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: bioinfo@nbsc.com
215
Figure 50: Power Schematics, Detail B
New Brunswick Scientific Co., Inc. User’s Guide

216
Figure 51: Vessel Piping & Instrumentation
BioFlo 4500 M1254-0050 User’s Guide

217
Figure 52: Console Piping & Instrumentation

218

219

220
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

221
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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223
39 APPENDIX A: CORROSION
RESISTANCE TABLES
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

224

225

226

227

228

229

230

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40 APPENDIX B: GENERAL
CHARACTERISTICS OF EPR
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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41 APPENDIX C: STANDARD PID

VALUES
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

234

235
42 APPENDIX D: ADVANCED
CONFIGURATION SETTINGS
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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237
43 APPENDIX E: FOUR-GAS MIX

ALGORITHM
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% .

238
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.

239
44 INDEX
A C
Abort Button, 113, 177 Cal. Button, 56, 111
Aborting Automatic Sterilization, 176 Calibrating, 79
AC Power In, 41 Calibration
AC Pump Output, 41, 107 Conductance Probe, 121
Add Button, 73 Conductance Probe Sensitivity, 122
Add New Loop Prompt, 73 DO Probe, 132
Adding a Control Loop to the Display, 73 pH Probe, 124, 126
Adding Control Loops, 73 Pumps, 110
Adding Media to the Vessel, 166 Totalizing Control Loops, 111
Addition Valve, 179 Calibration Selection Window, 56, 111
Operation, 180 CalibrationEnabling, 79
Sterilization, 179 Casc Button, 145
Advanced Settings Button, 80 Cascade
Advanced Settings Screen Casc Button, 145
Enabling a Loop, 80 Cascade Screen, 146
Agitation Control System, 85 Control Screen, 145
Factory Settings, 86 Creating A Control Scheme, 145
Operation, 86 Max. SP, 147
Air System Min. SP, 146
Factory Settings, 90 Output %, 146, 147
Alarm Contacts, 39 Cascade Control
AlarmButton, 155 Overview, 145
Alarms, 38, 155 CAUTION
Absolute Alarm Mode, 156 Symbol for, vii
Alarm Mode, 156 Change Loop Settings Window, 64
Alarms Screen, 155 Chemical Foam Control System with Pump, 115
Audible, 157 Circuit Diagrams, 211
Deviation Alarm Mode, 156 Cleaning, 197
Enabled or Visual, 157 Computer Setup, 36
External, 39 Conductance Probe Calibration, 121
High Foam Safety System, 118 Conductance Probe Grounding, 122
Responding to, 158 Config Button, 71, 72
Setting, 155 Configure Button, 75
Shutdown Feature, 157 Configuring Control Loops, 74
Standard, 39 Connector ID, 80
Analog Inputs, 40 Control Loop
Antifoam Setup Limits, 76
Pump 3 Factory Settings, 120 Control Loops
Automatic Pressure Control, 90 Adding, 73
Automatic Sterilization Configuring, 74
Enabling, 79 Deleting, 81
Automatic Sterilization Control Dialog, 170 Operations, 73
Control Mode Selection, 67
Control Schematics, 211
B Control Type, 66
Baffles, 43 Control Type Button, 66
Basic Operations Password, 71 Controller
Battery Replacement, 200 Settings Screen, 79
BioCommand, 39, 161, 163 Controller Icon, 96, 97, 102
Controller Output %, 64

240
Controller Settings Screen, 80, 98, 103 pH Control System, 124

Cool A Operation, 173 Pump 3 Antiform Setup, 120
Cool B Operation, 173 Temperature, 83
Cool Time, 172 Temperature Control System, 84
Copyright Notice, vii Features
Corrosion Resistance Tables, 223 Process Piping, 32
CPU Serial Number, 66 Sight Glass, 28
Vessel, 27
Fermentor Assembly
D Baffles, 43
Deadband Headplate Installation, 45
Explanation of, 161 Fermentor Operation
Setting a, 161 Initial Preparation, 53
Deleting a Loop, 81 Setup, 55, 61
Disclaimer Notice, vii Water Priming, 54
Display Gauge, 63, 74, 153 Fermentor Rushton
Control Mode, 100, 104, 105 Impeller, 43
Controller Output %, 64 Firmware ID, 66
Measured Unit, 64 Foam Control System, 115
Setpoint, 111 Alarm Settings, 118
DO Control System, 131 Chemical Foam Control, 115
Overview, 131 Foam Probe Setup, 116
Probe Calibration, 132 High Foam Probe Setup, 117
Probe Polarization, 132 High Foam Safety System, 117
DO Probe Foam Probe, 116
Calibration, 132 Four-Gas Mixer, 94
Calibration by Sparging with Nitrogen, 134
Electronic Calibration, 133 G
Polarization, 132
Span Calibration, 134 Gas Control
Zero Calibration, 133 Air, 93
Drain, 51 CO2, 93
Drain Operation, 173 N2, 93
Drain Temp, 171 O2, 93
Drain Valve, 56 Gas Mix Algorithm, 237
Drawing Index, 220 Gas Mix Controller, 94
Gas Mix Status Window, 105
Gas Mixing
E Four Gas, 104
Electrical Connections, 51 Oxygen Enrichment, 95
Electrical Connections, Computer and Monitor, Set Cycle Button, 106
37 Setting Cycle, 106
Enable Three Gas, 103
Sterilization, 80 Two Gas, 101
Enter Button, 113 Gauge Button
EPR Operation, 153
General Characteristics of, 231 Gauge Screen, 55, 61, 62, 63, 65, 71, 72, 73, 74,
Exhaust, 50 81, 96, 97, 100, 102, 103, 104, 105, 111, 121,
Exhaust Air (Gas) Filters, 91 141, 142, 143, 145, 149, 153, 155, 159, 170,
Exhaust Gas Treatment, 92 176, 177
External Pump Connections, 41
H
F Headplate Installation, 45
Factory, 79, 90, 91, 129, 131, 135 Heat A Operation, 173
Factory Settings Heat B Operation, 173
Configuration Foam Control System, 116 Heat B Temp, 171
Configuration High Foam Safety System, 118 Heat Labile Media, 167
Configuration/Agitation, 88 Heat Time, 171
DO Control System, 131 High Foam Probe, 117
Loop configuration, 83
Nutrient Control System, 137

241
I N
Initial Preparation, 53 Node Number, 67, 68
Water Priming, 54 Norm Const, 77
Inoculation and Addition, 179, 180 NOTE
Inoculation Valve, 179 Symbol for, vii
Input Device Icon, 76 Nutrient Control System, 137
Input Device, Setting, 76
Input Type, 76
Inspection
O
of boxes, 33 Operating Mode, 68
Instrument Name, 67 Output Action
International Offices 2 Ch Direct, 79
List of, iii Center Off, 78
Direct, 78
K Direct w Enable, 79
Reverse, 78
Keyboard, 68, 70 Output Device Icon, 80
Keyboard Operation, 70 Output Options, 77
Output Type, 80
Overview
L Specifications, 22
Leveling the Unit, 35 Oxygen Enrichment, 95
Load Button, 142 Cascade Setup, 100
Loading a Process Configuration, 142
Local Control Setup Screen, 68 P
Local Control Setup Window, 67, 68
Local Control Software Version, 66 Password
Local Operating Mode, 68 Basic Operations, 69
Location System Configuration, 69, 70, 73, 81, 141,
environment, 33 142
physical, 33 Password Button, 69
Lock Button, 71 Passwording, 69
Locking pH Control System
Removing Controller Lock, 71 Cascade Setup with Pumps, 128, 129
Locking, 69, 71 Overview, 123
Lock Button, 71 pH Probe, 124
Loop Configuration Screen, 74, 80, 96, 97, 99, pH Probe Calibration, 124
102, 103, 104, 105 System with Pumps, 123, 128, 129
Loop Control Mode, 75, 77 pH Probe, 124
Analog, 75 Calibration, 124
Local, 75 Gel Filled, 125
Off, 77 Gel Filled Calibration, 125
Loop Setpoint Mode Screen, 75 Liquid Filled, 124
Loops Window, 75 Liquid Filled Calibration, 124
Recalibration After Sterilization, 127
Span Calibration, 126
M Zero Calibration, 126
Main Configuration Screen, 65, 67, 69, 71, 72, Positioning the Fermentor, 35
73, 74, 96, 97, 100, 102, 103, 104, 141, 142, Prefilter/Regulator Kits, 52
143 Preparing for Fermentation, 165
Main Power Switch, 55, 61 Preventive Maintenance, 197
Manual Backpressure Control, 90 Cleaning, 197
Manual Conventions, vii One Year Intervals, 198
Meas. Units Box, 77 Sterile Inlet and Exhaust Filters, 199
Measured Unit, 64 Three Month Intervals, 197
Monitor Proportional Constant, 78
Calibration, 55 Pump AC Power In, 107
Multidrop Address, 67 Pump Capacity, 108
Pumps, 107
Calibration, 110
Configuration, 107

242
Loading Tubing, 109 Ster Temp, 171

Pump Capacity, 108 Ster Time, 172
Tubing Selection Chart, 108 Sterilization
Pure Steam, 50 Aborting, 176
Automatic, 169
Automatic Sterilization Control Dialog, 170
R Cool A Operation, 173
Rate Function, 111 Cool B Operation, 173
Rear, 36 Drain Operation, 173
Rename Mode Dialog Box, 68 Enabling, 176
Replacement Parts Heat A Operation, 173
Descriptions, 205 Heat B Operation, 173
Part Numbers, 205 Heat Labile Media, 167
Run Button, 112, 113 Liquid in Vessel, 170
Run Function, 112, 113 Overiew, 169
Presterilization Systems Check, 165
Shutdown, 175
S Ster Operation Operation, 173
Sampling Valve, 183 Sterilize Button, 176
Sterilization, 184 Valve Sequencing, 171, 172
Save Button, 141 Vessel Empty, 178
Saving the Controller Configuration, 139 Sterilization Process, Enabling, 176
Screensaver Sterilization Shutdown Selections Window, 175
Enabling, 72 Sterilize Button, 176
Feature, 72 Syringe Port Assembly, 188
Window, 72 Syringe Port Assemmbly, 190
Select Calibration Window, 121, 125, 127, 133, System Info Button, 66
134 System Information, 66
Select Input Device Screen, 76 Systems Check Prior to Fermentation, 165
Select Output Device Screen, 80
Select Pointing Device Dialog, 56 T
SelectInputDeviceScreen, 76
Septum Port Kit, 187 Temperature Control System, 83
Service/Utility Factory Settings, 83
Connections, 46, 48 Three-Gas Mixer, 94
Drain, 51 Total, 111
Electrical, 51 Totalizing Control Loops
Exhaust, 50 Calibration, 111
Prefilter/Regulator Kits, 52 Trend Button, 149
Pure Steam, 50 Trend Graph, 149
Steam Supply, 50 Creating, 149
Utility Steam, 50 Setup Window, 150
Water & Water Return, 52 Trend Plot, 153
Set Cycle Button, 106, 126 Troubleshooting, 203
Set Point Icon, 75 Tubing Selection
Set Rate Button, 111 Chemical Capability, 108
Set Total Button, 111 Tubing Types, 108
Set Total Function, 111 Two Gas Control Module, 93
Setpoint Button, 64 Two Gas Mixing, 93
Setting Gas Mix Cycle, 106, 126 Two-Gas Mixer, 94
Setting Up Gas Mixer Option, 94
Settings U
Advanced Configuration Settings, 235
Shutdown During Sterilization, 175 Unit ID, 67
Solid State Relays, 95 Utility Steam, 50
Span Calibration
DO Probe, 134
pH Probe, 126
V
Sparge Air (Gas) System, 92 Valve Sequencing, 171, 172
Start Up, 55, 61 Valve Sequencing Chart, 174
Steam Supply, 50 Vessel
Ster Operation, 173 Vessel Cross Section, 28

243
Vessel Front View, 27 Water & Water Return, 52

Vessel Exhaust Air (Gas) Filters, 91 Water Priming, 54
Vessel Pressure, 90 Wiring Diagrams, 211
W Z
WARNING Zero Calibration, 111
Symbol for, vii DO Probe, 133
Warranty, ix pH Probe, 126

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BioFlo 4500

NEW BRUNSWICK SCIENTIFIC CO., INC.

Figure 50: Power Schematics, Detail B

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

Figure 51: Vessel Piping & Instrumentation

BioFlo 4500 M1254-0050 User’s Guide

Figure 52: Console Piping & Instrumentation

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

Figure 53: Console Piping & Instrumentation

BioFlo 4500 M1254-0050 User’s Guide

Figure 54: Console Piping & Instrumentation

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

38.2 List of Drawings

Figure Description Page

BioFlo 4500 M1254-0050 User’s Guide

Figure Description Page

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

THIS PAGE INTENTIONALLY BLANK

BioFlo 4500 M1254-0050 User’s Guide

Corrosion Rate less than 0.002” per year

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

BioFlo 4500 M1254-0050 User’s Guide

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

BioFlo 4500 M1254-0050 User’s Guide

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

BioFlo 4500 M1254-0050 User’s Guide

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

BioFlo 4500 M1254-0050 User’s Guide

Common Names EPR, EPT, EPDM

Durometer Range (Shore A) 30-90 (NBS uses 80 for most O-rings)

Ethylene Propylene is a polymer with outstanding properties. It has exceptionally good

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

THIS PAGE INTENTIONALLY BLANK

BioFlo 4500 M1254-0050 User’s Guide

41 APPENDIX C: STANDARD PID

Proportional Integral Derivative

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

THIS PAGE INTENTIONALLY BLANK

BioFlo 4500 M1254-0050 User’s Guide

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

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

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BioFlo 4500 M1254-0050 User’s Guide

43 APPENDIX E: FOUR-GAS MIX

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% .

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% .

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% .

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

BioFlo 4500 M1254-0050 User’s Guide

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

Controller Settings Screen, 80, 98, 103 pH Control System, 124

BioFlo 4500 M1254-0050 User’s Guide

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

Loading Tubing, 109 Ster Temp, 171

BioFlo 4500 M1254-0050 User’s Guide

Vessel Front View, 27 Water & Water Return, 52

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