Bio Flo 4500 Part 2

BioFlo 4500

Benchtop Fermentor/Bioreactor

MANUAL NO: M1254-0050

Revision H September 27, 2002

Part 2 of 2

NEW BRUNSWICK SCIENTIFIC CO., INC. BOX 4005 • 44 TALMADGE ROAD • EDISON, NJ 08818-4005 Telephone: 1-732-287-1200 • 1-800-631-5417 Fax: 732-287-4222 • Telex: 4753012 NBSCO Internet: http://www.nbsc.com • E-mail: [email protected]

New Brunswick Scientific Co., Inc. User’s Guide

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Figure 50: Power Schematics, Detail B

BioFlo 4500 M1254-0050 User’s Guide

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Figure 51: Vessel Piping & Instrumentation


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Figure 52: Console Piping & Instrumentation


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38.2 List of Drawings Figure Description Page

1 Vessel Front View 27 2 Vessel Cross Section 28 3 Headplate Penetrations, Top View 29 4 Upper Side Wall Penetrations, Top View Cross Section 30 5 Lower Side Wall Penetrations, Top View Cross Section 31 6 Level Adjustment (shown without vessel) 35 7 Console Rear Panel Connections 36 8 Touchscreen Connections 37 9 External Computer & Alarm Connections 39

10 BioCommand Connections 40 11 External Analog Inputs 41 12 External Pump Connections 42 13 Vessel Cross Section 44 14 Motor & Bearing Housing 45 15 Headplate & Motor Installation 46 16 Service Connections 48 17 Gas Connections 49 18 Console Side Panel 53 19 Drain Valve Detail 57 20 Display Gauge 63 21 Temperature Control Loop Configuration 88 22 Agitation Control Loop Configuration 91 23 Airflow Control Loop Configuration 94 24 Pressure Control Loop Configuration 95 25 Oxygen Enrichment Control Configuration 105 26 Pump Configuration (piping removed) 111 27 Loading Tubing 114 28 Foam Control Loop Configuration 120 29 High Foam Control Loop Configuration 122 30 Auxiliary Pump Control Loop Configuration (for Antifoam Addition) 124 31 pH Control Loop Configuration 128 32 DO Control Loop Configuration 135 33 Level Control Loop Configuration 140 34 Nutrient Control Loop Configuration 141 35 Side Panel Removal 144 36 Gauge Screen 157 37 Addition Valve Detail 184 38 Sampling Valve Detail 187 39 Septum & Septum Cover 191 40 Syringe Port Assembly 192 41 Luer Lok Syringe Adapter 193 42 Syringe Assembly Connection 194 43 Hose Barb Ports 195


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Figure Description Page 44 Back Panel Removal 204 45 Motor Removal 205 46 Basic Control Schematics, Detail A 215 47 Basic Control Schematics, Detail B 216 48 Power Schematics 217 49 Power Schematics, Detail A 218 50 Power Schematics, Detail B 219 51 Vessel Piping & Instrumentation 220 52 Console Piping & Instrumentation 221 53 Console Piping & Instrumentation, Detail A 222 54 Console Piping & Instrumentation, Detail B 223


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3399 AAPPPPEENNDDIIXX AA:: CCOORRRROOSSIIOONN

RREESSIISSTTAANNCCEE TTAABBLLEESS

Corrosion Rate less than 0.002” per year

Corrosion Rate less than 0.020” per year Corrosion Rate from 0.020” to 0.050” per year

Corrosion Rate greater than 0.050” per year This table shows the resistance of Type 316 350 662 20 40 60 80 100 stainless steel to the more common 300 - - - chemicals. Many factors influence the 250 482 resistance of materials to various solutions 212 - - - Factors which must be given consideration 175 347 for service in corrosive environments are: 150 - - - temperature, concentration, aeration, influ- 125 257 ence of inhibiting or accelerating contamin- 100 212 ents, influence of recirculation, solids in 75 167 suspension, velocity; frequency of use, and 50 - - - equipment design. The corrosion data is 25 77 20 40 60 80 100 reprinted from Corrosion Data Survey, 1967 C F Percent Concentration in Water and 1974 Editions, published by the National Association of Corrosion Engineers The influence of contaminants is probably the most important from a commercial standpoint. Corrosive solutions are seldom found that will be free to all contaminates. However, the majority of these contaminants have no influence on corrosion, but the ones that do generally affect the conditions greatly.

When reviewing these corrosion tables, it is good to keep the following in mind: Stainless Type 316 is resistant to chemicals.

FOOTNOTES Footnotes for Corrosives: Footnotes for Data Squares: 1 Poison 20 Agitated 2 Toxic 21 7 pH 3 Explosive 22 < 7 pH 4 Flammable 23 > 7 pH 5 Ingestion poison 24 No HCI, H2SO4, HaC1 6 Inhalant poison 34 No stress 7 Attacks skin 36 300 psi 8 Irritant 37 Stress relieved 9 Vapor harmful 45 < 60 psi 10 Ignites Organics 51 > 2.25% Mo 11 Fuming liquid 72 over 400ºC 12 Hygroscopic 79 300 psi 13 Liberates HCL in water 80 No SO3 14 Narcotic 15 Volatile 16 Hazardous under pressure 17 Ignites combustibles 24 Exothermic with water


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4400 AAPPPPEENNDDIIXX BB:: GGEENNEERRAALL

CCHHAARRAACCTTEERRIISSTTIICCSS OOFF EEPPRR

EPR

Common Names EPR, EPT, EPDM Trade Names Resist-O (NordleR) –

Compound No. AX-60660 ASTM D-2000Classification CA Military (MIL STD 417) RS Chemical Definition Ethylene Propylene

GENERAL CHARACTERISTICS

Durometer Range (Shore A) 30-90 (NBS uses 80 for most O-rings) Tensile Range (P.S.I.) 500-2500 Elongation (Max. %) 600 Compression Set Good Resilience - Rebound Good Abrasion Resistance Good Tear Resistance Fair Solvent resistance Poor Oil resistance Poor Low Temperature Usage -20 to -60°F (-29 to -51°C) High Temperature Usage to 350°F (177°C) Aging Weather - Sunlight Excellent Adhesion to Metals Fair to Good

COMMENT Ethylene Propylene is a polymer with outstanding properties. It has exceptionally good weather aging and ozone resistance; excellent water and chemical resistance; excellent resistance to gas permeability, and excellent temperature usage range up to 350°F (177°C). Ethylene Propylene is a polymer where oil and solvent resistance is poor, however, it is fairly good in ketones and alcohols. It is not recommended for exposure to aromatic hydrocarbons.


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4411 AAPPPPEENNDDIIXX CC:: SSTTAANNDDAARRDD PPIIDD VVAALLUUEESS

Proportional Integral Derivative

TEMP 30 1.0 0 AGIT 0.3 4.0 0

PRESS 0.75 0.65 0 AIR 0.05 2.0 0

FOAM 1.0 0 0 LEVEL 1.0 0 0

HIGH FOAM 1.0 0 0 PUMP 1 1.0 0 0 PUMP 2 1.0 0 0 PUMP 3 1.0 0 0


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4422 AAPPPPEENNDDIIXX DD:: AADDVVAANNCCEEDD

CCOONNFFIIGGUURRAATTIIOONN SSEETTTTIINNGGSS

In some cases miscalibrating a loop may make it very difficult to properly recalibrate it again. You can resolve this problem by returning to the default calibration settings: Press the Default calibration checkbox. The default calibration settings will then be restored at the time the loop configuration is completed. For most loops, the calibration and input scaling is assumed to be linear. However, certain parameters, such as dissolved CO2, may have a logarithmic relationship to the raw reading from the probe. In these cases, you should change the input scaling to “logarithmic” before calibrating the probe. Note, too, that standard NBS RTD temperature sensors require the RTD input scaling selection for proper linearization of the input signal. Some loops may have a “noisy” reading, which means that the measured value jumps around. You can reduce the noise level by applying a digital filter to the displayed value.

The input filter settings apply to the digital filter algorithm that runs once per second and calculates the displayed value (DV) from the current value (CV) as follows:

If the CV is different from DV by more than the Band setting, then DV = CV.

Otherwise, DV new = Gain * CV + (1 - Gain) * DV old .


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4433 AAPPPPEENNDDIIXX EE:: FFOOUURR--GGAASS MMIIXX

AALLGGOORRIITTHHMM Selecting the GAS MIX control output invokes an algorithm that blends air, oxygen, nitrogen and carbon dioxide in response to culture demand, as indicated by pH and DO loop outputs. The pH and DO loops have their own digital PID control algorithm. They generate demands for base/acid (pH), and oxygen/nitrogen (DO). Their outputs range from -100% to +100%. Four-Gas mix percentages are determined from the pH and DO loop outputs as follows:

Carbon Dioxide (CO2):

When pH Output is negative, %CO2 = 0.2 x pH Output (%), and When pH Output is positive, %CO2 = 0, where %CO2 ranges between 0 and 20% .

Nitrogen (N2):

When DO Output is negative, %N2 = -1 x DO Output (%), and when DO Output is positive, %N2 = 0, where % N2 ranges between 0 and 100% .

Oxygen (O2):

When DO Output is positive, %O2 = DO Output (%) + 0.25 x %CO2,

and when DO Output is negative, %O2 = 0, where % O2 ranges between 0 and 100% .


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Air: %Air = 100% - %CO2 - %N2 - % O2, %, where Air ranges between 0 and 100%.

3-Gas and 2-Gas mixes are calculated as above, except only two or three of the gases are used.


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4444 IINNDDEEXX

A Abort Button, 113, 177 Aborting Automatic Sterilization, 176 AC Power In, 41 AC Pump Output, 41, 107 Add Button, 73 Add New Loop Prompt, 73 Adding a Control Loop to the Display, 73 Adding Control Loops, 73 Adding Media to the Vessel, 166 Addition Valve, 179

Operation, 180 Sterilization, 179

Advanced Settings Button, 80 Advanced Settings Screen

Enabling a Loop, 80 Agitation Control System, 85

Factory Settings, 86 Operation, 86

Air System Factory Settings, 90

Alarm Contacts, 39 AlarmButton, 155 Alarms, 38, 155

Absolute Alarm Mode, 156 Alarm Mode, 156 Alarms Screen, 155 Audible, 157 Deviation Alarm Mode, 156 Enabled or Visual, 157 External, 39 High Foam Safety System, 118 Responding to, 158 Setting, 155 Shutdown Feature, 157 Standard, 39

Analog Inputs, 40 Antifoam Setup

Pump 3 Factory Settings, 120 Automatic Pressure Control, 90 Automatic Sterilization

Enabling, 79 Automatic Sterilization Control Dialog, 170

B Baffles, 43 Basic Operations Password, 71 Battery Replacement, 200 BioCommand, 39, 161, 163

C Cal. Button, 56, 111 Calibrating, 79 Calibration

Conductance Probe, 121 Conductance Probe Sensitivity, 122 DO Probe, 132 pH Probe, 124, 126 Pumps, 110 Totalizing Control Loops, 111

Calibration Selection Window, 56, 111 CalibrationEnabling, 79 Casc Button, 145 Cascade

Casc Button, 145 Cascade Screen, 146 Control Screen, 145 Creating A Control Scheme, 145 Max. SP, 147 Min. SP, 146 Output %, 146, 147

Cascade Control Overview, 145

CAUTION Symbol for, vii

Change Loop Settings Window, 64 Chemical Foam Control System with Pump, 115 Circuit Diagrams, 211 Cleaning, 197 Computer Setup, 36 Conductance Probe Calibration, 121 Conductance Probe Grounding, 122 Config Button, 71, 72 Configure Button, 75 Configuring Control Loops, 74 Connector ID, 80 Control Loop

Limits, 76 Control Loops

Adding, 73 Configuring, 74 Deleting, 81 Operations, 73

Control Mode Selection, 67 Control Schematics, 211 Control Type, 66 Control Type Button, 66 Controller

Settings Screen, 79 Controller Icon, 96, 97, 102 Controller Output %, 64


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Controller Settings Screen, 80, 98, 103 Cool A Operation, 173 Cool B Operation, 173 Cool Time, 172 Copyright Notice, vii Corrosion Resistance Tables, 223 CPU Serial Number, 66

D Deadband

Explanation of, 161 Setting a, 161

Deleting a Loop, 81 Disclaimer Notice, vii Display Gauge, 63, 74, 153

Control Mode, 100, 104, 105 Controller Output %, 64 Measured Unit, 64 Setpoint, 111

DO Control System, 131 Overview, 131 Probe Calibration, 132 Probe Polarization, 132

DO Probe Calibration, 132 Calibration by Sparging with Nitrogen, 134 Electronic Calibration, 133 Polarization, 132 Span Calibration, 134 Zero Calibration, 133

Drain, 51 Drain Operation, 173 Drain Temp, 171 Drain Valve, 56 Drawing Index, 220

E Electrical Connections, 51 Electrical Connections, Computer and Monitor,

37 Enable

Sterilization, 80 Enter Button, 113 EPR

General Characteristics of, 231 Exhaust, 50 Exhaust Air (Gas) Filters, 91 Exhaust Gas Treatment, 92 External Pump Connections, 41

F Factory, 79, 90, 91, 129, 131, 135 Factory Settings

Configuration Foam Control System, 116 Configuration High Foam Safety System, 118 Configuration/Agitation, 88 DO Control System, 131 Loop configuration, 83 Nutrient Control System, 137

pH Control System, 124 Pump 3 Antiform Setup, 120 Temperature, 83 Temperature Control System, 84

Features Process Piping, 32 Sight Glass, 28 Vessel, 27

Fermentor Assembly Baffles, 43 Headplate Installation, 45

Fermentor Operation Initial Preparation, 53 Setup, 55, 61 Water Priming, 54

Fermentor Rushton Impeller, 43

Firmware ID, 66 Foam Control System, 115

Alarm Settings, 118 Chemical Foam Control, 115 Foam Probe Setup, 116 High Foam Probe Setup, 117 High Foam Safety System, 117

Foam Probe, 116 Four-Gas Mixer, 94

G Gas Control

Air, 93 CO2, 93 N2, 93 O2, 93

Gas Mix Algorithm, 237 Gas Mix Controller, 94 Gas Mix Status Window, 105 Gas Mixing

Four Gas, 104 Oxygen Enrichment, 95 Set Cycle Button, 106 Setting Cycle, 106 Three Gas, 103 Two Gas, 101

Gauge Button Operation, 153

Gauge Screen, 55, 61, 62, 63, 65, 71, 72, 73, 74, 81, 96, 97, 100, 102, 103, 104, 105, 111, 121, 141, 142, 143, 145, 149, 153, 155, 159, 170, 176, 177

H Headplate Installation, 45 Heat A Operation, 173 Heat B Operation, 173 Heat B Temp, 171 Heat Labile Media, 167 Heat Time, 171 High Foam Probe, 117


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I Initial Preparation, 53

Water Priming, 54 Inoculation and Addition, 179, 180 Inoculation Valve, 179 Input Device Icon, 76 Input Device, Setting, 76 Input Type, 76 Inspection

of boxes, 33 Instrument Name, 67 International Offices

List of, iii

K Keyboard, 68, 70 Keyboard Operation, 70

L Leveling the Unit, 35 Load Button, 142 Loading a Process Configuration, 142 Local Control Setup Screen, 68 Local Control Setup Window, 67, 68 Local Control Software Version, 66 Local Operating Mode, 68 Location

environment, 33 physical, 33

Lock Button, 71 Locking

Removing Controller Lock, 71 Locking, 69, 71

Lock Button, 71 Loop Configuration Screen, 74, 80, 96, 97, 99,

102, 103, 104, 105 Loop Control Mode, 75, 77

Analog, 75 Local, 75 Off, 77

Loop Setpoint Mode Screen, 75 Loops Window, 75

M Main Configuration Screen, 65, 67, 69, 71, 72,

73, 74, 96, 97, 100, 102, 103, 104, 141, 142, 143

Main Power Switch, 55, 61 Manual Backpressure Control, 90 Manual Conventions, vii Meas. Units Box, 77 Measured Unit, 64 Monitor

Calibration, 55 Multidrop Address, 67

N Node Number, 67, 68 Norm Const, 77 NOTE

Symbol for, vii Nutrient Control System, 137

O Operating Mode, 68 Output Action

2 Ch Direct, 79 Center Off, 78 Direct, 78 Direct w Enable, 79 Reverse, 78

Output Device Icon, 80 Output Options, 77 Output Type, 80 Overview

Specifications, 22 Oxygen Enrichment, 95

Cascade Setup, 100

P Password

Basic Operations, 69 System Configuration, 69, 70, 73, 81, 141,

142 Password Button, 69 Passwording, 69 pH Control System

Cascade Setup with Pumps, 128, 129 Overview, 123 pH Probe, 124 pH Probe Calibration, 124 System with Pumps, 123, 128, 129

pH Probe, 124 Calibration, 124 Gel Filled, 125 Gel Filled Calibration, 125 Liquid Filled, 124 Liquid Filled Calibration, 124 Recalibration After Sterilization, 127 Span Calibration, 126 Zero Calibration, 126

Positioning the Fermentor, 35 Prefilter/Regulator Kits, 52 Preparing for Fermentation, 165 Preventive Maintenance, 197

Cleaning, 197 One Year Intervals, 198 Sterile Inlet and Exhaust Filters, 199 Three Month Intervals, 197

Proportional Constant, 78 Pump AC Power In, 107 Pump Capacity, 108 Pumps, 107

Calibration, 110 Configuration, 107


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Loading Tubing, 109 Pump Capacity, 108 Tubing Selection Chart, 108

Pure Steam, 50

R Rate Function, 111 Rear, 36 Rename Mode Dialog Box, 68 Replacement Parts

Descriptions, 205 Part Numbers, 205

Run Button, 112, 113 Run Function, 112, 113

S Sampling Valve, 183

Sterilization, 184 Save Button, 141 Saving the Controller Configuration, 139 Screensaver

Enabling, 72 Feature, 72 Window, 72

Select Calibration Window, 121, 125, 127, 133, 134

Select Input Device Screen, 76 Select Output Device Screen, 80 Select Pointing Device Dialog, 56 SelectInputDeviceScreen, 76 Septum Port Kit, 187 Service/Utility

Connections, 46, 48 Drain, 51 Electrical, 51 Exhaust, 50 Prefilter/Regulator Kits, 52 Pure Steam, 50 Steam Supply, 50 Utility Steam, 50 Water & Water Return, 52

Set Cycle Button, 106, 126 Set Point Icon, 75 Set Rate Button, 111 Set Total Button, 111 Set Total Function, 111 Setpoint Button, 64 Setting Gas Mix Cycle, 106, 126 Setting Up Gas Mixer Option, 94 Settings

Advanced Configuration Settings, 235 Shutdown During Sterilization, 175 Solid State Relays, 95 Span Calibration

DO Probe, 134 pH Probe, 126

Sparge Air (Gas) System, 92 Start Up, 55, 61 Steam Supply, 50 Ster Operation, 173

Ster Temp, 171 Ster Time, 172 Sterilization

Aborting, 176 Automatic, 169 Automatic Sterilization Control Dialog, 170 Cool A Operation, 173 Cool B Operation, 173 Drain Operation, 173 Enabling, 176 Heat A Operation, 173 Heat B Operation, 173 Heat Labile Media, 167 Liquid in Vessel, 170 Overiew, 169 Presterilization Systems Check, 165 Shutdown, 175 Ster Operation Operation, 173 Sterilize Button, 176 Valve Sequencing, 171, 172 Vessel Empty, 178

Sterilization Process, Enabling, 176 Sterilization Shutdown Selections Window, 175 Sterilize Button, 176 Syringe Port Assembly, 188 Syringe Port Assemmbly, 190 System Info Button, 66 System Information, 66 Systems Check Prior to Fermentation, 165

T Temperature Control System, 83

Factory Settings, 83 Three-Gas Mixer, 94 Total, 111 Totalizing Control Loops

Calibration, 111 Trend Button, 149 Trend Graph, 149

Creating, 149 Setup Window, 150

Trend Plot, 153 Troubleshooting, 203 Tubing Selection

Chemical Capability, 108 Tubing Types, 108 Two Gas Control Module, 93 Two Gas Mixing, 93 Two-Gas Mixer, 94

U Unit ID, 67 Utility Steam, 50

V Valve Sequencing, 171, 172 Valve Sequencing Chart, 174 Vessel

Vessel Cross Section, 28


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Vessel Front View, 27 Vessel Exhaust Air (Gas) Filters, 91 Vessel Pressure, 90

W WARNING

Symbol for, vii Warranty, ix

Water & Water Return, 52 Water Priming, 54 Wiring Diagrams, 211

Z Zero Calibration, 111

DO Probe, 133 pH Probe, 126

Bio Flo 4500 Part 2

Documents

b new brunswick scientific

so3 new brunswick scientific

blank bioflo

corrosion tables

year corrosion rate

corrosion data survey

influence of contaminants

view cross section lower