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NEW BRUNSWICK SCIENTIFIC BioFlo CelliGen 115 - User Manual

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New Brunswick Scientific PO Box 4005 44 Talmadge Rd. Edison, 08818-4005 USA
1.800.631.5417 1.732.287.1200 bioinfo@nbsc.com
www.nbsc.com
Guide to Operations
BioFlo
®
/CelliGen
®
115
Benchtop Fermentor & Bioreactor
MANUAL No: M1369-0050
Revision B
June 2, 2009

Table of Contents

Questions and Answers

Summary

Warnings and Cautions

Warnings

Lists critical safety warnings for equipment operation, including high voltage and hazardous materials.

Cautions

Details operational cautions to prevent equipment damage and personal injury, emphasizing manual adherence.

Inspection and Unpacking of Equipment

Inspection of Boxes

Procedure for inspecting shipment for damage and reporting issues to the carrier or sales department.

Packing List Verification

Instructions for verifying received materials against the packing list and reporting missing items.

Basic Components

Lists the essential components expected with the system, detailing their general function.

Introduction and Overview

System Description

Overview of the BioFlo/CelliGen 115 as a versatile fermentor/bioreactor system for various culture types.

Vessel Types and Features

Details the variety of glass vessels, including non-jacketed and water-jacketed options and their ports.

Agitation System

Describes the removable agitation motor, its connection, speed range, and cascading with DO control.

Temperature Control

Explains temperature setpoint selection, control mechanisms via heater/coil, and media sensing.

Aeration System

Covers gas introduction, flow control via rotameters or TMFC, and 4-gas mixing options.

pH Control

Details pH control range, sensing via pH probe, and use of peristaltic pumps or gases for adjustment.

DO Control

Explains dissolved oxygen control range and methods, including agitation, TMFC, and oxygen percentage.

Foam;Level Control

Describes foam monitoring and control using a probe and antifoam addition, plus internal level control.

Exhaust System

Details the exhaust gas path, including condenser for moisture removal and a 0.2 μm filter.

Recommended Accessories & Supplies

Lists essential accessories and supplies required for system assembly and operation.

Supervisory Software

Introduces optional BioCommand software for remote control and data logging via PC.

Installation

Physical Location Requirements

Specifies requirements for a smooth, level, sturdy surface with adequate space around the unit.

Environment Conditions

Defines acceptable ambient temperature range (10-35°C) and relative humidity (up to 80%).

Control Cabinet Installation

Guidance on positioning the control station cabinet and connecting the power cord.

Connecting Utility Cabinets

Instructions for connecting utility stations to the control station using a bus cable.

Utilities Connections

Details service connections for electrical, facility water, process air, gases, and exhaust.

Important Warnings

Highlights critical warnings for safety and equipment protection during assembly and operation.

Non-Jacketed Vessel Assembly

Step-by-step guide for assembling non-jacketed vessels, including headplate and heat blanket.

Water-Jacketed Vessel Assembly

Procedures for assembling water-jacketed vessels, including headplate, base plate, and water jacket.

Cooling Coil and Sparger Installation

Instructions for installing cooling coils and spargers in different vessel types.

Harvest Tube and Sampler Tube Installation

Guidance on installing harvest and sampler tubes, noting specific configurations for 1.3L vessels.

Thermowell and Foam Probe Installation

Steps for installing the thermowell for the RTD and the foam sensor into the headplate ports.

Exhaust Condenser and Sampler Installation

Procedures for installing the optional exhaust condenser and the aseptic sampler system.

Foam Trap Installation

Instructions for installing the foam trap kit, including bottle holder and bottle placement.

Plug Unused Ports

Guidance on closing off unused headplate ports and access tubes to maintain system integrity.

Headplate Installation

Steps for orienting and securing the headplate to the vessel, including baffle positioning.

Main Power Switch

Location and operation of the main power switch, with a caution before turning power on.

Optional BioCommand Software

Information on connecting the system to supervisory host computers via SCADA port.

Specifications

Certifications

Details compliance with US, Canadian, and European electrical and safety standards.

Operating Controls

Touchscreen Interface

Describes the touchscreen as the primary interface for the BioFlo/CelliGen 115.

Display Screens Overview

Introduces various display screens including Calibration, Summary, and Gauge screens.

Touchscreen Calibration

Guide for calibrating the touchscreen display for optimal touch response.

Start-Up and Summary Screens

Explains the initial start-up screen and the main SUMMARY screen for system monitoring.

Keypads for Input

Details the alphanumeric and numeric keypads used for entering data and setpoints.

Gauge Screens

Describes how to access and interpret gauge screens for individual control loops.

Selecting Loop Control Modes

Explains different control modes (ON, OFF, AUTO, MANUAL, etc.) for loops and pumps.

Entering and Modifying Setpoints

Guide for setting and adjusting desired parameter values for control loops.

Calibration Screen

Screen used for calibrating pH, DO, and level probes.

Cascade Control Screen

Interface for setting up and viewing cascade control functions between loops.

Pump Screen

Provides access to pump gauges for monitoring and setting pump parameters.

Setup Screen

Master screen for configuring controller, system settings, and hardware.

Probe Preparation and Calibration

pH Probe Inspection and Calibration

Covers inspecting the pH probe, calibration procedure with buffers, and probe maintenance.

DO Probe Preparation and Installation

Details inspecting, preparing, polarizing, and installing the dissolved oxygen probe.

DO Probe Calibration

Provides methods for setting zero and span for DO probe calibration.

Level Probe Calibration

Explains the calibration process for level sensors, covering Dry and Wet modes.

Pump Calibration

Guidance on calibrating pumps to ensure accurate flow rates, especially after tubing changes.

Vessel Sterilization

Initial Preparation for Autoclaving

Steps to prepare the vessel and components for autoclaving, including disconnections and protection.

Autoclaving the Vessel

Procedure for placing the vessel assembly into the autoclave and the sterilization process.

Sterilization Time and Temperature

Recommends starting sterilization time and temperature, with cautions on venting and exhaust.

Reinstalling the Vessel Assembly

Reinstall Vessel Assembly

Steps for reconnecting the vessel assembly to the control cabinet after sterilization.

Load Pump Tubing

Detailed guide on how to properly load tubing into the pump heads.

Cascade Control

Creating a Cascade Control Loop

Instructions on how to set up cascade control between different loops like DO and Agitation.

About Pumps

Pump Assignment

Guide on assigning specific functions (e.g., Acid, Base, Foam) to available pumps.

Pump Setpoint Configuration

Steps for entering setpoints for pumps and understanding output multiplier features.

Pump Control Modes

Explanation of available pump control modes: Off, On, and Prime.

Pump Flow Rate and Calibration

Details on pump flow rates based on tubing size and the calibration process.

Pump Period Setting

How to set the pump cycle time (period) in seconds for controlled additions.

Using Level Probes for Feed Pumps

Configuring feed pumps to add liquid or harvest based on level probe signals.

Using the Setup Screen

Controller Setup Configuration

Guides on setting the controller's operating mode and vessel size.

System Settings

Covers changing date/time, updating software, and recalibrating the touchscreen.

Hardware Setup

Procedures for scanning and adding new hardware, and removing utility stations.

Performing a Run

Set Up Foam Control

Steps to set up and verify the foam probe and antifoam addition system.

Preparing for a Fermentation Run

Initial connection and setup steps before starting a fermentation run.

Inoculation Procedure

Methods for introducing inoculum into the vessel using aseptic techniques.

Starting BioCommand

Instructions for starting the BioCommand supervisory software and setting initial parameters.

Sampling Procedure

Detailed steps for aseptically collecting samples from the vessel using the sampler system.

Fermentation Phases

Description of the typical phases of a fermentation run: Lag, Exponential Growth, Steady State, Decline.

Batch and Fed Batch Operations

Explanation of batch and fed batch operation modes and their characteristics.

Continuous and Microaerophilic Culture

Overview of continuous operation and techniques for anaerobic/microaerophilic cultures.

Harvesting and Shutdown Procedures

Steps for harvesting culture broth and safely shutting down the system.

Essential Operating Tips

Precautions for Glass Vessel Assembly

Advice on avoiding glass vessel cracking or breakage during assembly and autoclaving.

Exhaust Condenser and Filter Maintenance

Instructions for cleaning and maintaining the exhaust condenser and its filters.

Installing a Double Filter System

Guidance on installing a Y-fitting with dual exhaust filters for flexibility during runs.

Cleaning Procedures

Cleaning the Vessel

Steps for cleaning the vessel with detergent and water, including list of wetted parts.

Cleaning the Control Cabinet

Routine cleaning instructions for the metal and plastic parts of the unit.

Maintenance

pH Probe Maintenance and Storage

Guidelines for pH probe maintenance, storage, and handling precautions.

DO Probe Maintenance and Storage

Instructions for DO probe cleaning, membrane inspection, and storage.

Vessel and Tubing Care

Recommendations for cleaning the vessel, headplate, and replacing tubing and filters.

Periodic Inspection Schedule

Checks and inspections to be performed at three-month intervals for proper operation.

Agitator Bearing Housing Maintenance

Routine checks and cleaning for agitator bearings and shaft seals every 3-6 months.

Replacement Parts

List of common replacement parts with NBS part numbers for ordering convenience.

Service and Troubleshooting

Troubleshooting Guide

A list of common problems and their possible solutions for temperature, agitation, probes, and gas flow.

Drawings and Tables

List of Drawings

An index of all figures and diagrams in the manual, with corresponding page numbers.

List of Tables

An index of all tables in the manual, including their titles and page numbers.

Appendix A: Some General Concepts

What is a Controller?

Explains the function of a multi-loop process controller and its role in maintaining setpoints.

What is a Control Loop?

Defines a control loop as a system comprising a sensor, controller, and actuator for process automation.

Probe Calibration Principles

Describes the process of establishing correspondence between probe output and actual measured values.

Understanding P-I-D Constants

Explains proportional, integral, and derivative terms and their impact on control signal magnitude.

P-I-D Tuning Process

Discusses the iterative process of establishing controller settings for proper loop control.

Meaning of Control Constants

Explains how proportional, integral, and derivative constants influence the control signal calculation.

Appendix B: OTR

Determining Oxygen Transfer Rate (OTR)

Details the standard sulfite oxidation test method for determining OTR and calculation formulas.

Factors Affecting OTR and Horsepower

Discusses factors influencing OTR and horsepower, including impeller type, size, and placement.

Appendix C: Fermentation Techniques

Media Formulation for Fermentation

Provides an example of a complex media formulation for E. coli fermentation.

Antifoam Formulation and Use

Recommends antifoam agents, concentrations, and pump settings for foam control.

Tubing Size Recommendations

Guidance on selecting appropriate tubing sizes for acid, base, antifoam, and nutrient feeds.

Acid and Base Concentration Guidelines

Recommendations for acid and base concentrations and usage to avoid vessel damage.

Glucose Feed Concentration

Information on glucose feed concentration and automatic control via BioCommand software.

Recommended Process Control Settings

Suggests typical settings for temperature, pH, agitation, DO, and gas sparge rate.

Typical Fermentation Run Setup to Shutdown

Outlines the step-by-step process from vessel preparation to run shutdown and cleaning.

Appendix D: Corrosion Resistance

Appendix E: General Characteristics of EPR

Identifying EPR Materials

Lists common names, trade names, and definitions for EPR (Ethylene Propylene).

General Characteristics of EPR

Details physical properties of EPR, including durometer, tensile strength, and resistance properties.

Index

NEW BRUNSWICK SCIENTIFIC BioFlo CelliGen 115 Specifications

General IconGeneral
Temperature ControlYes
pH ControlYes
DO ControlYes
Power Requirements100-240 VAC, 50/60 Hz
TypeFermentor
pH Control Range2 - 12
Dissolved Oxygen (DO) Control Range0 - 100%
Control SystemDigital
MaterialStainless steel or glass
SterilizationAutoclavable

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