locating pin. 5. Grasp the chart hub and locating pin and turn the chart until the desired time line on the chart is aligned with the time index on the chart plate and Pen #1. Push down the lifter to return the pens to the chart. 6. Close the door and apply power.
SECTION 7 – CALIBRATION The temperature and humidity systems can all be calibrated as necessary. CARON recommends an annual calibration check of each system. Before making a calibration adjustment, allow the cabinet to stabilize a minimum of 12 hours from a power off condition. If the unit has been in operation, allow a minimum of 3 hours of stable operation at all set-points.
If the incubator temperature display reads 40.0C and the calibrated independent sensor shows 40.3C, set the i.CAL offset value to 0.3C. If the calibrated independent sensor shows 39.6C, then the entered offset should be negative. In this example the required offset to i.CAL would be -0.4C.
Calibrating the Humidity If humidity calibration is needed, the following steps can be taken: Infinity Key Advance Key Locate the reference instrument’s temperature sensor in close proximity to the cabinet’s geometric center. Be sure that the stabilization times described earlier have been satisfied prior to performing this calibration. Press the advance key until the green display reads i.CAL (calibrate). Pressing the UP arrow will increase the Humidity calibration offset by 1%.
Calibrating the CO2 If CO2 set-point calibration is required, the following steps can be followed: Infinity Key Advance Key Locate the reference instrument’s CO2 sensor in close proximity to the cabinet’s geometric center or sample the incubator’s contents through the sample port located on the control panel bezel. Be sure that the stabilization times described earlier have been satisfied prior to performing this calibration. Press the advance key until the green display reads CAL (calibrate).
SECTION 8 – ALARMS Alarm System Overview The incubator control system is equipped with an alarm system that constantly monitors temperature, humidity and CO2 to ensure the user is notified if the cabinet goes into an alarm condition. Notification occurs via a RED indicator light and an buzzer. Each alarm condition has been factory programmed to minimize nuisance alarms while maximizing warning time.
SECTION 9 – PREVENTATIVE MAINTENANCE The CARON incubator has been robustly designed to minimize performance problems. However, regular maintenance is very important for continuous trouble free operation. As a general rule, CARON recommends an annual calibration check of the temperature, humidity and CO2 systems. CARON offers a full range of on-site calibration and validation services. We also offer preventative maintenance contracts on our equipment.
SECTION 10 – SPECIFICATIONS MODEL Temperature Range Temperature Control 6014 10°C Above Ambient to 60°C ± 0.1°C Temperature Uniformity Temperature Sensor Humidity Range 6016 5°C to 60°C ± 0.3°C 3-wire RTD Ambient to 95% RH Humidity Control ± 3% RH Humidity Sensor CO2 Range Capacitive 0-20% CO2 CO2 Control ± 0.
SECTION 11 – ELECTRICAL SCHEMATICS 6014 & 6016 Operations Manual Rev C 2/14/12 Page 49 of 56
SECTION 11 – ELECTRICAL SCHEMATICS (CONT) 6014 & 6016 Operations Manual Rev C 2/14/12 Page 50 of 56
SECTION 11 – ELECTRICAL SCHEMATICS (CONT) 6014 & 6016 Operations Manual Rev C 2/14/12 Page 51 of 56
SECTION 12 – TROUBLESHOOTING Problem – Unit will not turn on Is the unit connected to a dedicated electrical circuit as defined in the installation section of the manual? Is there power at the electric outlet the unit is plugged into? Is the unit’s power switch turned on? Problem – Unit temperature is above / below temperature set-point Has the unit’s temperature set-point been recently lowered / raised and if so has the unit been allowed 12 hours stabilize at the new set-point? Has the inner door
SECTION 13 – SPARE / REPLACEMENT PARTS General Part Number MTR-130 BLW-113 CTR-132 CTR-134 POW-108 FLTR303 CRD-113 STP-101 Description Blower Motor Blower Wheel Watlow Standard controller Watlow Delux Controller 24V DC Power Supply Condenser Filter Replacement Kit Power Line Cord 2” Rubber Port Stopper Temperature Related Part Number HTR-150 RMT-114 RMT-116 RTD-101 REL-103 CND-135 CND-137 CND-138 REL-152 REL-154 SOL-108 Description Air Heater 107C Air Heater Thermostat 121C Air Heater Thermostat Temp Sen
CO2 Related Part Number CO2-101 SOL-135 FIL-213 FIL-115 Description Carbon Dioxide Sensor CO2 Injection Solenoid In-line CO2 HEPA Filter HEPA Filter Fuse Related ID SW1 FUS1 FUS2 FUS3 FUS4 FUS5 FUS6 FUS7 FUS8 FUS11 Description Main circuit breaker switch Front mount chart recorder fuse Side mount chart recorder fuse Internal duplex outlet fuse Internal outlet transformer fuse Compressor fuse Condensate pump fuse Condensate pump transformer fuse Air & door heater fuse Humidity injection pump fuse 115V CB
SECTION 14 – ADVANCED USERS SECTION Unlocking the Controllers The temperature and humidity controllers are factory programmed for precise control. Unlocking the controllers gives the user access to all parameters. Modifying parameters that are not thoroughly understood can adversely affect incubator performance that will not be covered under warranty.
DECLARATION OF CONFORMITY Caron Products and Services, Inc.
