Forma Scientific, Inc.

P.O. Box 649

Marietta, Ohio 45750

Telephone: (740) 373-4763

Telefax: (740) 373-4189
________________________________________

Models:

Single Chamber
3158, 3164, 3154, 3166

Dual Chamber
3326, 3336, 3354

Water Jacketed Incubator

Manual No. 7053158

Important!

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.
 NOTE:

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.

MANUAL NO. 7053158

8/94 Corrected p. 5-10, removed reference to ringback on CO2

deviation.
11/93 Manual revised to current format.
REV ECN DATE DESCRIPTION
 GENERAL SAFETY NOTES

The Occupational Safety and Health Administration (O.S.H.A.) has revised Section
1910-147, The Control Of Hazardous Energy (Lockout/Tagout).

Hazardous energy may be: electric, air, hydraulic, water, steam, gravity, spring & all other
equally hazardous energy.

This revised regulation, states that you will de-energize all potential sources of energy
(may be more than one energy source) prior to performing service or maintenance on any
equipment. It also states that a lock shall be placed on the de-energized control, along
with a verified test (use of a voltmeter or other equipment) to insure no accidental starts.
If you are not familiar with this regulation, review the O.S.H.A. Regulation, Section
1910-147.

In field service, full compliance with this regulation is difficult at best.

Troubleshooting must often be performed with hazardous energy applied; therefore
extreme caution must be followed during these troubleshooting steps. Only Qualified
Personnel Must Perform This Work. This phase of the repair work must be coordinated
through the customer's facilities maintenance department or designated person.

When performing service or maintenance as an outside contractor/worker, follow the

Outside Work Force's Lockout/Tagout system. Be alert for new types of lockout/tagout
devices.

√ Always use the proper protective equipment (clothing, gloves, goggles etc.).
√ Always dissipate extreme cold or heat, or wear protective clothing.
√ Always follow good hygiene practices.
√ Each individual is responsible for his/her own safety.

For your safety adhere to all DANGER and CAUTION statements.

Danger: This word is used to call attention to immediate hazards of

equipment or conditions which, if not avoided, could result in personal
injury, loss of life or property damage.

Caution: This word is used to call attention to potential hazards of

equipment or conditions which, if not avoided, could
result in personal injury, loss of life or property damage.
 DO YOU NEED INFORMATION OR ASSISTANCE ON FORMA SCIENTIFIC
PRODUCTS?

If you do, please contact us 8:00 A.M. to 5:00 P.M. (Eastern Standard Time) at:

1-614-373-4763 Direct
1-800-848-3080 Toll Free, U.S. and Canada
1-614-373-4189 FAX
29-8205 Telex

International customers please contact your local sales group.

Forma's Inside Sales Support Group can provide information on pricing, give you
quotations, take your order and provide delivery information on major equipment items.

The Forma Product Service Group can supply technical information about proper setup,
operation or troubleshooting of your equipment and fill your needs for spare or replacement parts or
provide you with on-site service.

Whatever Forma products you need or use, we will be happy to discuss your applications. If
you are experiencing technical problems, working together, we will help you locate the problem and,
chances are, correct it yourself .... over the telephone without a service call.

When more extensive service is necessary, you can count on Life Sciences International
North America (LSI/NAS) for on-the-spot repairs by trained professional field technicians. In addition
to checking the reported problem, our technicians also check basic operation, such as:

Control Calibrations Electrical Circuits

Temperature Recorders
Blowers/Fans
CO2 Levels R.H. Levels
Compressors

The following cities and their surrounding areas are covered by LSI/NAS personnel.

Phoenix, AZ Chicago, IL Cincinnati, OH

Los Angeles, CA Boston, MA Philadelphia, PA
San Diego, CA Detroit, MI Washington, PA
San Francisco, CA St. Louis, MO Memphis, TN
Denver, CO Raleigh/Durham, NC Austin, TX
Washington, DC Newington, NH Dallas/Ft. Worth, TX
Atlanta, GA Newark, NJ Seattle, WA
Des Moines, IA New York City, NY

Within the continental United States, service coverage is by Life Sciences International North
America (LSI/NAS). They offer a Bi-Annual Performance Check which provides a complete
checkout of your equipment twice a year. This keeps minor problems from becoming major ones.
If you would like to know more about their Bi-Annual Performance Check, please contact LSI/NAS
on their Toll-free number, 1-800-467-4627.
 TABLE OF CONTENTS

SECTION 1 - RECEIVING

1.1 Preliminary Inspection

1.2 Visible Loss or Damage
1.3 Responsibility for Shipping Damage

SECTION 2 - UNPACKING LIST

2.1 Unpacking List

SECTION 3 - INTRODUCTION

3.1 The Water Jacket: Key Features

SECTION 4 - INSTALLATION AND START-UP

4.1 Location
4.2 Preliminary Disinfecting
4.3 Installing the #6 Neoprene Stopper (Access Port)
4.4 Installing the Shelf Brackets and Cam Latch Assembly to
the Duct Sheets
a. Installing the Shelf Brackets
b. Installing the Cam Latch Assembly
4.5 Installing the Duct Sheets
4.6 Installing the Shelves
4.7 Leveling
4.8 Connecting to a Power Source
 4.9 Preparing the Incubator for Filling
4.10 Filling the Water Jacket
a. Funnel Method
b. Tap Fill Method
4.11 Connecting the Optional Gas Guard
4.12 Connecting the Gas Supply without the Gas Guard
4.13 Filling the Humidity Reservoir or Pan
4.14 Setting the Chamber Temperature
4.15 Setting the Over Temp Safety Thermostat
4.16 Zeroing the CO2 Controller
4.17 Setting the CO2 Content

SECTION 5 - OPERATION

5.1 Operation
5.2 Overview of Humidification and CO2
5.3 Control Panel
a. Fill Fitting and Vent Hole
b. Power Switch and Pilot Light
c. Circuit Breaker
d. Variable/37°C Switch, Temp Control and Heater
Pilot Light
e. Gas Sample Port
f. Setpoint Adjustment Tool
5.4 (Factory-Installed Option) Gas Guard Stock #190410
a. Control Switch
b. Silence Switch
c. Gas Depletion Alarm
d. Active Tank Indicating Lights
e. Pressure Low Indicating Lights
 5.5 CO2 Module
a. CO2 Power Switch
b. CO2 Controller and Digital Display
c. Audible CO2 Alarm and Pilot Light
d. SET/SILENCE Push Button
e. Alarm Disable Switch
f. CO2 Inject Light
g. CO2 Zero Adjustment
5.6 Alarm/Monitor Module
a. Over Temperature Controller and SET/SILENCE
Button
b. Over Temperature Alarm and Pilot Light
c. Add Water Pilot Light and Audible Alarm

SECTION 6 - ROUTINE MAINTENANCE

6.1 Installing the Decontamination Kit

6.2 Disinfecting the Incubator Interior
6.3 Cleaning the Cabinet Exterior
6.4 Draining the Water Jacket
6.5 Changing the CO2 Filter
6.6 CO2 Test Instruments

SECTION 7 - SERVICE (For Qualified Personnel Only)

7.1 General Troubleshooting

7.2 CO2 Control Calibration
a. Stabilizing the Incubator
b. Adjusting the Zero Pot
c. Adjusting the Span Pot
d. Re-checking the Zero Adjustment
e. Checking the CO2 at the Desired Setpoint
7.3 37C° Control Calibration
7.4 Replacing the CO2 Sensor
SECTION 7 - SERVICE (continued)

7.5 Replacing the Triac

7.6 Replacing the CO2 Solenoid
7.7 Replacing the Temperature Control
7.8 Replacing the Pilot Lights
7.9 Replacing the Thermistor
7.10 Replacing the 0.3 Amp Fuse
7.11 Replacing the Blower Motor

SECTION 8 - SPECIFICATIONS

8.1 Capacity
8.2 Weight
8.3 Dimensions
8.4 Construction
8.5 Shelves
8.6 Alarm/Monitor Module
8.7 CO2 Module
8.8 Temperature Control
8.9 Heaters
8.10 Blower
8.11 Fittings
8.12 Electrical Characteristics
8.13 Performance Data

SECTION 9 - AUXILIARY EQUIPMENT

9.1 Auxiliary Equipment

SECTION 10 - PARTS LIST

SECTION 11 - SCHEMATICS

SECTION 12 - WARRANTY INFORMATION

Forma Scientific, Inc.
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SECTION 1 - RECEIVING

1.1 PRELIMINARY INSPECTION

This incubator was thoroughly inspected and carefully packed prior to shipment and all
reasonable precautions were taken to ensure safe arrival of the merchandise at its
destination. 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 in-transit damage.

1.2 VISIBLE LOSS OR DAMAGE

If any loss or damage is discovered, note any discrepancies on the delivery receipt.
Failure to adequately describe such evidence of loss or damage may result in the carrier
refusing to honor a damage claim. Immediately call the delivering carrier and request that
their representative perform an inspection. Do not discard any of the packing material and
under no circumstances 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 in-
transit damage.

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SECTION 2 - UNPACKING LIST

2.1 UNPACKING LIST

Remove the packing box from the incubator. If the unit is to be moved by fork lift,
leave the incubator on the skid until it has been moved to its designated location. A
plastic bag containing the following accessories is packed inside the incubator:

Qty. Stock # Description Purpose

1 190028 Decontamination Kit Maintenance
1 180001 Polypropylene Funnel Fill & Drain
3' 246011 Vinyl Tubing 3/8" ID Fill & Drain
6' 246010 Vinyl Tubing 3/16" ID CO 2 Connection
1 285057 Extender Card Maintenance & Calibration

Also packed with each incubator:

Qty. Stock # Description

24 23052 Stainless Steel Wing Nuts (#10-32)
20 55000 Stainless Steel Screws (Truss Head #10-32" x 5/8")
1 121034 Cam Latch (Nylon)
1 127019 Stainless Steel Spacer (1/4" Diameter x 9/16")
1 550017 Stainless Steel Screw (Truss Head #8-32" x 1")
1 23051 Stainless Steel Wing Nut (#8-32)
5 224140 Stainless Steel Shelves
1 600034 Snapper Hose Clamp (.375")
4 3113234 Shelf Brackets
1 3113224 Stainless Duct Channel, Top
1 3113222 Stainless Duct Sheet, Left
1 3113223 Stainless Duct Sheet, Right
1 130038 #6 Neoprene Stopper
1 190388 Telephone Line Cord, 12'
1 190392 Modular RJ-11 Jack
1 7053158 Instruction Manual

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SECTION 3 - INTRODUCTION

3.1 THE WATER JACKET: KEY FEATURES

The Forma Scientific Model 3158 water jacketed incubator is designed to meet the
stringent requirements of today's modern laboratory and is a combination of economy,
accuracy and reliability.

The Model 3158 Incubator features:

• Ultra-flat, vibration-free shelves to provide optimum culturing

conditions.

• Direct-set CO2, temperature, and over temperature alarm set points..

• Digital readout of temperature and CO2 levels in the chamber.

• A sealed chamber to minimize CO2 consumption.

• A sealed water jacket to minimize water evaporation.

The 3158 water jacket incubator is designed for easy and convenient servicing by
providing:

• Front access to all components so that the unit need not be moved for
service, repair, or routine maintenance.

• A slide-out control panel for easy access to electrical components.

• Plug-in CO2, and Temperature/Alarm modules to facilitate servicing or

replacement.

• Self-diagnostic switches in the control modules to aid in

troubleshooting the system and localizing problems.

• Minimal unit down-time to disinfect the water jacket.

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• No cracks or crevices in, or around, the chamber walls to harbor

hidden or hard-to-reach bacterial growth.

• Stainless steel shelves, shelf channels and duct sheets which are easily
removed without tools for cleaning and disinfecting the entire interior.

• A blower wheel which is disposable and easily replaced.

• An improved water jacket drain and fill system.

Careful consideration has been given to the importance of product protection through
the addition of:

• An audible Add Water alarm and pilot light to alert the operator when
the water level in the water jacket has become too low for efficient
operation.

• Audible and visual CO2 alarms which activate when the CO2 content
in the chamber deviates 1% above or below the CO2 control setpoint.

• An Over temperature Alarm which activates when the chamber temperature rises
above the control setpoint.

• An Add Water and Over temperature silence with 30 minute ring back.

• Remote alarm contacts for Over Temperature, Add Water, Power Failure and CO2
deviation.

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SECTION 4 - INSTALLATION AND START-UP

4.1 LOCATION

Locate the incubator on a firm, level surface capable of supporting the unit.

Approximate weight with water: Single Chamber = 357 lbs (162 kg)
Dual Chamber = 714 lbs (324 kg)

The incubator should be placed in an area of the laboratory away from any centrifuges,
sonicators, doors, windows and air-conditioning or heating ductwork that might produce
drafts. To help prevent microbial contamination, the incubator should not be located in
areas of high personnel traffic.

Adequate room must be provided behind the incubator for connections of electrical,
gas and other equipment. Also, since gases are emitted from the rear of the incubator, the
unit should not be installed in an unvented recess or in a poorly ventilated room.

Caution: To prevent injury to personnel and/or damage to equipment, lock inner

glass door and secure outer door before tipping unit to adjust the leveling
feet. Do not attempt to tilt the incubator without assistance while
adjusting the leveling feet.

4.2 PRELIMINARY DISINFECTING

Before installing the duct sheets and the shelves, remove the clear plastic film from the
shelf brackets and duct sheets. Forma Scientific, Inc. recommends disinfecting all interior
surfaces (including both door gaskets). Rinse the surfaces with sterile distilled water (50K
Ohm to 1 Meg Ohm). Also disinfect the CO2 sensor and the blower wheel, taking care
not to saturate the sensor.

The duct sheets and shelves must be washed with the same disinfectant solution and
rinsed with sterile distilled water prior to their installation in the chamber. Repeat rinsing
until you are satisfied that all of the disinfectant-detergent has been removed. Proceed
with the installation as noted. Refer to Section 6.2 of this manual.

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4.3 INSTALLING THE #6 NEOPRENE STOPPER (ACCESS PORT)

Open the incubator outer door and inner glass door. Locate the opening in the top left
corner of the interior chamber. Place the beveled end of the stopper in the opening.

4.4 INSTALLING THE SHELF BRACKETS AND CAM LATCH

ASSEMBLY TO THE DUCT SHEETS (Refer to Figure 4-1)

A plastic coating has been applied on the duct sheets and shelf brackets to protect the
finish during shipping and handling. This plastic coating must be peeled off before the
protected parts are installed.

a. Shelf Brackets

1. Locate the plastic bag containing the #10-32 x 5/8" truss head screws and wing nuts
(20).

2. With the duct sheet in a vertical position, align and mount the shelf brackets to the
unflanged side of the duct sheets. Wing nuts go on the flanged side.

b. Cam Latch Assembly

1. Locate the bag containing (2) #8-32 x 1" stainless steel truss head screws, (2) #8-32
wing nuts, (2) stainless steel spacers and (2) cam latches (nylon).

2. Place stainless steel spacer (sleeve) over the #8-32 x 1" screw and insert it into the
opening of the cam latch.

3. Locate the five (5) small adjustment holes at the top of each duct sheet.

4. Place the cam latch on the inside (or unflanged side) of duct sheet and insert screw
with spacer sleeve through the middle hole of the five hole adjustment. If the duct
sheets appear to be too tight or too loose, the cam latch assembly may be re-
positioned up or down one hole for proper alignment.

5. Secure screw on flanged side of duct sheet with #8-32 wing nut.

6. Repeat these procedures for the other duct sheet.

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Installing the Shelf Brackets and Duct Sheets

Figure 4-1

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4.5 INSTALLING THE DUCT SHEETS (Refer to Figure 4-1)

Note: The left duct sheet has large notches in both top and bottom edges. The right duct sheet
has a single notch in the top edge only.

1. Carefully put the right duct sheet into the incubator chamber with the flanges toward
the wall.

2. Put the left duct sheet into the chamber, with the square notch at the top and the
flanges toward the wall. Allow the top of the left-side duct sheet to lie diagonally
across the chamber, resting upon the right-side duct sheet.

3. Hook the top channel into the top opening of the right duct sheet. The top channel
must be positioned so that the brass CO2 sample tube (mounted in the ceiling of the
incubator) is aligned with the notched out area on the right rear side of the top
channel. The round opening will align with the blower wheel when it is slid into
place.

4. While supporting the blower channel, slide the left duct sheet up until it is vertical,
making sure that the blower channel lines up into the slot on both duct sheets.

5. Turn cam latch to a vertical position (up against bottom side of top channel) to
secure. If duct sheets appear to be too tight or too loose, upon installation, the cam
latch assembly may be re-positioned up or down one hole for proper alignment.

4.6 INSTALLING THE SHELVES

The shelves may be placed at any level in the chamber. Slide the shelf into the shelf
bracket at the desired level.

4.7 LEVELING

Check the level of the unit by placing a bubble-type gauge on one of the shelves. Turn
the hex nut located on the leveling leg clockwise to lengthen the leveling leg, or raise the
unit. Turning the hex nut counterclockwise will shorten the leg, or lower the unit. Be sure
to level the incubator before filling the water jacket.

Caution: To prevent injury to personnel and/or damage to equipment, lock inner

glass door and secure outer door before tipping unit to adjust leveling feet. Do not
attempt to tilt the incubator without assistance while adjusting the leveling feet.

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4.8 CONNECTING THE INCUBATOR TO A POWER SOURCE

With the incubator power switch OFF, connect the unit to an adequate power source.
Refer to the serial tag located on the back of the unit or see Section 8.10 of this manual
for specific power requirements.

Note: Forma Scientific, Inc. recommends that the incubator be connected to a separate
electrical circuit.

4.9 PREPARING THE INCUBATOR FOR FILLING

450 ML of rust inhibitor was placed in the water jacket before the incubator was
shipped. The rust inhibitor mixes with the distilled water during filling and provides a
protective coating on the interior of the water jacket.

The fill fitting is used to fill the water jacket without having to move the incubator.
The fill fitting is located on the center front of the unit, directly above the door. Refer to
Figure 4-3.

The vent hole, located adjacent to the fill fitting allows the air displaced by water
entering the jacket to escape. It also prevents distortion of the chamber by allowing air to
escape as the unit expands and contracts during heating and cooling.

Caution: Do not plug this vent. A plugged vent will damage the water jacket
chamber.

1. Remove the plastic protective cap from the fill fitting. Check to see that the vent hole
located adjacent to the fill fitting is not covered or plugged.

2. Remove the protective metal cover from the drain fitting and valve and make sure the
valve is closed (turned to the vertical position). Refer to Figure 4-4 for drain and
drain valve location.

3. Set the TEMP SELECT switch to the variable position (down) and turn the temp
control knob completely counterclockwise to keep the heater from coming on before
the water jacket is filled. Refer to Figure 4-2 and Figure 4-3 for component locations.

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4. Turn the incubator power switch ON. The ADD WATER warning light and audible
alarm will come on. Pressing the SET/SILENCE button on the alarm panel will
silence the audible alarm

5. Remove the adjusting screwdriver from the control panel. The black knob is the
handle of the adjusting screwdriver. Refer to Figure 4-2.

6. Push the SET/SILENCE button on the Monitor Alarm Module, and adjust the over
temp alarm setpoint to a setting 2° or 3° above the intended operating temperature.
(Refer to Section 4.14)

Electric Power and Temperature Control Module

Figure 4-2

7. Press the CO2 SET/SILENCE button and rotate the CO2 set screw until the display
reads 00.0. (Refer to Figure 4-7 for locations of the SET/SILENCE button and set
screw.)

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4.10 FILLING THE WATER JACKET

There are two methods of filling the water-jacket.

a. Funnel Fill Method

b. Tap Fill Method

Caution: Purity of the distilled water used in the water jacket and humidifier must
be within the 50K ohm to 1 Meg ohm range to protect and prolong the life
of the stainless steel water jacket. The use of tap water or distilled water
outside of the specified range will decrease the operating life of the unit
and will void the warranty.

Water Jacket Fill Fitting and Vent Hole

Figure 4-3

a. Funnel Fill Method (Refer to Figure 4-3)

A funnel and vinyl tubing are contained in the accessories bag included with each
incubator.

1. Verify that the water jacket drain valve on the bottom of the incubator frame is
closed. The valve is located behind a protective metal cover and will require two
screws to be removed. The valve is closed when the valve knob is turned vertical.
Refer to the illustration in Figure 4-4.

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2. Attach the funnel into one end of the 3/8" I.D. vinyl tubing.

3. Remove the plastic protective cap from the fill fitting.

4. Attach the free end of the funnel tubing to the fill fitting.

5. Hold funnel above the level of the fill fitting and pour the water into the funnel until
the ADD WATER alarm light goes out. The water jacket holds about 13 gallons (49
liters) of water.

6. Add one additional quart (one liter) of distilled water. The incubator is now properly
filled.

7. Remove the tubing from the fill fitting and replace the plastic protective cap.

Note: Water seepage may occur from vent hole when chamber temperature increases.

Figure 4-4
Incubator Base with Water Jacket Drain and Valve

b. Tap Fill Method (Refer to Figure 4-3)

Three feet of 3/8" ID vinyl tubing is provided in the accessories bag included with
each incubator. If the distilled water outlet is more than three feet from the incubator,
more tubing and a connector will be required.

1. Verify that the water jacket drain valve on the bottom of the incubator frame is
closed. The valve is located behind a protective metal cover and will require two
screws to be removed. The valve is closed when the valve knob is turned vertical.
Refer to the illustration in Figure 4-4.

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2. Remove the plastic protective cap from the fill fitting.

3. Connect the 3/8" I.D. vinyl tubing between the fitting and the distilled water tap.

4. Open the tap until water flows steadily into the water jacket.

Caution: A high rate of flow and high pressure can cause distortion to incubator
chamber walls.

5. Turn the water off immediately when the ADD WATER alarm light goes out.

6. Using the funnel, add an additional quart (one liter) of distilled water.

7. Remove vinyl tubing and reinstall the plastic protective cap.

4.11 CONNECTING THE OPTIONAL GAS GUARD (Refer to Figure 4-5)

a. Connecting the Outlet of the Gas Guard to the Incubator's Gas Inlet

Before connecting the gas supply tanks, connect a piece of supply tubing between the
outlet fitting and the gas inlet(s) on the back of the incubator. If both chambers are to be
monitored by the gas guard both inlets need to be connected. The gas outlet is located
between Tank 1 and Tank 2 inlet fittings. Check the connections for leaks.

b. Connecting The CO2 Supply Tanks

Note: Output pressure from the tanks must be regulated with a dual stage pressure
gauge set at 15 PSIG. Liquid substances must be supplied in tanks without
siphon tubes to ensure that only gas enters the incubator.

The high pressure gauge should have an indicating range of 0 to 2000 PSIG to monitor
tank pressure. The low pressure gauge should have an indicating range of 0 to 30 PSIG to
monitor actual input pressure to the incubator injection system. A suitable two-stage
pressure regulator is available from Forma Scientific, Inc., Stock #965010.

Supply pressure lower than 13.5 PSIG will cause improper operation of the gas guard
and may cause the occurrence of nuisance alarms. Pressure higher than 15 PSI will
damage the CO2 control system.

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Securely attach the gas lines from the supply tank to the barbed fittings located on the
back of the unit. The fittings are labeled. Check the connections for leaks.

Rear view of the control panel, stacked incubator model with Gas Guard
Figure 4-5

4.12 CONNECTING THE GAS SUPPLY WITHOUT GAS GUARD

(Refer to Figure 4-6)

If Gas Guard is not used, the gas supply is connected directly to the CO2 inlet.

Note: Output pressure from the tanks must be regulated with a dual stage pressure
gauge set at 10 PSIG. Liquid substances must be supplied in tanks without
siphon tubes to ensure that only gas enters the incubator.

The high pressure gauge should have an indicating range of 0 to 2000 PSIG to monitor
tank pressure. The low pressure gauge should have an indicating range of 0 to 30 PSIG to
monitor actual input pressure to the incubator injection system. A suitable two-stage
pressure regulator is available from Forma Scientific, Inc., Stock #965010.

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Securely attach the gas lines from the supply tank to the desired barbed inlet fitting(s)
located on the back of the unit. The fittings are labeled. Refer to Figure 4-6. Check the
connections for leaks.

Rear view of the control panel, stacked model without Gas Guard
Figure 4-6

4.13 FILLING THE HUMIDITY RESERVOIR OR PAN

Do not use plastic pans for humidification as they will have an unpredictable effect on
humidity and O2/CO2 levels in the incubator. Use only the floor of the unit or the
optional stainless steel humidity pan.

Do not use de-mineralized or de-ionized water in the humidity reservoir or pan unless
it has been boiled immediately prior to use as it may be contaminated with bacteria.

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Listed below are two recommended methods of providing elevated humidity in the
chamber.

Note: Frequent door openings will cause humidity loss from chamber and may result in
desiccation of the product. Recovery time will also be affected.

a. Reservoir

The reservoir in the bottom of the incubator may be filled with at least 3/4" of sterile
distilled (50K ohm to 1 Meg ohm) water.

b. Humidity Pan

The optional humidity pan (Forma Stock #237001) will hold 1.6 gallons (6 liters) of
sterile distilled (50K ohm to 1 Meg ohm) water. This pan may be autoclaved. The best
humidity and temperature response from the humidity pan is obtained when the pan is
placed directly on the incubator floor.

The water level in the humidity reservoir should be checked frequently. If a

disinfectant has been added to the water in the reservoir, it should be changed once a
week to help prevent microbial contamination. If a disinfectant has not been added to the
sterile distilled water, the water should be changed at least twice a week.

It is important that the water level in the reservoir or pan be kept relatively constant as
fluctuations or "dry-outs" will have an adverse effect on the humidity level and CO2
control in the chamber.

Caution: When installing the humidity pan, exercise care to avoid tearing the inner
door gasket.

4.14 SETTING THE CHAMBER TEMPERATURE (Refer to Figure 4-7)

Before the initial temperature setting is made, push the SET/SILENCE button on the
Alarm Monitor Module. Using the adjustment screwdriver , turn the OVER TEMP set
screw until the display shows a temperature that is two to three degrees above the desired
operating setpoint. The over temp safety may be reset after the chamber temperature has
stabilized at setpoint.

If a chamber temperature of 37°C is desired, set the Variable/37°C switch on the

Temperature Control panel to the 37°C (up) position. (Figure 4-2.)

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If a value other than 37°C is desired, set the switch to the Variable position (down),
and set the temperature control knob to the desired setpoint. Any temperature between
5°C above ambient to 50°C may be selected.

4.15 SETTING THE OVER TEMP SAFETY THERMOSTAT (See Figure 4-7)

Once the chamber temperature has stabilized (as indicated by the digital display), the
Over Temp Safety should be set as follows:

1. Push the SET/SILENCE button on the Alarm Monitor Module.

2. Using the screwdriver mounted on the control panel, turn the OVER TEMP set screw
until the desired over temp alarm point is shown on the digital display. The over temp
setpoint can be set within 0.1° of the operating setpoint, but it is recommended that it
not be set within 0.5 of setpoint.

Note: The Over Temp Safety should be checked quarterly to insure proper operation. To
check the over temp control, push the SET/SILENCE button on the Alarm Monitor
Module and turn the Set screw counterclockwise until the over temp safety light is lit.
Reset the Over Temp Safety after the test.

Temperature and Alarm Monitor Module, Figure 4-7

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4.16 ZEROING THE CO2 CONTROLLER (See Figure 4-8)

Important!

This adjustment is made using the CO2 gas content of ambient air (0.03%),
the most accurate standard available.

Tools Required:

Adjustment screwdriver (provided on the panel)

FYRITE CO2 Analyzer (use only for checking) or other CO2 measuring device.

a. Stabilizing the Incubator

1. Stabilize the incubator at the operating temperature and humidity level with no CO2
in the interior chamber.

2. Turn off the CO2 at the supply.

3. Fill the humidity reservoir or pan.

4. Allow the incubator temperature and humidity to stabilize. This will take a minimum
of eight hours. On initial start-up, however, allow the unit three days to stabilize.

b. Adjusting the Zero Set Pot (Refer to Figure 4-8)

1. Using the small screwdriver mounted on the control panel, adjust the CO2 control
zero pot to read 00.0 on the digital display. Wait 5 minutes. Repeat if necessary until
the display is stable.

2. Turn on the CO2 at the supply.

3. Turn the CO2 setpoint to the desired %.

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c. Checking the CO2 at the Desired Setpoint

1. Allow the incubator to reach setpoint and control (inject light will cycle) for a
minimum of 30 minutes.

2. Check the CO2 level with a FYRITE until two consecutive readings agree. If the
FYRITE and display are not within plus or minus 1.0%, consult the factory.

Note: After proper zeroing, the CO2 display will be more accurate than the FYRITE because
the zero adjustment was accomplished using absolute.

4.17 SETTING THE CO2 CONTENT

The following conditions must be satisfied before the CO2 percentage can be set:

Allow the temperature and humidity in the chamber to stabilize. For initial settings of
CO2, it is recommended that temperature and humidity be allowed to stabilize for three
days.

Check the CO2 control zero (See Section 4.15 for detailed instructions).

To set the CO2 percentage, press the CO2 SET/SILENCE button and rotate the CO2
set screw until the desired percentage is indicated on the digital display.

Note: If the unit is in Over Temp and a CO2 injection occurs, a brief, high CO2 percentage
will appear on the digital display. This is due to the shut down of the internal fan
during Over Temp. The high CO2 percentage occurs only at the sensor. CO2
throughout the chamber will remain normal.

CO2 Control Module, Figure 4-8

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SECTION 5 - OPERATION

5.1 OPERATION

The water jacket is filled with approximately 13 gallons (49 liters) of water through
the fill fitting located on the front of the unit. The water is then warmed by the chamber
heater, providing very stable heating of the incubator chamber. Not only does the water
stay at a constant temperature with a minimum of heater on-time, but it also acts as
insulation from ambient temperature conditions.

Temperature control is maintained by a proportional, zero-switching device which

provides temperature uniformity throughout the chamber. A separate and independent
over temperature controller assures product safety by assuming control at the over temp
setpoint if the primary controller malfunctions. Should an over temp condition develop,
the monitor alarm system will alert the operator that a malfunction has occurred.

An internal blower gently circulates the air in the chamber to prevent CO2
stratification and minimize culture desiccation.

5.2 OVERVIEW OF HUMIDIFICATION AND CO2

Thermal conductivity of the air inside of the incubator is affected not only by the
quantity of CO2 present, but by the quantity of water vapor present in the incubator
atmosphere. This effect is linearly related to the absolute humidity of the atmosphere (See
figure below).

Moisture Effect on CO2 Control Calibration

Figure 5-1

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When monitoring the effects of CO2, absolute humidity must be held constant so any
change in thermal conductivity is caused only by a change in the CO2 concentration.
Under the worst circumstances, a change in absolute humidity could cause such a
significant change in thermal conductivity that the controller could shift the CO2 content
by as much as 4%.

Maintaining the water level inside the incubator is a simple procedure, but an
important one to keep the humidity in the incubator constant. Any water pan, used in lieu
of flooding the incubator floor, must be stainless steel and at least 187 square inches of
surface area. Tests indicate that smaller pans, bowls or non-metallic pans do not provide
adequate humidification, which can lead to incubator humidity variations with ambient
humidity shifts, resulting in CO2 changes in the incubator.

When operating a dry incubator, as opposed to a humidified one, ambient humidity

fluctuations will affect CO2 calibrations. Since the fluctuations possible in extreme
ambient changes have less effect on the total absolute humidity, the CO2 calibration can
be affected by as much as 1.5%.

When a change in humidity or temperature is needed, the CO2 control can be easily
zeroed for the new condition.

Temperature changes have little affect on CO2 calibration, but do cause large changes
in the absolute humidity which is reflected in changes in CO2 calibration.

5.3 CONTROL PANEL (Figure 5-2)

a. Fill Fitting, Drain Fitting/Valve and Vent Hole

The fill and drain fittings are conveniently located on the front of the incubator. The
water jacket fill fitting is located directly above the incubator door. The drain fitting is
located below the door, behind a protective metal cover. A small valve is located adjacent
to the drain fitting for convenience when draining the water jacket.

The vent hole, located adjacent to the fill fitting, allows the air displaced by water
entering the jacket to escape. It also prevents distortion of the chamber by allowing air to
escape as the unit expands and contracts during heating and cooling. Under no
circumstances should the vent be plugged.

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Incubator Control Panel

Figure 5-2

b. Power Switch and Pilot Light

The main power switch controls the ON/OFF power to the unit. The power pilot light
is activated when the power switch is on, and the unit is receiving power.

c. Circuit Breaker (Reset)

The 5 amp circuit breaker for the incubator (labeled Reset) can be pushed to reset the
incubator power supply within a few seconds after the breaker has tripped. If it trips a
second time, the unit should be checked by a qualified electrician.

d. Variable/37°C Switch, Temp Control and Heater Pilot Light

When the Variable/37°C switch is set to the 37°C (up) position, chamber temperature
will automatically be maintained at +37°C. If necessary, the 37°C control can be
calibrated using the calibration screw located at the lower left side of the temperature
control dial. See Section 7.3 to calibrate the 37°C setting.

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When the Variable/37°C switch is set to the Variable (down) position, control is
assumed by the temperature control potentiometer. The numbers (0 to 60) around the
control knob indicate approximate setpoint values in degrees Centigrade. Any value
between +5°C above ambient temperature and 50°C may be selected. The heater pilot
light will be activated whenever the heater is energized.

e. Gas Sample Port

A sample port for checking CO2 percentage by independent means (e.g. FYRITE or
similar CO2 measuring device).

Important!

The Sample Port should never be capped. It is the vent for the incubator chamber.
Refer to Figure 5-2.

f. Setpoint Adjustment Tool

A small screwdriver, located below the circuit breaker, has been provided for setting
the CO2 and over temp setpoints. Pull out on the knob to release the screwdriver (the
knob is the handle of the screwdriver).

5.4 (FACTORY-INSTALLED OPTION) GAS GUARD STOCK #190410

(Refer to Figure 5-3)

Forma Scientific's stock # 190410 built-in Gas Guard is a monitoring and switching
device for incubator gas supplies.

The unit monitors a two cylinder gas supply. When the active supply tank is depleted,
an audible alarm sounds and the gas guard automatically switches to the second tank.

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a. Control Switch

The CONTROL switch controls

power to the gas guard control circuit
board. The yellow LEDs on the front
panel designate which tank is active and
indicate the unit is receiving power.

b. Silence Switch

The SILENCE switch silences the

alarm and selects the alternate tank. If
the SILENCE switch fails to silence the
alarm, it is an indication that both gas
tanks are depleted or incapable of
producing 15 PSIG.

Note: During initial start-up, the

incubator should not be injecting gas.

c. Gas Depletion Alarm

The gas depletion alarm sounds

automatically when the active supply
tank becomes empty. The other tank
Figure 5-3 becomes active with the sounding of the
Built-in Gas Guard alarm.
(Factory Installed Option)
Note: Should both supply tanks become
depleted, the only way to silence the
alarm is to turn the CONTROL switch
to Off.

d. Active Tank Indicating Lights

The two yellow indicating lights labeled "TANK1 On" and "TANK2 On," located on
the front of the control panel, indicate which of the gas tanks is active.

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e. Pressure Low Indicating Lights

The two red indicating lights, labeled "Pressure Low," indicate when a supply tank is
depleted. If both tanks are depleted both red indicating lights will be lit.

f. Start-Up Procedure

1. Turn the CONTROL switch on.

2. Select the active tank using the SILENCE switch.

5.5 CO2 MODULE (Refer to Figure 5-4)

a. CO2 Power Switch

The CO2 power switch controls the electrical power to the CO2 system, and it must be
ON when the incubator is to be operated with CO2. The switch should be turned on as
soon as power is applied to the unit to allow the CO2 system to warm up.

CO2 Control Module, Figure 5-4

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b. CO2 Controller and Digital Display

The LCD digital readout on the CO2 module continually displays the percent of CO2
in the chamber. The setpoint is displayed when the CO2 SET/SILENCE button is pushed.

The CO2 setpoint is changed by pushing the CO2 SET/SILENCE button and rotating
the CO2 set screw to the desired percentage.

c. Audible CO2 Alarm and Pilot Light

The audible CO2 alarm and pilot light are activated when the percent CO2 deviates
from setpoint by plus or minus 1% (nominal) for longer than approximately four minutes.

d. SET/SILENCE Push Button

When pushed, the SET/SILENCE button will silence the CO2 alarm and extinguish the
alarm light. This button must be pushed to set or display the CO2 setpoint.

e. Alarm Disable Switch (Figure 5-5)

Note: It is necessary to pull the CO2 module out slightly to gain access to the Alarm Disable
Switch. Grasp the black plastic button on the bottom of the control module, directly
beneath the Set/Silence push button. Pull on the button until the circuit board releases
from its internal connector strip. The Alarm Disable Switch is located on the side of
the module and is clearly marked. (See Figure 5-5.) To replace the module, push
firmly until the connector strip is seated. Press the black plastic button until it snaps
into place.

When the alarm switch is in the DISABLE position, the CO2 alarm is completely
disabled. When the switch is set to the NORMAL position, the alarm system is operative
and can be silenced by pressing the SET/SILENCE button.

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Alarm Disable Switch on the CO2 Control Module

Figure 5-5

f. CO2 Inject Light

The CO2 inject light is activated whenever there is a demand for CO2 to meet setpoint
requirements. Since the CO2 inject light is independent of the CO2 alarm, it will continue
to signal a need for CO2 when the CO2 alarm is set to either the defeat or silence
position.

g. CO2 Zero Adjustment

The CO2 zero adjustment is used for zeroing the CO2 controller to specific control
conditions. It is the only user calibration adjustment on the CO2 module. All internal
adjustments are for qualified service personnel only.

5.6 ALARM/MONITOR MODULE (Refer to Figure 5-6)

a. Over temperature Controller and SET/SILENCE Button

The over temperature setpoint is displayed when the SET/SILENCE button on the
module is pushed. Over temp control point is adjusted by pushing the SET/SILENCE
button and rotating the set screw on the module to the desired setpoint.

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b. Over temp Alarm and Pilot Light

The over temperature audible alarm and pilot light will come on in the event of an over
temp condition. The audible alarm can be silenced for approximately 30 minutes by
pressing the SET/SILENCE button. The audible alarm will ringback every 30 minutes for
as long as the over temp condition exists.

c. Add Water Pilot Light and Audible Alarm

The ADD WATER audible alarm and pilot light are activated whenever the water level
in the water jacket is low. The audible alarm can be silenced for approximately 30
minutes by pressing the SET/SILENCE button. The audible alarm will ringback every 30
minutes for as long as the low water condition exists. (See Sections 4.10).

Temperature Monitor and Alarm Control Panel

Figure 5-6

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5.7 REMOTE ALARM RELAY SYSTEM

Alarm states and alarm conditions are listed on Table 5-1. When the relay is off it is
in the alarm state.

Alarms and Indicators, Table 5-1

Alarm
Alarm Condition Visual Audible Reset Delay Relay
Indicator Alarm (Ringback) State

None Off Off On

* Temp.> Over Over Temp On 30 Minutes Off
Temp Setpoint LED On
* Low Water in Flash Add On 30 Minutes Off
Water Jacket Water LED
** % CO2 Dev CO2 Alarm On Off
Setpoint ± 1% LED On
*** Tank1 Low Pressure Low On Off
#1
*** Tank2 Low Pressure Low On Off
#2
Power Failure Off Off Off
* Silenced audible alarm will ring back in 30 minutes if the alarm condition still exists. The
Alarm LED will remain lit.
** Condition must exist for four minutes before alarm activates. Silenced alarm will extinguish
the led alarm light, silence the audible alarm and change the alarm relay to the on state.
*** When the CONTROL switch on the gas guard is turned off the indicator light will be
extinguished and the audible alarm will be silenced. The built-in alarm relay on the Model 3158,
however, remains active.

A SPDT relay is provided for monitoring alarm conditions on the incubator.

Connections are made by means of an RJ-11, telephone style jack, located on the rear of
the cabinet. Figure 5-7 shows the connector wiring diagram. Any of the incubator alarms
will activate the relay.

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Remote Alarm Relay Wiring Diagram

Figure 5-7

5.8 RECORDER OUTPUT

Incubator temperature and CO2

information may be directed to a recorder or
other data storage device from a four-pin
connector located on the back of the control
panel. The connector pin numbers are
identified in Figure 5-8 and are arranged as
they would be seen looking at the back of the
1 = Common cabinet.
2
3 = Temp
4 = CO2

Recorder Output Jack

Figure 5-8

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SECTION 6 - ROUTINE MAINTENANCE

6.1 INSTALLING THE DECONTAMINATION KIT

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6.3 CLEANING THE CABINET EXTERIOR

The incubator exterior may be cleaned with soap and water and a general use
laboratory disinfectant.

6.4 DRAINING THE WATER JACKET (Refer to Figure 6-1)

For best results, the water in the water jacket should be changed yearly.

1. Turn off the incubator and disconnect its electric plug from the power supply.

2. Remove the metal cover located below the door which protects the valve and the fill
fitting. Two knurled thumb screws hold it in place.

3. Attach the 3/8" I.D. vinyl tubing to the drain fitting.

4. Route the tubing to a drain or large bucket and turn the valve to the vertical position..

5. If the water jacket is to be refilled, return the drain valve to the vertical position and
review filling instructions in Section 4.10.

Incubator Base with Water Jacket Drain and Valve

Figure 6-1

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6.5 CHANGING THE CO2 FILTER (For Qualified Service Personnel Only)

Note: Under conditions of normal use, and dependent upon the purity of gas being used,
the CO2 filter should be last for about five years.

If the CO2 filter becomes clogged, replace it with Forma stock #770001.

1. Disconnect the unit from the power supply.

2. Turn the two 1/4 turn fasteners on the control panel, grasp the CO2 sample port, and
slide the control panel out.

3. Locate the CO2 filter at the back of the control panel. (Refer to Wiring Diagram,
140181-71-0-D for location)

4. Remove and replace the filter.

6.6 CO2 TEST INSTRUMENTS

The best standard available for zeroing or calibrating the CO2 controller is air, which
typically contains 0.033% CO2 by volume. Variations from this figure are insignificant.

It is very important that any Forma automatic CO2 incubator be zeroed to air (See
Section 4.15). CO2 test instruments should be used as a secondary check or to verify the
percentage of CO2 at operating levels.

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SECTION 7 - SERVICE

7.1 GENERAL TROUBLESHOOTING

Symptom Possible Cause

Problem 1: Pilot lights not on. Readouts • Unit unplugged, or main power switch not
are dark. CO2 power switch is on. on.
• Circuit breaker tripped.
• Outlet overload protection has tripped.
• No voltage at outlet.
• Defective incubator wiring.
Problem 2: Pilot lights on but heat light • 0.3 Amp Slo-Blo fuse in control panel is
and alarm monitor module lights out. blown.

Problem 3: CO2 system indicator and • Circuit breaker tripped.

readout are dark no control of CO 2 in • Defective switch or wiring.
chamber. Switch is on. • Defective CO2 module.

Problem 4: CO2 setpoint and display • FYRITE not zeroed.

agree. FYRITE reads lower. • Wool filter in FYRITE is dry.
• FYRITE fluid need to be changed.
• Chamber absolute humidity has decreased.
• Control is incorrectly zeroed.
• Defective CO2 sensor or control.
Problem 5: Alarm sounds periodically, • Over temp control set too low.
even with the alarm disabled. CO2 alarm • Shorted heater.
light not activated. • Defective temp control or sensor.

Problem 6: CO2 alarm and light are on. • CO2 level has deviated more than 1% from
Alarm can be reset or disabled. If reset, setpoint.
alarm activates again. • CO2 supply has been interrupted.
• CO2 inject circuit is defective.
• CO2 solenoid is defective.
• CO2 sensor fan is defective.

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Symptom Possible Cause

Problem 7: Digital CO 2 display and • Alarm is disabled.

FYRITE read more than 1% different from • Defective alarm circuit.
setpoint. CO 2 alarm not on. • Defective CO2 sampler or control.

Problem 8: CO2 display and FYRITE read • Loss of CO2 supply.

0% CO2. Setpoint is OK. CO 2 alarm is • Defective CO2 solenoid.
activated. CO2 inject light is on. • Clogged CO2 in-line filter.

Problem 9: CO2 display shows some • Defective readout board.

random number or decimal point. • Defective output to readout board from
CO2 control.
• Faulty interconnecting wiring.

Problem 10: CO2 display will not go to • Improper procedure. Close door and allow
zero no matter how long the door is left temperature and rh to stabilize eight hours.
open. • Defective CO2 sensor.
• Defective CO2 control.

Problem 11: Display flickers badly or • Defective readout board.

counts up and down three or four digits. • Excessive electrical interference near the
cabinet.
• Faulty grounding circuit.
• Sampler blower is improperly installed or is
defective.

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Symptom Possible Cause

Problem 12: CO2 setpoint cannot be • Defective CO2 control.

changed.

Problem 13: Unit cannot be zeroed. • Defective CO2 potentiometer.

• Defective zero control.
• Defective CO2 Sensor.

Problem 14: CO2 overshoots setpoint • Inoperative CO2 sampler blower.

badly. • Defective CO2 control.
• CO2 inlet pressure too high.
• Unit is in over temp.

Problem 15: Actual CO2 is higher than • Defective CO2 sensor.

setpoint and readout. Re-zeroing helps • Incorrect calibration of CO2 control.
for a time, then symptoms return.

Problem 16: CO2 alarm sounds while • Excessive RFI or EMI near unit.
CO2 level is controlling at setpoint. • Faulty grounding circuit.
• Defective CO2 control.

Problem 17: CO2 setpoint changes by • Faulty CO2 potentiometer.

itself. • Defective CO2 control.

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7.2 CO2 CONTROL MODULE CALIBRATION

These calibration procedures will be necessary only under the following

conditions. DO NOT calibrate the incubator for any other reasons!

♦ After the CO2 controller is replaced.

♦ After the CO2 sensor is replaced.

♦ If there is reason to believe that the controller has previously been calibrated
incorrectly.

Tools Needed:

Calibration screwdriver (provided).

Circuit board extender card (provided).

FYRITE CO2 Analyzer.

The following procedures are to be carried out in the sequence given. To

prepare the incubator for calibration:

1. Turn off all electric power to the incubator.

2. Remove the CO2 Control Module by pulling out the black plastic button
locking button on the bottom of the module. (Figure 7-2.)

3. Firmly pull the button rearward until the circuit card releases from the
internal connector strip.

4. Attach the extender card to the back of the control module circuit board.
(Refer to Figure 7-1.)

5. Return the control module with extender card attached to the incubator
control panel. Press the module firmly into the panel until the connector strip
is seated. The control module will protrude a few inches from the incubator
panel.

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CO2 Control Module showing the Extender Card

and Span Adjustment Pot Location
Figure 7-1

a. Stabilize the Incubator at operating temperature and humidity with no

CO2 in the chamber.

1. Turn OFF the CO2 supply at the source.

2. Fill the humidity pan with sterile distilled water.

3. Allow the chamber temperature and humidity to stabilize. This will take a
minimum of eight hours if the temperature setpoint has been recently
changed. Allow three days on initial start-up.

4. Turn the span pot counterclockwise 10 turns. (Refer to Figures 7-1 and 7-2.)

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b. Adjust the Zero Pot

1. Using the calibration screwdriver, adjust the CO2 control zero pot to read
00.0 on the digital display.

2. Wait 5 minutes, and repeat as necessary until the display is stable.

Side View of the CO2 Control Module

Figure 7-2

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c. Adjust the Span Pot (Refer to Figure 7-2.)

1. Turn ON the CO2 at the supply.

2. Turn the CO2 setpoint to 10%. Allow the CO2 to stabilize at 10% on the
readout and control (inject light will cycle) for a minimum of 15 minutes.

3. Using a FYRITE or other measuring device, check the CO2 level in the
chamber until two consecutive readings agree.

4. Turn the CO2 setpoint to 0.0% to prevent CO2 from being injected into the
chamber during the adjustment.

5. Adjust the span pot so the digital display agrees with the FYRITE reading.

6. Turn the setpoint back to 10%, and allow the CO2 to control and stabilize
for a minimum of 15 minutes.

7. Check the CO2 in the chamber with a FYRITE or similar device until two
consecutive readings agree. If the digital display is within plus or minus
1.0% of the FYRITE reading, proceed to the next step, "Recheck the Zero
Adjustment." If the reading is not within plus or minus 1.0%, repeat Steps 3
through 6 of this procedure.

d. Re-check the Zero Adjustment

1. Turn OFF the CO2 at the supply.

2. Open both doors wide for 45 seconds. Close the doors, and allow a minimum
of 15 minutes for the incubator to stabilize and assure a zero CO2 condition
in the chamber.

3. If the readout is greater than 00.4, repeat the door opening for 15 seconds,
and again allow the incubator to stabilize for a minimum of 15 minutes. If
the display is not less than the previous reading, consult the factory. If the
display now reads 00.4 or less, re-adjust the zero pot so the display reads
00.0.

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e. Check the CO2 at the desired setpoint

1. Turn ON the CO2 at the supply.

2. Turn the CO2 setpoint to the desired level.

3. Allow the incubator to reach setpoint and control for a minimum of 30

minutes.

4. Check the CO2 with a FYRITE or similar device until two consecutive
readings agree. If the FYRITE and display are not within 1.0%, consult the
factory.

Note: After proper calibration the CO2 display will be more accurate than the
FYRITE, because the zero adjustment was made using atmospheric
conditions.

Once the module is calibrated, the Extender Card must be removed and the
CO2 Control Module returned to its proper position in the incubator panel.

1. Turn off the incubator.

2. Firmly pull the Control Module rearward until it releases from the internal
connector strip.

3. Remove the Extender Card.

4. Replace the Control Module into its location in the incubator panel.

7.3 37°C CONTROL CALIBRATION

If the digital display indicates a temperature other than 37°C when the
chamber temperature has stabilized(temp select switch set to 37°C), it may be
necessary to re calibrate the adjustment.

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To calibrate:

1. Make a note of how much the display varies from 37°C.

2. Locate the 37°C calibration adjustment on the control panel. (See Figure
5-2 in Section 5.)

3. Using the calibration screwdriver, turn the calibration screw one turn
clockwise for every half degree that the display is below 37°C. Turning the
screw counterclockwise will lower the temperature.

4. Allow the temperature to stabilize, and check the display again. If it still
varies significantly, repeat Steps 1 through 3.

Caution: Servicing should be performed by qualified service personnel

only. Disconnect the incubator from the power source before
starting service procedures.

7.4 REPLACING THE CO2 SENSOR

1. Remove shelves, duct sheets, and blower channel from the chamber.

2. Locate CO2 sensor, and remove wing nuts. The sensor will drop down.

3. There is a clip that connects sensor wiring to incubator wiring. To open the
clip, pull out slightly on the clip tab to release the sensor.

4. Remove the O-ring, and place it on the new sensor.

5. Clip the new CO2 sensor onto the incubator wiring and return the sensor to
its original opening. Tighten the wing nuts securely to properly seal the
O-ring.

6. After the sensor has been replaced, calibrate the CO2 controller according
to the instructions in Section 7.2.

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7.5 REPLACING THE TRIAC (Refer to Wiring Diagram 140181-71-0-D)

1. Turn the incubator off and disconnect it from the power source.

2. Loosen the two 1/4-turn fasteners on the front of the control panel and pull
the panel out.

3. Open the incubator outer door to gain access to the triac mounting screws
from underneath the control panel.

4. Remove the two mounting screws which secure the triac.

5. Carefully disconnect the wires to the triac and note their connections.

6. Remove the triac from the unit. Note the thermal compound between the
base of the triac and the floor of the control panel housing. If necessary,
reapply more thermal compound before installing the new triac.

7. Install the new triac by reversing the above procedure.

7.6 REPLACING THE CO2 SOLENOID

(Refer to Wiring Diagram, 140181-71-0-D)

1. Loosen the two 1/4-turn fasteners on the front of the control panel and pull
the panel out.

2. Locate the CO2 solenoid and disconnect the tygon tubing attached to it.
Note how tubing is installed so that it can be attached to new solenoid in
same way.

3. Remove the screws that hold the solenoid in place.

4. Disconnect the wiring to the solenoid, making note of the connections.

5. Remove the solenoid and install the new unit by reversing the above
procedure. Note the flow direction marked on solenoid.

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7.7 REPLACING THE TEMPERATURE CONTROL

(Refer to Wiring Diagram, 140181-71-0-D)

1. Loosen the two 1/4-turn fasteners on the front of the control panel and pull
the panel out.

2. Remove the temperature control knob by loosening the two Allen head
screws recessed in the knob.

3. Remove the nut on the shaft on the outside of the panel, then remove the nut
on the back of the panel behind the control knob.

4. Remove the wiring to the temperature control and note the connections.

5. Remove the control and replace the new unit by reversing the above
procedure.

7.8 REPLACING PILOT LIGHTS

1. Loosen the two 1/4-turn fasteners on the front of the control panel and pull
the panel out.

2. Disconnect the wiring behind the defective light and break the retaining clip
loose. Remove the pilot light.

3. Insert the new pilot light from the front of the panel and install the new
retaining clip.

4. Reconnect the wiring.

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7.9 REPLACING THE THERMISTOR

1. Loosen the two 1/4-turn fasteners on the front of the control panel and pull
the panel out.

2. Locate the thermistors and remove the silastic around the thermistor cable.

3. Pull the defective thermistor out of the probe sheath.

4. Cut the wires to the defective thermistor, making note of the connections.

5. Attach the new thermistor using the electrical in-line connectors.

6. Install the new thermistor by reversing the above procedure. Take care not
to damage the probe tip and make sure that the probe is fully extended in the
sheath. Reseal the port with silastic or similar material.

7.10 REPLACING THE 0.3 AMP FUSE

(Refer to Wiring Diagram, 140181-71-0-D)

The 3/10 amp fuse is located in the center of the control panel tray behind the
CO2 monitor module housing.

To replace the fuse:

1. Disconnect all power to the incubator.

2. Loosen the 1/4-turn fasteners on the front of the control panel and pull the
panel out until the fuse holder in the center of the tray is accessible.

3. Use a fuse puller or a small screwdriver to lift one end of the fuse. Remove
the fuse and discard it.

4. Insert a new 0.3 Amp fuse into the fuse holder.

5. Re-secure the control panel.

6. Connect power to incubator. Turn power switch ON and check operation of

controls.

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7.11 REPLACING THE BLOWER MOTOR

Replacing the Blower Motor on Single Units

1. Disconnect the unit from the power source.

2. Remove the shelves, duct sheets and blower channel from the incubator
interior.

3. Remove and save the bottom blower wheel located inside the chamber by
firmly pulling it down. Remove the snap ring (if present) from the motor
shaft groove using needle-nose pliers.

4. Remove the four wing nuts that secure the blower mounting plate to the
incubator ceiling.

5. Pull the blower motor assembly down into the chamber area.

6. Remove and save the upper blower wheel/blower blade.

7. Cut the tie wrap(s) securing the blower wires to the blower shield plate.
Note: An extra tie wrap has been provided for resecuring the electrical
wiring.

8. Disconnect the blower motor electrical connectors and remove the bushing
securing the blower motor wiring.

9. Remove and save the two #6 nuts, washers and nylon spacers that secure the
blower motor. Discard the old blower motor. Save the #6 nuts, nylon spacers
and washers.

10. Remove the snap ring from the new blower motor shaft.

11. Install the new blower motor using the #6 nuts, nylon spacers and washers
from step #9.

12. Reconnect the wires to the blower motor.

13. Install the snap bushing (located around the electrical wires from the blower
motor) in the top of the blower shield plate.

14. Reinstall the new snap ring on the motor shaft groove.

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15. Reinstall the lower blower wheel (inside the chamber) by pushing the
blower wheel up against the snap ring.

16. Reinstall the upper blower wheel/blower blade.

17. Place the blower motor assembly into its original position.

Make sure that the vinyl tubing is not kinked and the wiring is not in
contact with the top blower wheel.

Replacing the Blower Motor on the bottom Incubator of stacked units

1. Disconnect the incubator from the power source.

2. Remove the shelves, duct sheets and blower channel from the incubator
interior.

3. Remove and save the bottom blower wheel (located inside the chamber) by
firmly pulling it down. Remove the snap ring (if present) from the motor
shaft groove using needle-nose pliers.

4. Remove the four wing nuts that secure the blower mounting plate to the
incubator ceiling.

5. Disconnect the door heater plug on the top unit.

6. Remove the screws securing the base of the front cover plate from the top
unit. Let cover plate hang on the left side of the cabinet.

7. Locate and disconnect the electrical connectors to the top unit's floor heater.
Slide the floor heater forward and remove it.

8. Remove the duct assembly directly over the blower motor.

9. Gently pull the blower motor assembly down into the chamber area.

10. Remove and save the upper blower wheel/blower blade.

11. Cut the tie wrap(s) securing the wires from the blower motor to the blower
shield plate. An extra tie wrap has been provided for securing the electrical
wiring.

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12. Disconnect the electrical connectors to the blower motor.

13. Remove the bushing securing the blower motor wiring.

14. Remove and save the two #6 nuts, washers and nylon spacers that secure the
blower motor. Discard the old blower motor.

15. Remove the snap ring from new blower motor shaft.

16. Install the new blower motor using the #6 nuts, nylon spacers and washers
saved in Step #14.

17. Reconnect the blower motor wires.

18. Install the snap bushing located around the wires from blower motor in the
top of the blower shield plate.

19. Reinstall the new snap ring on the motor shaft groove.

20. Reinstall the lower blower wheel (inside chamber) by pushing the blower
wheel up against the snap ring.

21. Reinstall the upper blower wheel/blower blade.

22. Replace the blower motor assembly, duct work and floor heater into their
original positions.

Caution! Make sure that the vinyl tubing is not kinked.

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SECTION 8 - SPECIFICATIONS

Models 3158/3164 and 3326/3336

Specifications:

Models 3158 (3164) Single Chamber

3154 Single Chamber Right hand door swing
3326 (3336) Dual Chamber
3354 Dual Chamber Right Hand Door Swing

Temperature

Control ±0.1oC @ +37oC (98.6oF)

Range +5oC above ambient to +60oC (140oF)
Sensor Thermistor
Controller Analog electronic proportional
Setpoint Variable analog or fixed +37oC
Display Digital LCD
Uniformity ±0.2oC

Temperature Alarm

Sensor Thermistor
Controller Independent analog electronic
Setpoint Digital with tamper resistant - screwdriver adjust
Display Audible/visual
Readability 0.1oC
Setability 0.1oC

CO2

CO2 Gas Control Better than ±0.1%

Range 0-20%
Inlet Pressure 10 PSIG
Filter 0.2 Micron, disposable
Sensor Thermal conductivity
Controller Electronic, digital
Setpoint Tamper resistant screwdriver adjust
Display Digital LCD

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Readability 0.1%
Setability 0.1%
Alarm Differential and Delay ±1.0% (nominal) for approx. 4 min.

Humidity

Humidity Control Ambient or 95% RH @ +37oC (98.6oF)

Humidity Reservoir 1.6 gal. (6 liters)
Humidity Pan 1.6 gal. (6 liters) optional

Fittings

Fill Port 1/4" FPT

Drain Port 1/4" FPT
Access Port 1.25" (3.17cm) with neoprene removable plug
CO2 Inlet 1/4" barbed

Unit Heat Load (per chamber)

115V 480 BTUH (140W)

220V 560 BTUH (160W)

Shelves

Standard 5 per chamber

Maximum 21 per chamber
Dimensions 17.75" x 17.75" (45.10cm x 45.10cm)
Construction Stainless steel, perforated, electropolished
Surface Area 2.2 sq. ft. (0.2 sq. m) per shelf
Max. Per Chamber 46.2 sq. ft. (4.2 sq. m)
Flatness ±.032" off horizontal plane

Construction

Volume 11.5 gal. (43.5 liters)

Volume Per Chamber 5.7 cu. ft. (161.4 liters)
Interior304 2B stainless steel
Exterior Cold rolled steel
Insulation 1-1/2" (3.8cm) Fiberglass

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Inner Door 1/4" (0.62cm) Fully tempered safety glass with cam
action latch
Inner Door Gasket Non-porous feather edge silicone
Outer Door Gasket Four sided molded magnetic vinyl
Finish Powder coated for a durable, easily
maintained surface

Electrical

3154/3158 90-130 Volts 50/60HZ, 1PH, 4.2 FLA

(3164) 180-260 Volts 50/60HZ, 1PH, 2.6 FLA
3326/3354 90-130 Volts 50/60HZ, 1PH, 8.0 FLA
(3336) 180-260 Volts 50/60HZ, 1PH, 3.8 FLA
Circuit Breaker 5 Amps/chamber
Power Switch 2 Pole
Line Cord 8 ft.
Data Output 10mv/unit temperature & CO2 (to Recorder output
connector)
Accessory Outlet 120V (75 Watts max.)
Remote Alarm Contacts Overtemperature, add water, power
failure, CO2 deviation

Certification

CSA Standard C22.2 No. 151

UL Standard No. 1262 (except 3164/3336)

Dimensions

Exterior (Single) 24.37"W x 42.75"H x 23.31"F-B

(61.91 cm x 108.59 cm x 59.22 cm)
Interior 19.75"W x 26.75"H x 18.75"F-B
(50.17 cm x 67.95 cm x 47.63 cm)
Exterior (Stacked) 24.37"W x 83.00"H x 23.31"F-B
(61.89 cm x 210.82 cm x 59.20 cm)

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Weights Single Dual

Net 250 lbs. (114 Kg) 500 lbs. (228 Kg)
Net Operational 357 lbs. (162 Kg) 714 lbs. (324 Kg)

Shipping
Motor 280 lbs. (127 Kg) 600 lbs. (272 Kg)
Air 345 lbs. (156 Kg) 700 lbs. (318 Kg)
Ocean 400 lbs. (181 Kg) 792 lbs. (359 Kg)

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SECTION 9 - AUXILIARY EQUIPMENT

9.1 AUXILIARY EQUIPMENT

1. Electropolished Stainless Steel Shelf

The perforated shelf is square for easy installation. 22 shelf capacity.
Catalog # 224140

2. Tissue Culture Shelves

These 11" x 16" stainless steel shelves for culture dishes are designed for
stacking to increase incubator storage space. Minimum order of 6 shelves.
Catalog # 500171

3. FYRITE CO2 Analyzer Kit

For checking chamber CO2 (0-20%) level in the chamber. Connects to the gas
sample port on the control panel. Kit comes complete with aspirator, sampling
tube, and carrying case.
Catalog # 220012

4. Extra FYRITE Fluid

For replacing FYRITE tester fluid. Three bottles per carton.
Catalog # 220051

5. Digital Thermometer
Hand-held, the size of a pocket calculator, it features clear liquid crystal
readout of temperature from -99.9°C to +99.9°C. Ideal for general laboratory
use.
Catalog # 853227

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6. Two Stage Pressure Regulator

Controls CO2 cylinder gas pressure. First stage reduces tank pressure to pre-
set intermediate level. Second stage reduces pressure to recommended incubator
inlet pressure. Permits stable CO2 flow on high or low demand through the entire
cylinder supply.
Catalog # 965010

7. CO2 Gas Guard

For use with automatic CO2 incubators only. Protects dual tank CO2 supply
by automatically switching to another tank when one supply is exhausted.
Audible alarm warns of tank depletion; reset button silences the alarm. Manual
tank switch-over included.
Model # 3050

8. Replacement CO2 Filter

Disposable 99.97% Microbiological filter to replace the inline CO2 filter
when it becomes clogged.
Catalog # 770001

9. Disinfecting Kit
Includes parts needed for improved disinfecting of the incubator. Includes
disposable blower wheel, O-ring for the CO2 sensor and motor mounting gasket.
Catalog # 190247

10. Humidity Pan

This humidity pan is made of stamped (seam-free) 304 stainless steel and will
hold 6.375 quarts (6 liters) of water. Cleaning and decontamination is very easy
due to the cove-shaped corners and seamless construction.
Catalog # 237001

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11. Hygrometer
For measuring chamber humidity. This instrument has a 4" dial and a range of
0 to 100% rh.
Catalog # 155010

12. Glass Thermometer

For independently measuring chamber temperature. Range from 0°C to 100°C.
Catalog # 285722

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SECTION 10 - PARTS LIST

STOCK # DESCRIPTION

770001 CO2 Disposable Filter

250085 CO2 Solenoid Valve 12VDC, 3W
300164 Over Temp Relay
431142 Four Sided Molded Magnetic Gasket
400296 Silicon Feather Gasket
230094 Glass Fuse .3A (Slow-Blow Type)
280004 #312 Green Pilot Light
280006 #312 Amber Pilot Light
111008 CLIP, Mounting, Pilot Light
285379 25A Triac
100071 Blower Wheel
227175 Blower Motor
231167 Alarm/Monitor Module
231039 CO2 Control Module
231047 Temperature Control
290027 1K, Thermistor Cable
285057 Extender Card Module

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SECTION 11 - SCHEMATICS

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