Forma Scientific, Inc. P.O.

Box 649 Marietta, Ohio 45750

U.S.A.
Telephone: (740) 373-4763 Telefax: (740) 373-4189 _______________________________________

Models:

8552 and 8553

4.5 cu. ft. Laboratory Freezers
Manual No. 7018552 Rev. 0

Read This Instruction Manual Failure to read, understand and follow the instructions in this manual may result in damage to the unit, injury to operating personnel and poor equipment performance.

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

Forma Scientific, Inc.

The material in this manual is for information purposes only. The contents and the product it describes are subject to change without notice. Forma Scientific, Inc. makes no representations or warranties with respect to this manual. In no event shall Forma Scientific, Inc. be held liable for any damages, direct or incidental, arising out of or related to the use of this manual. When contacting the factory regarding this unit, have the model, serial number and date of purchase available.

Manual No. 7018552

0
REV

16584 / FR-1171
ECR / ECN

10/15/97
DATE

Manual revised to conform to CE Mark specifications per J. Schmidt heg

DESCRIPTION

Forma Scientific, Inc.___________________________________________________Service

ii

Forma Scientific, Inc.____________________________________________________Safety

General Safety Notes used in this Manual

Important operating and/or maintenance instructions. Read the accompanying text carefully. Ce symbole attire lattention de lutilisateur sur des instructions importantes de fonctionnement et/ou dentretien. Il peut tre utilis seul ou avec dautres symboles de scurit. Lire attentivement le texte daccompagnement. Wichtige Betriebs- und/oder Wartungshinweise. Lesen Sie den nachfolgenden Text sorgfltig. Importante instruccions de operacion y/o mantenimiento. Lea el texto acompanante cuidadosamente.

Potential electrical hazards. Only qualified persons should perform procedures associated with this symbol. Ce symbole attire lattention de lutilisateur sur des risques lectriques potentiels. Seules des personnes qualifies doivent appliquer les instructions et les procdures associes ce symbole. Gefahr von Stromschlgen. Nur qualifizierte Personen sollten die Ttigkeiten ausfhren, die mit diesem Symbol bezeichnet sind. Potencial de riesgos electricos. Solo personas das capacitadadas deben ejecutar los procedimientos asociadas con este simbulo.

Equipment being maintained or serviced must be turned off and locked off to prevent possible injury. Risques potentiels lis lnergie. Lquipement en entretien ou en maintenance doit tre teint et mis sous cl pour viter des blessures possibles. Gerte, an denen Wartungs- oder Servicearbeiten durchgefhrt werden, mssen abgeschaltet und abgeschlossen werden, um Verletzungen zu vermeiden. El equipo recibiendo servicio o mantenimiento debe ser apagado y segurado para prevenir danos.

iii

Forma Scientific, Inc.__________________________________________________Contents

Table of Contents

Section 1 - Receiving
1.1 Preliminary Inspection ..........................................................................1-1 1.2 Visible Loss or Damage ........................................................................1-1 1.3 Responsibility for Shipping Damage.....................................................1-1

Section 2 - Installation
2.1 2.2 2.3 2.4 Location and Unpacking .......................................................................2-1 Freezer Lid Key Lock ...........................................................................2-1 Freezer Components .............................................................................2-2 Circuit Breaker (mains disconnect) .......................................................2-3

Section 3 - Control Panel

3.1 Control Panel Pictorial..........................................................................3-1 3.2 Setting the Operating Temperature........................................................3-3 3.3 Remote Alarm.......................................................................................3-4

Section 4 - Maintenance
4.1 Cleaning ...............................................................................................4-1 4.2 Defrosting the Freezer...........................................................................4-1 4.3 Cleaning the Condenser Filter and the Condenser .................................4-2

Section 5 - Service
5.1 5.2 5.3 5.4 5.5 Troubleshooting....................................................................................5-1 Adjusting the Span................................................................................5-2 Replacing the Microprocessor Board ....................................................5-4 Replacing the Battery............................................................................5-5 Servicing the System.............................................................................5-6

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Forma Scientific, Inc.__________________________________________________Contents

Section 6 - Specifications and Environmental Conditions

6.1 ...............................................................................................................6-1

Section 7 - Parts Lists

7.1 ...............................................................................................................7-1

Section 8 - Refrigeration Schematics

8.1 ...............................................................................................................8-1

Section 9 - Electrical Schematics

9.1 ...............................................................................................................9-1

Section 10 - Warranty Information

10.1 .............................................................................................................10-1

Forma Scientific, Inc._________________________________________________Receiving

Section 1 - Receiving

1.1 Preliminary Inspection This item was thoroughly inspected and carefully packed prior to shipment and all necessary precautions were taken to ensure safe arrival. Immediately upon receipt, before the unit is moved from the receiving area, carefully examine the shipment for loss or damage. Unpack the shipment and inspect both interior and exterior for any intransit damage.

1.2 Visible Loss or Damage If any loss or damage is discovered, note any discrepancies on the delivery receipt and call the delivering carrier and request that their representative perform an inspection. Do not discard any of the packing material and do not move the shipment from the receiving area.

1.3 Responsibility for Shipping Damage For products shipped F.O.B. Marietta, Ohio, the responsibility of Forma Scientific, Inc. ends when the merchandise is loaded onto the carrier's vehicle. On F.O.B. Destination shipments, Forma Scientific's and the carrier's responsibility ends when your Receiving Department personnel sign a free and clear delivery receipt. Whenever possible, Forma Scientific, Inc. will assist in settling claims for loss or intransit damage.

1-1

Forma Scientific, Inc.________________________________________________Installation

Section 2 - Installation

2.1 Location and Unpacking Locate the unit on a firm, level surface in an area of minimum temperature fluctuation. Avoid installing the unit near heat-emitting appliances, as heat can shorten component life and cause inefficient refrigeration. For proper ventilation and air flow, allow at least 4-5 inches of clear space behind and on both sides of the cabinet. Avoid placing the unit in a contaminated area where an excessive amount of dust is present or where chemicals are stored or gases are produced. Adjust the leveling feet to make firm contact with the floor. Turn the levelers counterclockwise to lengthen them, or clockwise to shorten them. Always shorten the leveling feet before moving the freezer to a new location.

The freezer must be connected to a grounded, dedicated electric circuit. Refer to Section 6 for the exact electrical specifications. Remove the packing material and open the freezer lid for a short time so that air can circulate freely inside. 2.2 Freezer Lid Key Lock A key lock is provided to secure the freezer lid. The lock is on the handle. Two keys are in the parts bag accompanying this manual.

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Forma Scientific, Inc.________________________________________________Installation

2.3 Freezer Components Use Figure 2-1 to become familiar with the various parts of the freezer, their location and their function.

Figure 2-1 Model 8552/8553 Exterior View (Refer to the key on the following page.)

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Forma Scientific, Inc.________________________________________________Installation

Freezer Parts Key (Refer to Figure 2-1)

! ! "

Door Lock Door

( )

Exhaust air outlet Do not block.

Magnet Door Gasket Seals the door and prevents the leakage of cold air.

Pocket Use for Instruction Manual, notebook or gloves.

* + ,

Control Panel Cover

Inner Lid Reduces cold air leakage when the door is opened.

Control Panel Refer also to Figure 3-1. Back-up System Connection The connection for the lines from the LN2 tanks. Located on the back of the cabinet. Digital Temperature Indicator Displays the chamber temperature or the setpoint temperature.

Access Port Serves as a through-the-wall port for thermometer leads for measuring the chamber temperature. Located on the left side of the cabinet.

% & '

Adjustable Feet Levels the unit. Casters

. Remote Alarm Terminal Refer to Section 3.2.

Grill Acts as an inlet for air to cool the motor. Do not block the grill. Pull down the grill to clean the condenser filter.

2.4 Circuit Breaker (Mains Disconnect) This freezer is equipped with a circuit breaker located on the back of the unit adjacent to the power cord. Make sure this circuit breaker is switched on before attempting to start the unit. (Refer to Figure 2-2)

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Forma Scientific, Inc.________________________________________________Installation

If the breaker cannot be reset at any time during normal freezer operation, disconnect the power cord and contact a qualified service person.
circuit breaker (mains disconnect)

Figure 2-2

Connect this freezer to a power source having the rated voltage and frequency indicated on the serial tag. This freezer must only be repaired and maintained by qualified service personnel.

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Forma Scientific, Inc.______________________________________________Control Panel

Section 3 - Control Panel

3.1 Control Panel Pictorial

Figure 3-1 (refer to the key on the following page.)

3-1

Forma Scientific, Inc.______________________________________________Control Panel

Control Panel Key

Power Supply Switch - Turning this

switch on activates all functions except the remote alarm circuitry.

Numerical Value Shift. (Up Arrow) This key is used to set the values in the digital display.

Remote Alarm Switch - Controls the

remote alarm. Must be on when operating the remote alarm.

Enter Key (ENT). Use this key to enter selected setpoint value.

!Buzzer Key - Silences the audible alarm.

Press the key to silence. When another alarm condition occurs the alarm will sound automatically. activates all functions except the remote alarm circuitry. Digital Display Panel Key Filter Check Lamp (FILTER CHECK). The lamp lights when the condenser filter is clogged. Clean the condenser filter as instructed in Section 4.3, Cleaning the Condenser Filter and the Condenser.

Alarm Test Key - Turning this switch on "

Temperature Setting Key (PV/SV) PV: Displays the chamber temperature. SV: Displays the operating temperature. When setting the temperature, press SV and enter the desired temperature. If no number is entered for 1 minute, the display will return to a display of the chamber temperature.

Alarm Lamp (ALARM). The lamp will

flash when the unit is in an alarm condition.

Digit Shift Key - (Right Arrow) Pressing this key when in the Temperature Set mode alternates between the left and right digit, causing them to flash.

Digital Temperature Indicator (Temperature C). Shows the chamber temperature. Used also when setting the system temperature.

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Forma Scientific, Inc.______________________________________________Control Panel

3.2 Setting the Operating Temperature

Operation
Plug in the freezer and turn the power switch on. Set the operating temperature.

Key
SV

Indication after operation

The temperature indicator will display the operating setpoint. Press digital shift key to select the settable (flashing) digit. Press up arrow to set the flashing digit. (The key scrolls 0-9)

Press the Entry key.

ENT

Operating setpoint temperature will be displayed and stored to memory.

When the freezer is powered up, the alarm lamp flashes and the buzzer sounds. Press the buzzer key to silence the alarm. If the alarm does not operate during startup, this does not indicate a malfunction but indicates that the Ni-cad battery has completely discharged. After the unit has been in operation for about three hours, push the test switch to determine whether the alarm is operational. About two days of continuous operation of the freezer is required to fully charge the battery.

This unit is not a "quick-freeze" device. Freezing large quantities of liquid, or high-water content items, will temporarily increase the temperature and will cause the compressors to operate for a prolonged time period. Damage to the compressors may result and product safety may be jeopardized.

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Forma Scientific, Inc.______________________________________________Control Panel

3.3 Remote Alarm

The remote alarm terminal block is located behind a silver metal cover plate on the back of the freezer cabinet as illustrated in Figure 3-2. Removing the two Phillips screws allows access to the terminal block. The electrical rating of the alarm contacts is listed below: Contact Rating: DC 30V @ 2 amps AC 100V @ 0.4 amps

Figure 3-2 8552/8553 Freezer, Rear View

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Forma Scientific, Inc.______________________________________________Control Panel

The Remote Alarm switch controls power to the remote alarm and must be on when operating the remote alarm. When the alarm is triggered, the audible alarm (Buzzer) will sound, and the digital temperature display will flash. The remote alarm contacts will also change state. Press the buzzer to silence the alarm. The high temperature alarm has been factory set at 10 C above the operating temperature of the freezer. The remote alarm will activated after a 15 minute delay. Refer to Table 3-1 below for all alarm and self-diagnostic functions.

Table 3-1 Alarm and Self-Diagnostic Functions

Alarm
Temperature

Situation
When the chamber temperature rises 15 C higher than the setpoint temperature.

Indication
Alarm lamp will flash. Remote alarm will activate after a 15 minute delay. Alarm lamp will flash. Remote alarm will activate.

Buzzer
Intermittent tone (15 minute delay)

Power Failure

When the power fails.

Intermittent tone

Filter Check

When the condenser filter becomes clogged.

Filter check lamp will flash. E1 will be displayed. E2 will be displayed.

Intermittent tone

Temperature sensor abnormality Temperature sensor abnormality

When the temperature sensor circuit is open. When the temperature sensor circuit shorts out.

3-5

Forma Scientific, Inc._______________________________________________Maintenance

Section 4 - Maintenance

4.1 Cleaning Clean the freezer once a month. Regular cleaning keeps the unit looking new. Use a dry cloth to wipe away small amounts of dirt from the outside and inside of the freezer. If the freezer is very dirty, use a neutral detergent. After cleaning, rinse the freezer with distilled water until all traces of the detergent are removed and wipe dry. The compressor and other mechanical parts are sealed and require no lubrication.

4.2 Defrosting the Freezer

Hazardous biological elements may be present.

A plastic ice scraper is provided in the parts bag containing this instruction manual. Use the scraper only to remove softened ice. Do not use it to pry or force ice from the freezer chamber. Move the freezer contents to another low temperature unit. Turn off the remote alarm and Back-up system if the unit has one. Turn off the power supply and unplug the freezer. Open the door and remove the inner lid. When all of the ice and frost has melted, wipe up the water accumulated in the chamber and dry the chamber with a soft cloth.

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Forma Scientific, Inc._______________________________________________Maintenance

Note: With the lid open and fans directing air into the chamber, defrosting will take 12 to 24 hours. Reset the freezer to the desired operating temperature. Refer to Section 3.1.

4.3 Cleaning the Condenser Filter and the Condenser

De-energize all potential sources of energy to this unit and lockout/tagout their controls. (O.S.H.A. Regulation, Section 1910-147.)

The condenser filter is located behind the grill at the bottom front of the freezer. Clean the filter once a month to protect the compressor from damage and to prevent poor cooling. Whenever the filter becomes clogged, the filter check lamp flickers and the buzzer sounds. Clean the filter as follows: Remove the mounting screw that secures the grill and pull the grill down. Pull the filter out and wash it with water. Reinstall the filter. Clean the condenser using a vacuum or air hose. Replace the grill and secure it with the mounting screw.

4-2

Forma Scientific, Inc.___________________________________________________Service

Section 5 - Service

Service must be performed by qualified personnel only!

5.1 Troubleshooting

Problem No refrigeration Noisy operation

Possible Cause Check electrical power Electric power has failed or the freezer's electric cord has been pulled. Temperature control not properly set Too many unfrozen items in the chamber Frost on the evaporator Freezer door opened and closed frequently Back of the freezer touching the wall Freezer not level Something touching the cabinet frame Weak flooring beneath the freezer

Poor Refrigeration

After Troubleshooting If the unit continues to operate unsatisfactorily, contact the Forma Scientific, Inc. Service Department with the following information: A description of the problem, as specific as possible Freezer model Serial number 5-1

Forma Scientific, Inc.___________________________________________________Service

5.2 Adjusting the temperature span (Refer to Figure 5-1)

The adjustments are made while the freezer is operating. Use care to avoid direct contact with electrical components. To determine the need for adjusting the temperature display, place a reliable thermometer inside the chamber (near the temperature probe) and permit the chamber temperature to stabilize. If the chamber temperature differs from the LED temperature display, the display should be adjusted.

Tools: (1) #1 Phillips Screwdriver (1) Small Adjustment Screwdriver Remove the two screws securing the digital display panel. Disconnect the wiring connector from the digital display panel and set the panel aside. Remove the top cover of the freezer by removing the four screws (with the large washers) securing it. Remove the screws securing the silver electrical component cover and set the cover to the rear, without disconnecting it. Reconnect the digital display panel for use during the adjustment procedure. Adjust the display until it agrees with the test thermometer. Use Table 5-1, Service Switches and Table 5-2, Adjustment Points. Refer to Figure 5-1, Microprocessor Board Layout. Reverse the above procedure to reassemble the unit. Use Tables 5-1 and 5-2 to perform the span adjustment, the zero adjustment and the low stage compressor start-up temperature adjustment.

5-2

Forma Scientific, Inc.___________________________________________________Service

Figure 5-1 Microprocessor Board

Table 5-1 Service Switches

Switch
SW2

Function
1. Press and hold the switch to display the cascade condenser temperature. 2. Adjust VR-3.

SW3 SW4

Factory use only. 1. Press and hold the switch to display the 0.1 digit of temperature. 2. Adjust VR-1 or VR-2.

SW5

Capillary heaters. Turn On then Off. Heaters will start their 12-minute duty cycle. LED 2 will light, LED 1 will extinguish.

SW6 SW7

Factory use only. Factory use only.

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Forma Scientific, Inc.___________________________________________________Service

Table 5-2 Adjustment Points

Adjustment Pot
VR-1

Check Item
Zero adjustment

Adjustment Point
Adjustment in low temperature range. Turn clockwise for a higher display. Turn counterclockwise for a lower display Adjustment in chamber temperature range. Turn clockwise for a higher display. Turn counterclockwise for a lower display Adjustment in low-stage compressor startup temperature Turn clockwise to decrease. Turn counterclockwise to increase.

VR-2

Span adjustment

VR-3

Low stage compressor start-up temperature adjustment

5.3 Replacing the Microprocessor Board (Stock no. 227690) (Refer to Figure 5-1)

De-energize all potential sources of energy to this unit and lockout/tagout their controls. (O.S.H.A. Regulation, Section 1910-147.)

Tools : (1) #1 Phillips Screwdriver (1) Snips for cutting tie wrap The temperature control board is located under the silver electrical component cover beneath the top cover of the freezer. If the board becomes defective replace it as follows: Remove the screws securing the digital display panel. Disconnect the wiring connector from the digital display panel and set the panel aside.

5-4

Forma Scientific, Inc.___________________________________________________Service

Remove the top cover of the freezer by removing the four screws (with the large washers) securing it. Remove the screws securing the silver electrical component cover and set the cover to the rear (without disconnecting it). Cut the tie wrap on the wiring harness and disconnect all connectors, making note of the wiring configuration. Remove the board by removing the four screws securing it. Replace the board with part #227690. Reverse the above procedure to reassemble the unit. Remove lockout/tagout devices and re-energize the system per O.S.H.A. Regulation, Section 1910-147.

5.4 Replacing the Battery (Stock no. 227693) (Refer to Figure 5-1)

De-energize all potential sources of energy to this unit and lockout/tagout their controls. (O.S.H.A. Regulation, Section 1910-147.)

Tools: (1) #1 Phillips Screwdriver (1) Snips for cutting tie wrap The battery is located under the silver electrical component cover beneath the top cover of the freezer. Replace the battery once a year. Remove the two screws securing the digital display panel. Disconnect the wiring connector from the digital display panel and set the panel aside. Remove the top cover of the freezer by removing the four screws (with the large washers) securing it.

5-5

Forma Scientific, Inc.___________________________________________________Service

Remove the screws securing the silver electrical component cover and set the cover to the rear, without disconnecting it. Cut the tie wrap on the wiring harness and disconnect the battery at the connector (orange and brown wires). Remove the battery by removing the screws from the two plastic anchors securing it. Replace the battery with part # 227693. Reverse the above procedure to reassemble the unit. Remove lockout/tagout devices and re-energize the system per O.S.H.A. Regulation, Section 1910-147. 5.5 Servicing the System In the event of a unit malfunction, check all electrical components including starting relays, thermal protectors and starting capacitors for the compressors. The components are located behind the top rear panel. Electrical schematics and drawings with parts for the refrigeration system are included with this manual.

5-6

Forma Scientific, Inc.________________________________________Specifications

Section 6 - Specifications
Models 8552 (8553)
Operating Temperature Exterior Dimensions Interior Dimensions Temperature Controller Compressors Refrigeration System Capacity Insulation Electrical Weight Options -152oC (-242oF) Ambient temperature: +30 C, no load. 55.1"W x 31.5"H x 37.2"F-B (140 cm x 80 cm x 94.5 cm) 19.7"W x 17.7"H x 22.5"F-B (50 cm x 45 cm x 57.2 cm) Microprocessor control system 1 C graduation. High Stage: 1.5 HP (Hermetic) Low Stage: 2.0 HP (Semi-hermetic) Non-CFC refrigerants 4.5 cu. ft. (128 liters) Non-CFC foamed-in-place polyurethane Model 8552: 220 VAC, 60 Hz, 1 PH, 11.3 FLA Model 8553: 230 VAC, 50 Hz, 1 PH, 8.5 FLA 628 lbs (285 kg) Automatic Temperature Recorder Inventory System LN2 Back-Up Accessories (Included with the unit) Noise Level (sound pressure) Maximum Pressure (refrig. design pressure) Refrigerant 2 keys, Ice Scraper, Instruction Manual 59dBA 2844kPa (412.5psia) Low Stage 1755kPa (254.6 psia) High Stage Low Stage - 29.8 oz. Mixed gas High Stage - 19.1 oz. TP5R
Continuing research and improvements may result in specification changes at any time

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Forma Scientific, Inc.________________________________________Specifications

Environmental Conditions
This equipment is designed to be safe at least under the following conditions Indoor use Altitude - up to 2,000 meters Temperature - 5C to 40C Maximum Relative Humidity - 80% rh up to 31C, decreasing linearly to 50% rh at 40 C Mains Supply Fluctuations - not to exceed 10% of the nominal voltage Other supply voltage fluctuations as stated my the manufacturer Transient overvoltages according to Installation Categories (Overvoltage categories) II 1 For mains supply the minimum and normal category is II Pollution Category II in accordance with IEC 8642

Installation category (overvoltage category) defines the level of transient overvoltage which the instrument is designed to withstand safely. It depends on the nature of the electricity supply and its overvoltage protection means. For example, in CAT II which is the category used for instruments in installations supplied from a supply comparable to public mains such as hospital and research laboratories and most industrial laboratories, the expected transient overvoltage is 2500 V for a 230 V supply and 1500 V for a 120 V supply.

Pollution degree describes the amount of conductive pollution present in the operating environment. Pollution degree 2 assumes that normally only non-conductive pollution such as dust occurs with the exception of occasional conductivity caused by condensation.

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Forma Scientific, Inc.___________________________________________Parts List

Section 7 - Parts List

Model 8552 Stock # 227673 227677 227679 227675 227566 227674 227678 227701 227702 227686 227687 227688 227689 227690 227691 227692 227693 227694 227695 227696 227697 227698 227703 227006 Description Compressor, High Stage Dryer #1 Fan Motor Oil Separator #1 Oil Separator #2 Compressor, Low Stage Dryer #2 Run Capacitor, High Stage Run Capacitor, Low Stage Start Capacitor, High Stage Start Capacitor, Low Stage Relay, Start Relay, Low Stage Magnetic Temp Control Board Sensor, PT Sensor, Filter Battery Sensor, Cascade Relay, Temp Control Display Board Transformer Power Transformer Relays, Overload Heater, Capillary Tube

7-1

Forma Scientific, Inc.___________________________________________Parts List

Model 8553

Stock # 227682 227677 227679 227675 227676 227683 227678 227684 227685 227686 227687 227688 227689 227690 227691 227692 227693 227694 227695 227696 227697 227875 227699 227006 227871

Description Compressor, High Stage Dryer #1 Fan Motor Oil Separator #1 Oil Separator #2 Compressor, Low Stage Dryer #2 Run Capacitor, High Stage Run Capacitor, Low Stage Start Capacitor, High Stage Start Capacitor, Low Stage Relay, Start Relay, Low Stage Magnetic Temp Control Board Sensor, PT Sensor, Filter Battery Sensor, Cascade Relay, Temp Control Display Board Transformer Power Transformer Relays, Overload Heater, Capillary Tube Circuit Breaker, 15A

7-2

Forma Scientific, Inc._______________________________Refrigeration Schematics

Section 8 - Refrigeration Schematics

8-1

Forma Scientific, Inc.__________________________________Electrical Schematics

Section 9 - Electrical Schematics

9-1