INSTRUCTION MANUAL

FT36

BLAST AND FLUID BED FREEZER

FT36
AL8721

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 LIGHTS

ON 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 this

instruction manual we wish to alert you to potential hazards so that they may be
avoided.

Although designed for safe operation, any laboratory equipment may involve
processes or procedures which are potentially hazardous. The major potential
hazards 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 is
included in this manual, to assist staff and students in this regard. The list is not
intended to be fully comprehensive but for guidance only.

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

- i -
The COSHH Regulations

The Control of Substances Hazardous to Health Regulations (1988)

The COSHH regulations impose a duty on employers to protect employees and

others from substances used at work which may be hazardous to health. The
regulations require you to make an assessment of all operations which are liable to
expose any person to hazardous solids, liquids, dusts, vapours, gases or micro-
organisms. You are also required to introduce suitable procedures for handling
these substances and keep appropriate records.

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

Part of the above regulations are to ensure that the relevant Health and Safety Data
Sheets are available for all hazardous substances used in the laboratory. Any person
using a hazardous substance must be informed of the following:
Physical data about the substance
Any hazard from fire or explosion
Any hazard to health
Appropriate First Aid treatment
Any hazard from reaction with other substances
How to clean/dispose of spilage
Appropriate protective measures
Appropriate storage and handling
Although these regulations may not be applicable in your country, it is strongly
recommended that a similar approach is adopted for the protection of the students
operating the equipment. Local regulations must also be considered.

-2-
USE OF EARTH LEAKAGE CIRCUIT BREAKER AS AN ELECTRICAL
SAFETY DEVICE
The equipment described in this Instruction Manual operates from a mains voltage
electrical supply. The equipment is designed and manufactured in accordance with
appropriate regulations relating to the use of electricity. Similarly, it is assumed that
regulations applying to the operation of electrical equipment are observed by the end
user.

However, it is recommended that an Earth Leakage Circuit Breaker (ELCB,

alternatively called a Residual Current Circuit Breaker or RCCB) be fitted to this
equipment. If through misuse or accident the equipment becomes electrically
dangerous, an ELCB wil switch off the electrical supply and reduce the severity of
any electric shock received by an operator to a level which, under normal
circumstances, wil not cause injury to that person.
If the electrical supply to the laboratory already incorporates an ELCB, then the device
supplied with the equipment need not be used. If the electrical supply does not
incorporate such protection then the loose ELCB supplied by Armfield Ltd should be
fitted by a competent electrician either in the supply to the laboratory or in the supply
to the individual item of equipment. Drawing Number BM20979 gives full
installation instructions.

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

At least once each month, check that the ELCB is 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 the equipment must be checked and
repaired by a competent electrician before it is used.

-3-
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-4-
RECEIPT OF EQUIPMENT

1. SALES IN THE UNITED KINGDOM

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

Any omissions or breakages should be notified to Armfield Limited within three

days of receipt.

2. SALES OVERSEAS

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

Any omissions or breakages should be notified immediately to the Insurance Agent

stated on the Insurance Certificate if the goods were insured by Armfield Ltd.

Your own insurers should be notified immediately if insurance was arranged by

yourselves.

-5-
 Expansion Valve 31
3 34 35

ODD 33 Heat Exchanger

Ca binet overheat Eva pora tor

defrost termination
control temperature
Thermostats
FREEZER CABINET

liquid line
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insulation l2 to

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low Cut Out
Pressure 24 Discharge
Cut Out
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Return Separator Water cooled Condenser
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010 011 012 013 014 015

016 017 018 019

020

CONTROL PANEL

-7-
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-8-
 CONTINUED FROM PREVIOUS PAGE

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-9-
 FUSE ITEM KW FLC FUSE
NUMBER SIZE
CF1 CONTROL 6
F1 F2 F3 COMPRESSOR MOTOR f. 8-4 20M 25
F4 F5 F6 EVAPORATOR FAN 0.75 27 6
F7 Fa F9 DEFR OST HEATERS 4.5 6.25 10
F10 CRANKCASE HEATER 0.2 - 4
F 11 DOOR HEATERS 0.2 - 6
F12 CABINET LI GHTS 0-2 - 6

- 10 -
CONNECTION TO SERVICES

Cooling Water
It is EXTREMELY IMPORTANT that the compressor must NEVER be run without a
continuous 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 flow
capacity of more than 25litres/min at 20°C.

Electricity

A suitable 3 phase supply must be connected through an Earth Leakage Circuit

Breaker 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 must
run in the direction indicated on the fan blades (embossed arrow). If the fan rotates
in the opposite direction, turn off the unit and swap over any two live connections.

- 11 -
 ACCESSORIES
TEMPERA TURE SENSORS

Four thermocouple temperature sensors can be connected to the Armfield Data

Logger for continuous storage an recording of selected temperatures within the blast
freezer compartment.

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

The Data Logger is supplied with a comprehensive instruction leaflet which should
be used for set up of the temperature sensors to the logger hardware and to a suitable
computer.
The thermocouple sensors are then positioned within the freezer compartment at
the desired locations. These locations wil depend on the experiment being
performed but can be, for example:
* Air temperature (sensor tip in airstream)
*
Tray temperature (sensor tip in contact with one or more of the
stainless steel trays using adhesive tape)
*
Food package temperature (sensor tip taped to outside/inside of food
package)
*
inside food sample being frozen (sensor tip positioned inside sample
after making an access passage - centre of good sample wil be last to
freeze)

ANEMOMETER

The telescopic anemometer is installed by insertion into the air stream in the blast
freezer duct through the plastic conduit located outside the freezer to the right of the
front 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 the
data logger so that the output can be stored and recorded continuously. The air speed
is 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 to
various settings of the baffles using either the meter readout or data logger. This
calibration wil be useful for later reference.

THE ANEMOMETER MUST NOT BE USED A TEMPERATURES BELOW 00 C. IT is

INTENDED ONLY FOR THE CALIBRA TION OF THE AIR SPEED ADJUSTING
BAFFLES AT AMBIENT TEMPERATURES AND SHOULD BE WITHDRAWN
FROM THE CONDUIT BEFORE SWITCHING ON THE REFRIGERA TION
COMPRESSOR.

- 12-
 OPERATING INSTRUCTIONS

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

1. The main Isolator must be left in the ON position to allow the

crankcase heater in the compressor to keep the oil warm. IF THIS IS
NOT POSSIBLE. the main switch must be switched on a
minimum of 24 hours before the machine is used.
2. Open inlet cooling water and run drain line to waste position. Make
sure there is a flow of water.

3. Switch on compressor control refrigeration on switch. The

evaporator fan and compressor wil start. The temperature wil begin
to fall and can be observed on the temperature controller (3). The
temperature wil fall until it reaches its desired temperature.
The water valve is pre-set during commissioning but may need to be
reset to achieve 35°C condensing temperature (12.8 bar) as dictated by
local conditions.

4. The refrigeration plant is now in operation and wil continue to run

until the desired temperature is reached (to a minimum of -35°C)
when it wil modulate to hold the temperature constant. The
compressor wil pump down and stop on low pressure, but the
evaporator 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 a
number of different items. An access connection is provided at the
ducting and the cabinet wall to allow thermocouple and leads to
monitor individual temperatures on a recorder outside the cabinet if
required. It is also possible to use a special extending anemometer in
this access connection to measure air flow in the duct. Standard
anemometers can be used at the Fluid Bed section.

6. Defrosting can be achieved overnight if the refrigeration on switch is

turned off and the cabinet doors are left open. Make sure there are no
traces of foodstuff left in the cabinet and before restarting, dry out the
interior of the cabinet.

QUICK DEFROST

Push the defrost button (19). Defrost light wil come on, evaporator
fan switches off and the compressor wil pump down, defrost heaters
wil come on. After pre-set, time heaters and the defrost light wil go
off automatically and refrigeration wil start automatically.
If refrigeration switch turned off and push button is pressed, the
cabinet wil defrost and then stop until the switch is put into position
again.
- 13 -
7. The fluid bed freezer section is accessed by the smaller door on the
right-hand end of the cabinet. Items such as peas or diced vegetables
can be fluidised here to differing degrees depending on the cold air
flow 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. The
maximum air velocity obtainable is 10 m.s.-I. When fluidising
material it is better to start with the minimum velocity and slowly
open the 'damper' until a satisfactory fluidised bed is achieved.

9. To prevent freezing up of the two doors, they are equipped with a

heating tape on their surround and each has an on/off switch on the
transformer boxes situated on the left-hand side of the cabinet. These
must remain on during operation of the freezer.

- 14 -
 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 on
with defrost thermostat satisfied.
8. Thermostat Satisfied Indicates when the cabinet is down to
temperature. It wil also indicate with the Low Pressure/Pump Down
Indicator.

9. Defrost Indicates once the Push Button (19) is depressed and also
means the defrost heaters in the cabinet are on. This indicator can
also be on with the Low Pressure /Pump Down Indicator. The defrost
wil terminate either by time or temperature in the cabinet.
10. Compressor Trip Indicates if an electrical fault has developed on the
compressor drive motor or supply to the control panel is defective.

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

12. Low Oil Pressure Indicates if the differential oil pressure in the
compressor 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. This
is 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.

- 15 -
 14. Cabinet Overheat Indicates if the cabinet temperature rises above a
pre-set leveL. The cabinet must be allowed to cool down naturally and
can be reset by depressing the button (18). Possible caused, defrosting
cabinet more than required.

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

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

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) is
switched off this button must be pressed to reset the control paneL.

19. Manual Defrost Push Button If it is required to defrost the cabinet

rapidly, 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

- 16 -
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

- 17 -
ROUTINE MAINTENANCE

To preserve the life and efficient operation of the equipment it is important that the
equipment is properly maintained. Regular servicing/maintenance of the
equipment is the responsibilty of the end user and must be performed by qualified
personnel 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 NOT

use abrasives or solvents.

- 18 -
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 be
understood 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 an
assistant 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 the
slings are attached to structural framework and do not foul adjacent pipework,
glassware etc. When using fork lift trucks, position the forks beneath
structural framework ensuring that the forks do not foul adjacent pipework,
glassware etc. Damage may go unseen during commissioning creating a
potential hazard to subsequent operators.
c Where special foundations are required follow the instructions provided and
do not improvise. Locate heavy equipment at low leveL.
d Equipment involving inflammable or corrosive liquids should be sited in a
containment area or bund with a capacity 50% greater than the maximum
equipment contents.
e Ensure that all services are compatible with the equipment and that
independent isolators are always provided and labelled. Use reliable
connections 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 Residual
Current Device (RCD) (alternatively called an Earth Leakage Circuit Breaker -
ELCB) to protect the operator from severe electric shock in the event of misuse
or accident.
g Potential hazards should always be the first consideration when deciding on a
suitable location for equipment. Leave sufficient space between equipment
and between walls and equipment.

a
3 Commissioning

a Ensure that equipment is commissioned and checked by a competent member

of 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 leave
equipment 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 a
planned basis.
b Do not permit faulty equipment to be operated. Ensure that repairs are carried
out competently and checked before students are permitted to operate the
equipment.

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 repair
must be effected by a competent electrician before the equipment or electrical
supply 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 they
come into contact. Never operate portable electric appliances adjacent to
equipment involving water unless some form of constraint or barrier is
incorporated 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 extinguishers

appropriate to the potential hazards.
b Where inflammable liquids are used, smoking must be forbidden. Notices
should 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 contain
vapour 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,
an ex-proof extraction system. Vents on the
the area should be ventilated by

equipment 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 protective
clothing when handling such substances. Clean up any spilage immediately
and ventilate areas thoroughly using extraction equipment. Beware of slippery
floors.
b Do not allow food to be brought into or consumed in the laboratory. Never
use chemical beakers as drinking vessels.
c Where poisonous va pours are involved, smoking must be forbidden. Notices
should 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 parts
of 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 arise
pours or splinters. Beware of debris from fast
from powders, liquid splashes, va

moving 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 arc
lamp. 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 starting
equipment.

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.