INSTRUCTION MANUAL

FT36

BLAST AND FLUID BED FREEZER

FT36AL8721

ISSU E 1

OCTOBER 1996

ARMFIELD LIMITED

OPERATING INSTRUCTIONS AND EXPERIMENTS

FT36 - BLAST AND FLUID BED FREEZER

PAGE NO.

SAFETY 1

RECEIPT OF EQUIPMENT 5

FLOW DIAGRAM 6

CONTROL PANEL DIAGRAM 7

WIRING DIAGRAM 8

WIRING DIAGRAM 9

FUSES 10

CONNECTION TO SERVICES 11

OPERATING INSTRUCTIONS 12

DESCRITION OF INDICATOR LIGHTSON CONTROL CONSOLE 14

ROUTINE MAINTENANCE 17

GENERAL SAFETY a

SAFETY IN THE USE OF EQUIPMENT SUPPLIED BY ARMFIELD

Before proceeding to install, commission or operate the equipment described in thisinstruction manual we wish to alert you to potential hazards so that they may beavoided.

Although designed for safe operation, any laboratory equipment may involveprocesses or procedures which are potentially hazardous. The major potentialhazards associated with this particular equipment are listed below.

. INJURY THROUGH MISUSE

INJURY FROM ELECTRIC SHOCK

POISONING FROM TOXIC MATERIALS (E.G. MERCURY)

INJURY FROM ROTATING COMPONENTS

DAMGE TO CLOTHING

.

.

.

.Accidents can be avoided provided that equipment is regularly maintained and staf

and students are made aware of potential hazards. A list of general safety rules isincluded in this manual, to assist staff and students in this regard. The list is notintended to be fully comprehensive but for guidance only.

Please refer to the notes overleaf regarding the Control of Substances Hazardous toHealth Regulations.

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The COSHH Regulations

The Control of Substances Hazardous to Health Regulations (1988)

The COSHH regulations impose a duty on employers to protect employees andothers from substances used at work which may be hazardous to health. Theregulations require you to make an assessment of all operations which are liable toexpose any person to hazardous solids, liquids, dusts, vapours, gases or micro-organisms. You are also required to introduce suitable procedures for handlingthese substances and keep appropriate records.

Since the equipment supplied by Armfield Limited may involve the use ofsubstances which can be hazardous (for example, cleaning fluids used formaintenance or chemicals used for particular demonstrations) it is essential thatthe laboratory supervisor or some other person in authority is responsible forimplementing the COSHH regulations.

Part of the above regulations are to ensure that the relevant Health and Safety DataSheets are available for all hazardous substances used in the laboratory. Any personusing a hazardous substance must be informed of the following:Physical data about the substanceAny hazard from fire or explosionAny hazard to healthAppropriate First Aid treatmentAny hazard from reaction with other substancesHow to clean/dispose of spilageAppropriate protective measuresAppropriate storage and handling

Although these regulations may not be applicable in your country, it is stronglyrecommended that a similar approach is adopted for the protection of the studentsoperating the equipment. Local regulations must also be considered.

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USE OF EARTH LEAKAGE CIRCUIT BREAKER AS AN ELECTRICALSAFETY DEVICE

The equipment described in this Instruction Manual operates from a mains voltageelectrical supply. The equipment is designed and manufactured in accordance withappropriate regulations relating to the use of electricity. Similarly, it is assumed thatregulations applying to the operation of electrical equipment are observed by the enduser.

However, it is recommended that an Earth Leakage Circuit Breaker (ELCB,alternatively called a Residual Current Circuit Breaker or RCCB) be fitted to thisequipment. If through misuse or accident the equipment becomes electricallydangerous, an ELCB wil switch off the electrical supply and reduce the severity ofany electric shock received by an operator to a level which, under normalcircumstances, wil not cause injury to that person.

If the electrical supply to the laboratory already incorporates an ELCB, then the devicesupplied with the equipment need not be used. If the electrical supply does notincorporate such protection then the loose ELCB supplied by Armfield Ltd should befitted by a competent electrician either in the supply to the laboratory or in the supplyto the individual item of equipment. Drawing Number BM20979 gives fullinstallation instructions.

Note: If any doubt exists whether the electrical supply incorporates a device then theELCB supplied should be fitted.

At least once each month, check that the ELCB is operating correctly by pressing theTEST button. The circuit breaker MUST trip when the button is pressed. Failure totrip means that the operator is not protected and the equipment must be checked andrepaired by a competent electrician before it is used.

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RECEIPT OF EQUIPMENT

1. SALES IN THE UNITED KINGDOM

The apparatus should be carefully unpacked and the components checked against theAdvice Note. A copy of the Advice Note is supplied with this instruction manualfor reference.

Any omissions or breakages should be notified to Armfield Limited within threedays of receipt.

2. SALES OVERSEAS

The apparatus should be carefully unpacked and the components checked against theAdvice Note. A copy of the Advice Note is supplied with this instruction manualfor reference.

Any omissions or breakages should be notified immediately to the Insurance Agentstated on the Insurance Certificate if the goods were insured by Armfield Ltd.

Your own insurers should be notified immediately if insurance was arranged byyourselves.

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334

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SUPPLY ON

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- 8 -

LIGUID SOLENOID

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FUSE ITEM KW FLC FUSENUMBER SIZECF1 CONTROL 6F1 F2 F3 COMPRESSOR MOTOR f. 8-4 20M 25F4 F5 F6 EVAPORATOR FAN 0.75 27 6F7 Fa F9 DEFR OST HEATERS 4.5 6.25 10F10 CRANKCASE HEATER 0.2 - 4F 11 DOOR HEATERS 0.2 - 6F12 CABINET LI GHTS 0-2 - 6

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CONNECTION TO SERVICES

Cooling Water

It is EXTREMELY IMPORTANT that the compressor must NEVER be run without acontinuous supply of cooling water. The cooling water inlet and outlet connections

are located at the extreme left-hand side of the unit at the rear.

The water supply must have a line pressure of not less than 3.0 bar and a flowcapacity of more than 25litres/min at 20°C.

Electricity

A suitable 3 phase supply must be connected through an Earth Leakage CircuitBreaker as detailed previously.The supply required is:-

415V /3ph/50Hz - 5kW

Ensure that the live wires are correctly wired by briefly switching on the compressor.The compressor motor can run in either direction but the fan inside the cabinet mustrun in the direction indicated on the fan blades (embossed arrow). If the fan rotatesin the opposite direction, turn off the unit and swap over any two live connections.

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ACCESSORIES

TEMPERA TURE SENSORS

Four thermocouple temperature sensors can be connected to the Armfield DataLogger for continuous storage an recording of selected temperatures within the blast

freezer compartment.

The sensors are located into the blast freezer compartment by inserting themthrough the plastic conduit via the gland outside the freezer cabinet, to the right ofthe front door.

The Data Logger is supplied with a comprehensive instruction leaflet which shouldbe used for set up of the temperature sensors to the logger hardware and to a suitablecomputer.

The thermocouple sensors are then positioned within the freezer compartment atthe desired locations. These locations wil depend on the experiment beingperformed but can be, for example:

* Air temperature (sensor tip in airstream)

* Tray temperature (sensor tip in contact with one or more of thestainless steel trays using adhesive tape)

* Food package temperature (sensor tip taped to outside/inside of foodpackage)

* inside food sample being frozen (sensor tip positioned inside sampleafter making an access passage - centre of good sample wil be last tofreeze)

ANEMOMETER

The telescopic anemometer is installed by insertion into the air stream in the blastfreezer duct through the plastic conduit located outside the freezer to the right of thefront door. It is used for measuring the air speed in the freezer duct.

The anemometer has an analogue readout display and can also be connected to thedata logger so that the output can be stored and recorded continuously. The air speedis adjusted using the manual baffle adjusting handwheel on the freezer cabinet.

Before using the freezer it is advisable to take readings of the air speed relating tovarious settings of the baffles using either the meter readout or data logger. Thiscalibration wil be useful for later reference.

THE ANEMOMETER MUST NOT BE USED A TEMPERATURES BELOW 00 C. IT isINTENDED ONLY FOR THE CALI BRA TION OF THE AIR SPEED ADJUSTINGBAFFLES AT AMBIENT TEMPERATURES AND SHOULD BE WITHDRAWNFROM THE CONDUIT BEFORE SWITCHING ON THE REFRIGERA TIONCOMPRESSOR.

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OPERATING INSTRUCTIONS

It is assumed that the Blast and Fluid Bed Freezer has been installed and connected tothe appropriate services as detailed in previous sections.

1. The main Isolator must be left in the ON position to allow thecrankcase heater in the compressor to keep the oil warm. IF THIS ISNOT POSSIBLE. the main switch must be switched on aminimum of 24 hours before the machine is used.

2. Open inlet cooling water and run drain line to waste position. Makesure there is a flow of water.

3. Switch on compressor control refrigeration on switch. Theevaporator fan and compressor wil start. The temperature wil begin

to fall and can be observed on the temperature controller (3). Thetemperature wil fall until it reaches its desired temperature.The water valve is pre-set during commissioning but may need to bereset to achieve 35°C condensing temperature (12.8 bar) as dictated bylocal conditions.

4. The refrigeration plant is now in operation and wil continue to rununtil the desired temperature is reached (to a minimum of -35°C)when it wil modulate to hold the temperature constant. Thecompressor wil pump down and stop on low pressure, but theevaporator fan wil continue to run.

5. The stainless steel trays in the ducting inside the cabinet are

removable so that a variety of substances can be frozen. For example,use only two trays to freeze a large item or use several trays to freeze anumber of different items. An access connection is provided at theducting and the cabinet wall to allow thermocouple and leads tomonitor individual temperatures on a recorder outside the cabinet ifrequired. It is also possible to use a special extending anemometer inthis access connection to measure air flow in the duct. Standardanemometers can be used at the Fluid Bed section.

6. Defrosting can be achieved overnight if the refrigeration on switch isturned off and the cabinet doors are left open. Make sure there are notraces of foodstuff left in the cabinet and before restarting, dry out theinterior of the cabinet.

QUICK DEFROST

Push the defrost button (19). Defrost light wil come on, evaporatorfan switches off and the compressor wil pump down, defrost heaterswil come on. After pre-set, time heaters and the defrost light wil gooff automatically and refrigeration wil start automatically.If refrigeration switch turned off and push button is pressed, thecabinet wil defrost and then stop until the switch is put into positionagain.

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7. The fluid bed freezer section is accessed by the smaller door on theright-hand end of the cabinet. Items such as peas or diced vegetables

can be fluidised here to differing degrees depending on the cold airflow velocity.

8. The air flow rate from the fan can be adjusted using the external

adjust handwheel which moves a 'damper' plate inside the duct. Themaximum air velocity obtainable is 10 m.s.-I. When fluidisingmaterial it is better to start with the minimum velocity and slowlyopen the 'damper' until a satisfactory fluidised bed is achieved.

9. To prevent freezing up of the two doors, they are equipped with aheating tape on their surround and each has an on/off switch on thetransformer boxes situated on the left-hand side of the cabinet. Thesemust remain on during operation of the freezer.

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DESCRIPTION OF INSTRUMENTS ON CONTROL CONSOLE

Refer to diagrams on pages 6 and 7.

1. Compressor Ammeter

2. Compressor Hours Run

3. Temperature Controller/Indicator

4. Compressor Running Indicator Light

5. Evaporator Running Indicator Light

6. Supply On Indicates Main Supply Switched on

7. Low Pressure/Pumpdown Indicates a normal condition when onwith defrost thermostat satisfied.

8. Thermostat Satisfied Indicates when the cabinet is down totemperature. It wil also indicate with the Low Pressure/Pump DownIndicator.

9. Defrost Indicates once the Push Button (19) is depressed and alsomeans the defrost heaters in the cabinet are on. This indicator canalso be on with the Low Pressure /Pump Down Indicator. The defrostwil terminate either by time or temperature in the cabinet.

10. Compressor Trip Indicates if an electrical fault has developed on thecompressor drive motor or supply to the control panel is defective.

11. Evaporator Fan Trip Indicates the evaporator fan has cut out on thethermal overload. Possible cause would be running for too long withthe air flow damper closed.

12. Low Oil Pressure Indicates if the differential oil pressure in thecompressor drops below a pre-determined setting. Possible cause,compressor control switch switched off or main supply to control

panel off for long periods, not allowing the oil to be kept warm. Thisis reset on the oil control switch on the compressor.

13. High Pressure Indicates when the discharge pressure is too high.Possible cause water not switched on to the condenser. To reset,

depress the red button on the control marked 'High Pressure', below

the compressor.

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14. Cabinet Overheat Indicates if the cabinet temperature rises above apre-set leveL. The cabinet must be allowed to cool down naturally andcan be reset by depressing the button (18). Possible caused, defrostingcabinet more than required.

15. Safety Cut Out Indicates if the emergency stop push button (21) hasbeen activated, also the light wil indicate if the cabinet has been outon cabinet overheat. These faults can only be reset by reset button(18).

16. Compressor Control This switch should only be used to turn off thecompressor for servicing and should always be left in the ONposition.

17. Refrigeration Off/On This switch activates the liquid solenoid valve

and the evaporator fan. Starting the refrigeration cycle.After finishing with the freezer, turn this switch to OFF.This is the only switch required to operate the freezer.

18. Control Reset Push Button Each time the mains switch (20) isswitched off this button must be pressed to reset the control paneL.

19. Manual Defrost Push Button If it is required to defrost the cabinetrapidly, press the button. This starts the defrost cycle.

20. Main Isolator.

21. Emergency Stop

22. Compressor

23. High Pressure Gauge

24. High Pressure cut-out

25. Oil Return Solenoid

26. Oil Separator

27. Liquid Received

28. Filter Drier

29. Liquid Solenoid Valve

30. Sight Glass

31. Heat Exchanger

32. Expansion Valve

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33. Evaporator

34. Cabinet Overheat Thermostat

35. Defrost Termination Thermostat

36. Suction Accumulator

37. Low Pressure cut-out

38. Suction Pressure Gauge

39. Low Oil Pressure cut-out

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ROUTINE MAINTENANCE

To preserve the life and efficient operation of the equipment it is important that theequipment is properly maintained. Regular servicing/maintenance of theequipment is the responsibilty of the end user and must be performed by qualifiedpersonnel who understand the operation of the equipment.

In addition to regular maintenance the following notes should be observed:-

1. The equipment should be disconnected from the electrical supply when

not in use.

2. The exterior of the equipment should be periodically cleaned. DO NOTuse abrasives or solvents.

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GENERAL SAFETY RULES

1 Follow Relevant Instructions

a Before attempting to install, commisslOn or operate equipment, all relevant

suppliers/manufacturers instructions and local regulations should beunderstood and implemented.

b It is irresponsible and dangerous to misuse equipment or ignore instructions,

regulations or warnings.c Do not exceed specified maximum operating conditions (eg. temperature,

pressure, speed etc.)

2 Installation

a Use lifting tackle where possible to install heavy equipment. Where manual

lifting is necessary beware of strained backs and crushed toes. Get help from anassistant if necessary. Wear safety shoes where appropriate.

b Extreme care should be exercised to avoid damage to the equipment during

handling and unpacking. When using slings to lift equipment, ensure that theslings are attached to structural framework and do not foul adjacent pipework,glassware etc. When using fork lift trucks, position the forks beneathstructural framework ensuring that the forks do not foul adjacent pipework,glassware etc. Damage may go unseen during commissioning creating apotential hazard to subsequent operators.

c Where special foundations are required follow the instructions provided anddo not improvise. Locate heavy equipment at low leveL.

d Equipment involving inflammable or corrosive liquids should be sited in acontainment area or bund with a capacity 50% greater than the maximumequipment contents.

e Ensure that all services are compatible with the equipment and thatindependent isolators are always provided and labelled. Use reliableconnections in all instances, do not improvise.

f Ensure that all equipment is reliably earthed and connected to an electrical

supply at the correct voltage. The electrical supply must incorporate a ResidualCurrent Device (RCD) (alternatively called an Earth Leakage Circuit Breaker -ELCB) to protect the operator from severe electric shock in the event of misuseor accident.

g Potential hazards should always be the first consideration when deciding on a

suitable location for equipment. Leave sufficient space between equipmentand between walls and equipment.

a

3 Commissioning

a Ensure that equipment is commissioned and checked by a competent memberof staff before permitting students to operate it.

4 Operation

a Ensure that students are fully aware of the potential hazards when operating

equipment.b Students should be supervised by a competent member of staff at all times

when in the laboratory. No one should operate equipment alone. Do not leaveequipment running unattended.

c Do not allow students to derive their own experimental procedures unless

they are competent to do so.d Serious injury can result from touching apparently stationary equipment

when using a stroboscope to 'freeze/ rotary motion.

5 Maintenance

a Badly maintained equipment is a potential hazard. Ensure that a competent

member of staff is responsible for organising maintenance and repairs on aplanned basis.

b Do not permit faulty equipment to be operated. Ensure that repairs are carriedout competently and checked before students are permitted to operate theequipment.

6 Using Electricity

a At least once each month, check that ELCB's (RCCB's) are operating correctly

by pressing the TEST button. The circuit breaker must trip when the button is

pressed (failure to trip means that the operator is not protected and a repairmust be effected by a competent electrician before the equipment or electricalsupply is used).

b Electricity is the commonest cause of accidents in the laboratory. Ensure that

all members of staff and students respect it.c Ensure that the electrical supply has been disconnected from the equipment

before attempting repairs or adjustments.

d Water and electricity are not compatible and can cause serious injury if theycome into contact. Never operate portable electric appliances adjacent toequipment involving water unless some form of constraint or barrier isincorporated to prevent accidental contact.

e Always disconnect equipment from the electrical supply when not in use.

b

7 A voiding fires or explosion

a Ensure that the laboratory is provided with adequate fire extinguishersappropriate to the potential hazards.

b Where inflammable liquids are used, smoking must be forbidden. Noticesshould be displayed to enforce this.

c Beware since fine powders or dust can spontaneously ignite under certain

conditions. Empty vessels having contained inflammable liquids can containvapour and explode if ignited.

d Bulk quantities of inflammable liquids should be stored outside the laboratory

in accordance with local regulations.e Storage tanks on equipment should not be overfiled. All spilages should be

immediately cleaned up, carefully disposing of any contaminated cloths etc.Beware of slippery floors.

f When liquids giving off inflammable vapours are handled in the laboratory,the area should be ventilated by an ex-proof extraction system. Vents on theequipment should be connected to the extraction system.

g Students should not be allowed to prepare mixtures for analysis or other

purpose without competent supervision.

8 Handling poisons, corrosive or toxic materials

a Certain liquids essential to the operation of equipment, for example mercury,

are poisonous or can give off poisonous vapours. Wear appropriate protectiveclothing when handling such substances. Clean up any spilage immediatelyand ventilate areas thoroughly using extraction equipment. Beware of slipperyfloors.

b Do not allow food to be brought into or consumed in the laboratory. Neveruse chemical beakers as drinking vessels.

c Where poisonous va pours are involved, smoking must be forbidden. Noticesshould be displayed to enforce this.

d Poisons and very toxic materials must be kept in a locked cupboard or store

and checked regularly. Use of such substances should be supervised.e When diluting concentrated acids and alkalis, the acid or alkali should be

added slowly to water while stirring. The reverse should never be attempted.

9 A voiding cuts and burns

a Take care when handling sharp edged components. Do not exert undue force

on glass or fragile items.b Hot surfaces camiot in most cases be totally shielded and can pl'duce severe

burns even when not 'visibly hot~. Use common sense and think which partsof the equipment are likely to be hot.

c

10 Eye protection

a Goggles must be worn whenever there is a risk to the eyes. Risk may arisefrom powders, liquid splashes, va pours or splinters. Beware of debris from fastmoving air streams. Alkaline solutions are particularly dangerous to the eyes.

b Never look directly at a strong source of light such as a laser or Xenon arclamp. Ensure that equipment using such a source is positioned so that passers-by cannot accidentally view the source or reflected ray.

c Facilities for eye irrigation should always be available.

11 Ear protection

a Ear protectors must be worn when operating noisy equipment.

12 Clothing

a Suitable clothing should be worn in the laboratory. Loose garments can cause

serious injury if caught in rotating machinery. Ties, rings on fingers etc.should be removed in these situations.

b Additional protective clothing should be available for all members of staff and

students as appropriate.

13 Guards and safety devices

a Guards and safety devices are installed on equipment to protect the operator.The equipment must not be operated with such devices removed.

b Safety valves, cut-outs or other safety devices wil have been set to protect the

equipment. Interference with these devices may create a potential hazard.c It is not possible to guard the operator against all contingencies. Use common

sense at all times when in the laboratory.d Before starting a rotating machine, make sure staff are aware how to stop it in

an emergency.

e Ensure that speed control devices are always set at zero before startingequipment.

14 First aid

a If an accident does occur in the laboratory it is essential that first aid

equipment is available and that the supervisor knows how to use it.b A notice giving details of a proficient first-aider should be prominently

displayed.c A 'short list/ of the antidotes for the chemicals used in a particular

laboratory should be prominently displayed.

d