bod manual

User Manual 2.0

BOD Incubator Page 1 of 32

BOD INCUBATOR

OPERATION & MAINTENANCE MANUAL

Model Number : NLBI7SI Serial Number : BOD/14-012U

Newtronic Lifecare Equipment Private Limited 108-ABCD, Kandivli Co-Op. Industrial Estate, Mumbai 400067, India. Phone: +91 22 28679326 Fax: +91 22 28676059 Email: [email protected], [email protected] Web: www.newtronic.in

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mailto:[email protected]:[email protected]://www.newtronic.in/

User Manual 2.0


Table of Content 1. Company Information and Assistance ............................................................................... 3 2. Safety Warnings ................................................................................................................ 4 3. Receiving of BOD Incubator .............................................................................................. 6

3.1. Transportation ............................................................................................................. 6 4. Installation Instructions ...................................................................................................... 6

4.1. Location and Installation of Unit ................................................................................... 6 4.2. Power Connection ....................................................................................................... 7

5. Product Description ........................................................................................................... 9 5.1. Heating System ........................................................................................................... 9 5.2. Air Circulation ............................................................................................................ 10 5.3. Cooling System ......................................................................................................... 11

6. Technical Specifications .................................................................................................. 12 6.1. Specification Summary .............................................................................................. 12 6.2. Technical Specifications of Components ................................................................... 13

7. Incubator Operations ....................................................................................................... 14 7.1. Installation checks ..................................................................................................... 14 7.2. General Safety Features on the Machine: Interlocks ................................................. 15 7.3. Controller ................................................................................................................... 15

8. Operations ....................................................................................................................... 16 8.1. Power ON .................................................................................................................. 16 8.2. Controller Settings ..................................................................................................... 16 8.3. Set Parameters .......................................................................................................... 16

9. Troubleshooting ............................................................................................................... 29 10. Maintenance ................................................................................................................. 30

10.1. Interior/Exterior surfaces ........................................................................................ 30 10.2. Door Gasket ........................................................................................................... 30 10.3. General Electrical Connections .............................................................................. 30 10.4. Electric Heater(s) .................................................................................................... 31 10.5. Controller / Calibration ............................................................................................ 31 10.6. Preventative Maintenance Schedule / Log ............................................................. 31

11. Supporting Documents ................................................................................................. 32

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1. Company Information and Assistance Congratulations on purchasing a BOD Incubator from NEWTRONIC. You probably already know us as NEWTRONIC Lifecare Equipment Private Limited. Weve changed expanded our vision with the intent to provide you with more diversified solutions to your study and testing. We truly hope that every aspect of BOD Incubator design and quality will measure up to your strictest standards. Your BOD Incubator has been designed to operate with the reliability you expect for the demands you impose on your product and research testing. NEWTRONIC has head office in Mumbai which is located in western part of India. The company has sales and servicing center in many parts of India and in other countries also. Contact sales department to get latest information on sales offices around the world. For servicing of equipment and support; contact servicing department.

Parts and service inquiries for equipment within each division should be directed to NEWTRONIC by any of the following methods. Important! Please mention the Model and Serial Numbers of your unit while communicating with us. Newtronic Lifecare Equipment Private Limited 108-ABCD, Kandivli Co-Op. Industrial Estate, Near Hindustan Naka, Charkop, Kandivli (West) Mumbai 400067, India. Phone : +91 22 28679326 Fax : +91 22 28676059 Email : [email protected], [email protected] Web : www.newtronic.in Parts Replacement Your BOD Incubator has been designed and manufactured to provide years of reliable service. In the event a component should fail, it is recommended that only OEM approved parts be used as replacements. Please contact the Service Department for component replacement, or repair.

mailto:[email protected]:[email protected]://www.newtronic.in/

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2. Safety Warnings o Read this entire Operation Manual, as well as the vendor manuals and cut-sheets

provided before operating this equipment! Failure to adhere to any Safety Warning, or failure to follow the proper operating procedures listed throughout any of the information provided, could cause damage to your equipment, personal injury, or death.

o Operators and service personnel must be familiar with the location and function of all

controls and the inherent dangers of the equipment before operating or maintaining it. o Only qualified service personnel should ever be permitted to perform any service-related

procedure on this equipment o This is not an explosion resistant chamber. Do not install test articles that may release

explosive or flammable vapors in the chamber. o Do not place the unit near combustible materials or hazardous fumes or vapors. o Do not install unit in a corrosive environment. A corrosive environment may lead to poor

performance and deterioration of unit. o Make sure the chamber and any remote equipment provided are leveled when installed.

The chamber door may swing shut on personnel if it is tilted. o A main power disconnect may not be provided with your unit. If not provided, we

recommend that a fused disconnect switch on a separate branch circuit be installed as the power source in accordance with all National and Local Electrical Codes. If your unit is equipped with a power cord and plug, you must utilize a receptacle with the appropriate rating, which is on a branch circuit of its own.

o Do not position the equipment in a manner that would make it difficult to operate your main

power disconnect switch. o Your power supply line voltage may be too low or too high to properly and safely operate

your equipment. Before making the power supply connection to your equipment, you must follow the specific directions stated under Electric Supply in the Installation Instructions section. Failing to perform the directions stated may damage your equipment and void your warranty!

o Control panels, gauge boxes, etc., contain exposed electrical connections. Keep panels in

place properly when the unit is in operation. Disconnect and Lock-Out /Tag-Out all electrical power from the unit at its source before servicing or cleaning.

o Do not modify any component on this unit. Use only original equipment manufactured

(OEM) parts as replacement parts. Modifications to any component, or the use of a non-OEM replacement part could cause damage to your equipment, personal injury, or death.

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INTERNATIONAL WARNING / SAFETY SYMBOL DEFINITIONS Obey all DANGER, WARNING, and CAUTION labels shown in the manual and mounted on the equipment. Do not remove any labels mounted on the equipment.

WARNING OF HAZARDOUS AREA

WARNING OF DANGEROUS ELECTRIC VOLTAGE

WARNING OF HOT SURFACE

DANGER ROTATING FAN

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3. Receiving of BOD Incubator

3.1. Transportation

All NEWTRONIC BOD Incubators are factory tested and certified free from defects, when shipped.

Inspect BOD Incubator and shipping crate immediately upon receipt. If any damage is apparent, you should discuss it with the trucking delivery person and contact the transportation company immediately. Make notes of any damage on the Bill Of Lading. Retain all shipping materials for inspection. Any claims for damage must start at the receiving point. Check packing slip carefully and make sure all materials have been received as indicated on the packing ticket. Unless otherwise noted, YOUR ORDER HAS BEEN SHIPPED COMPLETE.

4. Installation Instructions Read this section completely before attempting to install, or operate the equipment.

4.1. Location and Installation of Unit

Your equipment has been fully operated, tested, and balanced in our plant prior to shipment, unless notified otherwise. Follow the installation requirements below. Do not place the unit near combustible materials or hazardous fumes or vapors. Do not locate unit in areas of wide ambient temperature variation such as near

vents or outdoor entrances. Do not install unit in a corrosive environment. A corrosive environment may lead to

poor performance and deterioration of unit. Do not position the unit in a manner that would make it difficult to operate

your main power disconnect switch. Make sure the unit is leveled when set up.

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4.2. Power Connection

Warning! Before making the power supply connection to your unit, you must perform the following procedure:

1. Verify the power supply voltage rating established for your chamber (listed above). The

voltage rating is also found on the serial tag on the side of the oven. Note the rated value here:

2. Measure and record the intended voltage source.

Note the measured value here:

3. Reference the Line Voltage Min/Max Tables below. Verify that the power supply voltage source you measured and recorded is within the minimum and maximum allowable operating voltages for your chamber rating. If it is not within this operating range, do not make the power connection! Otherwise, erratic operation and damage may occur to your equipment, which may void your warranty. If you have any questions, please call the NEWTRONIC Service Department.

Important! One of the most common causes of equipment malfunction is low line voltage as the power source to the unit. Ordinarily in this condition, the heat output would be reduced and the system's motors would operate erratically, eventually overheat, and shut down. You must be certain that your equipment is connected to a circuit with an adequate voltage and current source. An oversupply voltage would also cause erratic operation and eventual shutdown, or damage to your equipment.

Supply Voltage should remain 23010Volts at all-time having 50Hz frequency Operation outside this limits can results in damage to controller.

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Making the Power Supply Connection to the Chamber: A main power disconnect switch is normally provided with your small chamber. We recommend that a fused disconnect switch on a separate branch circuit be installed as the power source to your chamber, in accordance with all national and local electrical codes. Reference your Electrical or Power Schematic for all electrical requirements. The power connection is made via a cord and plug for standard units. Connect the plug to a receptacle that has the appropriate power supply on a branch circuit of its own.

Warning! High Accessible Current An Earth connection is essential before connecting the power supply. Make sure equipment is properly grounded in accordance with all codes.

Application of Power Before energizing any equipment, make a visual inspection for loose components,

electrical connections, fittings, etc. Shut all operating switches to the OFF position before energizing.

Have trained personnel start and check out the equipment before its first cycle.

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5. Product Description System Overview: NEWTRONICs BOD Incubators are engineered with precise control action. Heaters are mounted on the right side of chamber. Air circulation system provides maximum uniformity. The air circulation system sucks air from chamber; allows it to pass trough heater and back in the chamber. Accurate Temperature PID controller ensures tight control without over shoots of temperatures. Over temperature safety device provides protection against overshoots of temperature.

5.1. Heating System

Heating is done by long lasting stainless steel tubular heaters. Heating system controls temperature in the BOD Incubator using PID function. Supply to heaters is controlled by solid state relay. Safety relay prevents excessive temperatures and possible damage to samples or equipment.

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5.2. Air Circulation

Air circulation system is provided for maximum uniformity of temperature. The circulation motor is mounted on the back side of equipment. It remains continuously ON for uniformity of temperature. Process air is conditioned as it is drawn through the chamber by fan/blower wheel. It is than passed through heaters and the refrigeration coil. The conditioned air is discharged down and then enters the workspace through semi-pierced openings over the entire width of plenum of the working chamber. Air flows horizontally across the working space and then gets distributed on both side of the chamber. It is then passes through product vertically/horizontally and exits the workspace through circular semi-pierced openings at the top of plenum. Processed air flows from bottom and returns to the plenum for reconditioning. A inbuilt Temperature sensor is used to measurement of temperature inside the chamber. The control sensor is placed in the discharge air in the right side duct wall for better accuracy and control. Adjustable ventilation is provided for air changes in the Incubator.

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5.3. Cooling System

CFC free (Refrigerant 134A) cooling system consists of hermitically sealed compressor coupled with evaporation coil and condenser provides required cooling. Compressor is been safe guarded by time delay programmed in the controller and by using a robust electromagnetic relay circuit. The condenser unit is mounted in the top compartment of the chamber. Temperature will raise minimum 5C above ambient in case of Cooling System OFF/ not working Low temperature safety thermostat prevents excessive cooling.

It is recommended to keep Cooling ON for set temperature of 10C to 35C. For

temperature above 35C cooling should be kept OFF. Note: 1. The ambient/ environment room condition where chamber is going to be

placed/kept must be between 25C to 30

Compressor

Condenser Motor and

Condenser

Drier

Compressor relay / Capacitor

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6. Technical Specifications

6.1. Specification Summary

Model NLBI7SI

Internal Size 800(H) 500(W) 500(D) mm

External Size 1350(H) 630(W) 945(D) mm

Power Supply 230 Volts AC and 50HZ mains supply

Temperature Range +5C to 60C

Accuracy from set Temperature

0.5 C.

Temperature Uniformity 1C

Inner Chamber(MOC) Made of Stainless Steel Graded 304

Outer Chamber(MOC) Made of Stainless Steel Graded 304

Insulation PUF insulation between outer chamber and inner chamber.

Trays Rod Type Trays 3 Nos.

Tray Size 430 x 460 mm

Scanner Four Point Temperature Scanner

Door Full length inner glass door and outside metal door with door seal gasket and lock.

Control System PID controller with Ethernet interface

Heating System Long lasting stainless steel tubular heaters with S.S. fins

Chamber Cooling Using Hermitically sealed compressor coupled with evaporation coil and condenser, safe guarded by time delay. CFC Free Refrigerant.

Display panel Panel at front to view temperature, real time clock. The front panel consists of Controller, ACK button and HT, LT indications.

Control panel Panel at top to consists of wiring, Safety thermostat and other standard accessories.

Alarms Audio and Visual alarms generated for temperature variation

Safety Safety relay for temperature. Capillary Thermostate for temperature overshoots and undershoots in case of malfunction.

Note: 1. Control Accuracy is of control sensor (Sensor 1) w.r.t set point.

2. Uniformity is the measure of variation in temperature at different, locations within the working area of chamber w.r.t set value.

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6.2. Technical Specifications of Components

Component Qt. Make Model/Type Specification

PID Controller 1 Microcubs NW 480

Input 24VDC, Output - 240VAC/30VDC

SMPS 1 OMRON S8JC-Z05024CD Input -200 240VAC,

50/60Hz, 0.5 Amp Output 24VDC,1.5Amp

SSR 1 UNISON 801ZDA 33 25 00 24 330VAC, 25 Amp

Safety Thermostat

2 Elcon _ 2C 85C, 15 Amps,

230/250 V

MCB 1 Hager NCN116N C16 16 Amps, 240/415 V, 1 Pole

1 Hager NCN202N C2 2 Amps, 240/415 V,2 Pole

Relays 2 Allen Bradley 700-HC22A2-4L 240V , 50/60 HZ, 10 Amps/240VAC

Temperature Sensor

4 Radix PT 100 Temp Range - -30 to 65C

Circulation Motor 1 ELTEK T.E.F.C. Type 1/12HP ,230 Volt, 50Hz,

1440 RPM

Blower 1 ---- Alluminium blower 7 * 3 * 3/8 Bore

Dry Heaters 1 Rishina Electricals 14 U Type S.S. Fin heaters 500 W , 230V

Condensing Unit 1 EMERSON KCN 372LAG Refrigerant-134A,

Drier- EK-032 Motor CF 01-01

Sumo lamps on front control panel

2 SUMO Panel LED 16 mm 240V AC LEDs in Red for HT

& LT indication

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7. Incubator Operations Note: Before starting the chamber cross check all the requirements are satisfied for smooth running of the Incubator/equipment.

7.1. Installation checks

Warning! Before switching ON the Incubator all the requirement should match. Failing to do so will hamper chambers performance or damage its components. In such case, Warranty will be void.

Description Required for installation Actual Available

Required Power Supply Single Phase, 230 V 10 %, 50Hz YES NO

UPS Power Supply UPS supply Single Phase, 220 V 10 %, 50Hz to the control and display unit, 1.5KVA

YES NO

Cable Specs. 3 Core YES NO

Metal clad Socket with MCB

25 Amps YES NO

Distance between power socket & chamber

Less than 3 Meters YES NO

Proper Grounding Must YES NO

Drainage At the backside bottom of the Equipment. YES NO

Surrounding Temp 25C ~ 30C YES NO

Area Clean & free from dust YES NO

Level Horizontally leveled YES NO

Clearance Space

Side Minimum 450mm YES NO

Back Side Minimum 500mm YES NO

Front Minimum 1000mm YES NO

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7.2. General Safety Features on the Machine: Interlocks

Following are the list of safety devices and interlocks. Cross checking of those safety devices at regular interval is very essential for its operations

Safety Device Function

Low Temperature safety thermostat (LT) & Indicator

Cuts off the supply of cooling system and LT indicator will be illuminated if chamber temperature falls below temperature set on the dial of Low Temperature Thermostat.

Operator has to set the dial on 10C below the actual set temperature.

Auto Reset, once the temperature is above dial set temperature.

High Temperature safety thermostat (HT) & Indicator

Cuts off the supply of heating, humidity system and HT indicator will be illuminated if chamber temperature rises more than temperature set on the dial of High Temperature Thermostat.

Operator has to set the dial on 10C above the actual set temperature.

Auto Reset, once the temperature is below dial set temperature

7.3. Controller

Accurate PID controller is used to control required temperature. The controller has features like Auto Tuning, Temperature Deviation alarms, Over Temperature safety trip, Soak timer.

Measured Temperature in

C

SET / Select key

ENT / Enter key

Keys: Change Set Parameters

Compressor

Alarms

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8. Operations Following are the instructions and procedures to use BOD Incubator. Please read carefully before operating.

8.1. Power ON

Turn ON the power switch. The motor will start rotating and controller display will be ON.

8.2. Controller Settings

Temperature controller NW-480 is PID controller and Ethernet port with data logging facility.

8.3. Set Parameters

Press SET key to scroll through parameters. Press ENT key to select parameter to be change or register new value in memory. Use arrow keys to change parameter value.

Note: This procedure is only for the chambers which does not have ICDAS software connections. To change the set values using software please refer ICDAS operation manual.

Warning! Set the High Temperature safety thermostat at 10C above set

temperature and Low Temperature safety thermostat at 10C below the set temperature. Improper setting of thermostat will affect functions of chamber.

Following parameters can be access by pressing SET key

Default Window >> Enter Lock Code .

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Set Temperature & Press Enter Key

Set PID Parameters & press Enter key

Set Date & Time Setting & Press Enter Key Set Alarm Low & High Alarm limits

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Set Calibration Offset

Print Command Erase Memory

Set IP Address

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Set lock code & Press Enter

SCANNER

It shows reading of Each Sensor. In One Display it shows Temperature reading for 1 to 4 sensors in degree C. For remaining sensors press up arrow key. It shows reading of Each Sensor. In One Display it shows Temperature reading for 5 to 8 sensors in degree C.

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To set parameters such as temperature, alarm limits, PID values, Real time clock, Calibration Offset, Print Command, Erase Memory, and Set IP Address No & Set Pass Code use the following procedure.

8.3.1. Set Temperature

Set Temperature & Press Enter Key Set Temperature Use arrow keys to change set temperature then

press ENT key to register new value in memory.

8.3.2. PID Parameters

Set PID Parameters & press Enter key CAUTION: These parameters affect accuracy of controller; do not change if you are not a qualified engineer.

Press ENT key and following parameters will be displayed. Use arrow keys to

change parameter value; then press ENT to register it in memory and go to next

parameter.

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Proportional Band Integral time Derivative time Cycle time time

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Compressor Delay Time Compressor Hystresis Compressor ON Compressor OFF

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8.3.3. Set Date & Time Set Date & Time Setting & Press Enter Key

Press ENT key and following parameters will be

displayed. Use arrow keys to change parameter

value; then press ENT to register it in memory and

go to next parameter. Set Minutes & press Enter Set Hours & press Enter Set Year & press Enter

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Set Month & press Enter Set Date & press Enter Set Print Interval Time

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8.3.4. Temperature Alarm Limits Set Alarm Low & High Alarm limits



value; then press ENT to register it in memory

and go to next parameter. Temperature Deviation High Alarm The controller will generate alarm if the measured temperature is above this value with respect to set temperature. Temperature Deviation Low Alarm The controller will generate alarm if the measured temperature is below this value with respect to set temperature.

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8.3.5. Calibration Offset Set Calibration Offset



value; then press ENT to register it in memory.

Add the calibration offset in C.

8.3.6. Print Command

Press ENT key and data will be printed on the

connected printer and following window will appear. CAUTION: Before giving print command verify printer is connected properly, powered ON and sufficient papers are present.

Note: The controller is compatible to a DOS base printer on Parallel port.

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8.3.7. Erase Memory

Pressing ENT key controller memory will be

erased and it will come to default window.

8.3.8. Set IP Address No.

Set IP Address

Setting for IP address: Enter 192 and press enter Again enter 168 and press enter

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Again enter 0 and press enter And enter 139 and press enter

8.3.9. Set Lock Code

Set lock code & Press Enter Set the password and press enter.

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9. Troubleshooting

Problem Possible Cause and Rectification

No display on controller Check electric supply, mains switch. If supply voltage less than 200V than rectify the supply.

Temperature is not achieving

Check the set temperature.

If the set temperature is below or near ambient temperature turn ON cooling system.

Temperature not decreasing.

Check cooling system is turned ON.

LT (Low temperature safety thermostat) is not illuminating. If it is ON than check settings on Low temperature thermostat;

it should be 10C below set value.

Temperature is not rising Check the controller is not OFF.

Check the set value

Check controller output to Solid State Relay and to the heater as the circuit diagram.

Check Over temperature Safety relay.

Check heater continuity.

Temperature is overshooting

Check Solid State Relay. It may have been shorted.

PID tuning may be disturbed.

Temperature is not

controlled in 3C accuracy Check Solid State Relay. It may have been shorted.

Check circulation motor. It is not running then may require replacement.

PID tuning may be disturbed.

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10. Maintenance Only qualified service personnel should ever be permitted to perform any service related procedure on this chamber! Disconnect and Lock-Out / Tag-Out all electrical power from the facility at its source before servicing or cleaning.

Frequency of preventive maintenance procedures depends upon how the facility is used and upon other circumstances. Because of this, a hard and fast schedule of maintenance operations is difficult to present. Indeed, an inflexible schedule might be suitable for one user, but completely inadequate for another. Therefore, we have provided periodic figures when to perform maintenance procedures, based on the average chamber use. We suggest that you maintain a preventive maintenance log. In this log you will record operating notes, pressures, temperatures, and electric readings. The log is valuable because it will help maintenance and service people by documenting long term trends and by showing parameter levels when the chamber is operating properly.

10.1. Interior/Exterior surfaces

The interior and exterior surfaces of the chamber are best cleaned by using warm water with mild soap and a clean soft cloth. For finger prints or other stains, mild, non-abrasive cleaners may be used. On stainless steel outer body with a satin finish, run strokes in the direction as the grain. Inspection Period: 15Days

10.2. Door Gasket

Door gaskets should be cleaned on a regular basis. To clean the gasket, use baking soda and warm water, wiping dry with a soft cloth. The vinyl gasket from around the inside door will assure an air tight seal if properly maintained and inspected regularly. When inspecting, check that the gaskets are properly seated in their retainers. A visual check for wear and tear is also required. If gaskets should become torn or broken, they should be replaced immediately. Inspection Period: 30Days

10.3. General Electrical Connections

Warning! Remove All Power From Chamber!

Inspect inside the control panel and the machinery compartment for loose electrical connections, frayed wires, loose components, or other potential problems. Inspection Period: 6 Months

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10.4. Electric Heater(s)

Warning! Remove All Power From Chamber!

Inspect the electric heater(s) inside the chamber conditioning plenum and look for defects. Inspection Period: 6 Months

10.5. Controller / Calibration

The controller, sensors should be rechecked for its accuracy and for the proper activation of limit or alarm outputs. Inspection Period: 1 Year

10.6. Preventative Maintenance Schedule / Log

Important: For each of the items to be inspected, refer to item description sections for details on maintenance and service.

Preventative Maintenance Schedule / Log

Item to be Inspected

Inspection Period

Actual Date Inspected / Serviced




Interior/ Exterior surfaces

15Days

Door Gasket 30Days

General Electrical Connections

6 Months

Electric Heaters 6 Months

Controller Calibration

1 Year

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11. Supporting Documents As applicable to the chamber model and serial number, the following are included in the Supplemental Instructions Section of this manual.

Document

Electrical Schematic Diagram

General Assembly Drawing

SOP

Test Certificates

Material of Construction test certificate

PID Controller Certificate

Circulation Motor test certificate

Condensing unit test certificate

Temperature sensors test certificate

Dry heaters test certificate

bod manual

Documents

bod incubator page

incubator operations

user manual

installation of unit

installation instructions

installation checks

safety warnings

heating system