REACH-IN CO2 INCUBATOR OPERATIONS MANUAL FOR MODELS 6024, 6026, 6044, 6046 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 – Equipment Installation .................................................................
Calibrating the Temperature Calibrating the Humidity Calibrating the CO2 Section 8 – Alarms .......................................................................................... 45 Alarm System Overview Changing Alarm Set-points Section 9 – Preventative Maintenance .......................................................... 46 Section 10 – Specifications ............................................................................ 47 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.
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 hot surface Warning of dangerous electric voltage Earth (ground) protective conductor WARNINGS Local government may require proper disposal 6024 & 6044 Series Operations Manual Rev F 02/14/12 Page 9 of 56
SECTION 2 – EQUIPMENT OVERVIEW Congratulations! You have just purchased the latest technology in CO2 incubators. Before using the equipment, familiarize yourself with key components of the product and thoroughly read this manual.
SECTION 2 – EQUIPMENT OVERVIEW – CONTINUED INCUBATOR CONTROL PANEL Start Decon Cycle Switch Temperature Controller CO2 Disable 6024 & 6044 Series Operations Manual Humidity Disable CO2 Controller Humidity Controller Alarm Silence Rev F 02/14/12 Alarm Indicator LED 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.
Installing the Port Stoppers The unit has an access port built into each side of the cabinet. The ports are designed to allow customer access for equipment validation or for installation of other equipment inside the chamber. These ports should be sealed with the provided rubber stoppers to allow the incubator to function properly. Install the stoppers provided in the port on each side of the unit.
Connecting the Drain When using a pressurized water source, failure to connect the unit to a drain could result in facility flooding. The incubators control humidity by injecting water only as needed. This eliminates standing water which is a primary source of contamination and corrosion. There are several ways to take advantage of this feature. The simplest method is to connect the drain fitting and tubing supplied with the incubator to a local floor drain.
Connecting the Water Supply Use only distilled or deionized water with a resistivity between 50K-CM and 1M-CM and a pH of greater than 6.5. Using water outside this range will void your warranty. Do not use water that contains chloramines. Chloramines can damage internal rubber gaskets resulting in leaks. To ensure proper operation, distilled or deionized water is required as a supply on units that have humidity control. If these water sources are not available contact CARON customer service.
regulator to the hose barb fitting using the tubing and clamps provided. An inline HEPA filter is provided to remove any contaminants in the CO2 gas supply. Check the connections closely for leaks. If the unit is equipped with a built in gas guard system, there will be 2 gas inlets. Each of the inlets should be connected to an individual gas tank as described above. Connecting Electrical Power Connect each incubator to a grounded circuit. Failure to do so could result in electrical shock.
SECTION 4 – OPTIONAL 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 for temperature, humidity, or CO2 alarms. With the purchase of DLUX303, a set of terminals is provided to connect RS485 communications and analog outputs. With the alarm contacts, the terminals provided allow for a NO (normally open) output, a NC (normally closed) and COM (common) connection.
Installing Carboy water system (BOTL301) Incubators can be purchased with an optional 2.5 gallon carboy water system. The carboy system is preassembled and shipped inside the chamber. The four ¼” bolts required to mount the carboy to the unit will be mounted in the left hand side of the chamber. Remove the carboy assembly from inside the chamber and attach it to the chamber using the ¼” bolts.
Installing Cell Roller Ramp & Support Kit (CELR301) For applications that require a cell roller, a reinforced floor, cell roller ramp, and interior outlet are provided with CELR301. The cell roller adaptor kit was designed around a 5 tier Wheaton R2P cell roller. With the purchase of this kit, the standard interior shelving and pilasters are removed to allow for the physical space of the cell roller. Support braces that have tracks to guide the cell roller wheels into the incubator are factory installed.
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 (and humidity) values.
to 247 controllers (Modbus) or 16 controllers (Standard Bus). Chambers have three controllers each. 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. When connecting multiple chambers, route wires in a daisy chain fashion. A termination resistor of 120 ohms may be placed across RS-485(-) and RS-485(+) of the last chamber in the daisy chain.
Installing a Drain Water Pump (PUMP301) In applications where a floor drain is not available and a CARON water recycling system is not being used, a drain pump can be purchased to pump any excess condensate from the incubator to a local sink or drain. The pump is located near the middle of the back of the incubator. Connect the supplied tubing from the pump to the sink / drain. The tubing may be run vertically into a ceiling but should not exceed 15 feet height.
SECTION 5 –OPERATION With the incubator properly installed and with water and CO2 connected, the power switch on the front lower left of the control bezel can be turned on. Within a few minutes, the temperature, humidity, and CO2 will begin moving toward their 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: 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. If CO2 is not required in the chamber, the CO2 system can be disabled by turning off the Enable CO2 switch.
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 – OPTIONAL ACCESSORY OPERATION Using the Carboy Water System (BOTL301) To fill the carboy while attached to the chamber, 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 chamber by pressing the metal lever at the tubing connects / disconnects at the bottom of the carboy.
Operation of the Delux Controller System (DLUX303) The chambers can be purchased with upgraded controllers. The controllers have additional features of RS485 communications and analog outputs. RS485 Communications: Each controller on the network (connected to the same PC or master device) must be programmed with a unique address. If multiple chambers are being connected, each controller will have to be assigned a unique address.
Analog Outputs: With DLUX303 controllers, there is an analog output signal for temperature, humidity, and CO2 which represents the actual chamber values. This allows the chamber 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).
Built In Gas Guard System (GASG301 ) An optional built in gas guard system is available to allow two tanks of CO2 to be connected to an incubator requiring approximately 15 psig of gas pressure. The unit is designed to automatically switch from the primary tank to the secondary tank when low gas pressure of approximately 10 psig is detected on the primary tank. This allows for a continuous supply of CO2 to an incubator after the primary tank is empty.
OUTL301 & OUTL302 Interior Electrical Outlet An optional interior duplex electrical outlet is available to supply power to small interior appliances such as shakers or stirrers. It is not intended to power high current draw devices. The outlet is 115V and GFI protected. For incubators that have a single interior duplex outlet, the outlet is fused at 2.0 Amps. Incubators with two interior duplex outlets are fused at 4.0 Amps total.
RCDR301/RCDR302 Built In Temp or Temp/Rh 6” Pen Recorders 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.
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.
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.
RCDR303/RCDR304 Built In Temp or Temp/Rh 10” Thermal Recorders 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.
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.
RDCR305/RCDR306 Side Mounted Temp/Rh 10” Pen Recorder 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, humidity, and CO2 systems can all be calibrated as necessary. CARON recommends an annual calibration check of all three systems. If calibration is required, 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.
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 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 chamber’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 The incubators are 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 LED and an audible alarm. Each alarm condition has been factory programmed to minimize nuisance alarms while maximizing warning time.
SECTION 9 – PREVENTATIVE MAINTENANCE Your 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, 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 Temperature Uniformity Temperature Sensor Humidity Range Humidity Control Humidity Sensor CO2 Range CO2 Control CO2 Sensor Interior Dimensions Interior Construction Exterior Dimensions Exterior Construction Work Space # of Shelves Shelf Construction Shelf Dimensions Model Shipping Weight Model Electrical 6024 10°C Above Ambient to 60°C 6026 6044 10°C Above Ambient to 60°C 5°C to 60°C 6046 5°C to 60°C ± 0.1°C ± 0.
SECTION 11 – ELECTRICAL SCHEMATICS 6024 & 6044 Series Operations Manual Rev F 02/14/12 Page 48 of 56
SECTION 11 – ELECTRICAL SCHEMATICS 6024 & 6044 Series Operations Manual Rev F 02/14/12 Page 49 of 56
SECTION 11 – ELECTRICAL SCHEMATICS 6024 & 6044 Series Operations Manual Rev F 02/14/12 Page 50 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 do
SECTION 13 – SPARE REPLACEMENT PARTS General Part Number MTR-130 BLW-112 CTR-131 CTR-134 POW-108 FLTR303 CRD-113 STP-101 Description Blower Motor Blower Wheel Watlow Standard controller Watlow Ramp and Soak 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-115 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 Te
SECTION 13 – SPARE REPLACEMENT PARTS (CONTINUED) 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* FUS3* FUS5* FUS5* FUS6 FUS7 FUS8 FUS9 FUS10 FUS11 FUS13 FUS14 Description Main circuit breaker switch Front mount chart recorder fuse Side mount chart recorder fuse Internal outlet fuse (single duplex) Internal outlet fuse (double duplex) Int.
SECTION 13 – SPARE REPLACEMENT PARTS (CONTINUED) Options Related Part Number CLM-132 FIT-348 LGT-134 LGT-156 PEN-101 PEN-102 PEN-103 PEN-104 PPR-101 PPR-104 PPR-105 PPR-106 TUB-145 TUB-174 WIR-102 Description Option Nylon tube clamp 1/4”barb-1/4” push-in adapter UVA replacement bulb 8 11/32 long 24W HO florescent bulb Red pen for 10 inch recorder Purple pen for 10 inch recorder Red pen for 6 inch recorder Blue pen for 6 inch recorder 10 inch recorder paper, 24hr / 7 day 6 inch recorder paper, 7 day 0-60C
SECTION 14 – ADVANCED USERS SECTION Unlocking the Controllers The temperature, humidity, and CO2 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.
