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Transcript of PBR 1000L INSTRUCTION MANUAL 1 - Pentair · PDF filePBR 1000L -INSTRUCTION MANUAL 1.92 ....


  • Revision 1.92



    1. NEVER clean the bioreactor with Windex,Acetone, Ammonia, or other solventbased cleaners. This will destroy theacrylic tank. If cleaning the outside of thetank is required, dilute soap and water isrecommended.

    2. Only use cotton to clean the acrylic tank.Most sponges and paper towel (cellulosebased) will scratch the tank, if manualcleaning is required, use cotton rags. If youare unsure, test on a small patch first andlook for scratching, or send us an e-mail.

    3. Ensure that the pallet is well supported ona flat sturdy floor. A cement pad is ideal. When full of water the system weighs 2600lbs(1180kg), and can sink into soft ground, which could break the tank as the supportbecomes uneven.

    4. Do not run the main water pump with less than 20L of liquid in the tank.

    5. If moving the tank without a pallet jack after adding the wooden support blocksunderneath, be careful - these blocks can pinch and damage your fingers.

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    Unscrew and remove the top panels of thebig and small crate.

    Remove the screws along the bottom ofthe big crate.

    Remove the bolts along the edges of thebig crate. It will come apart as 4 panels

    Remove all plastic wrap and tape


    1) Bolt the blue metal brackets for the CO2tank, and the water cistern (if using thechiller upgrade) into place onto the blackpallet.

    2) Mount the control system on the reactor bysliding it into the sockets and attaching theback white bracket to the reactor and thecontrol system.

    3) Loosen the bolts securing the pump andslide it back to create space for the shorttriclamp pipe. Ensure that a triclampgasket is clean and in place at each end ofthis pipe, and secure this pipe in place withthe clamps.

    4) Lock the pump in place by tightening the 4bolts to the pump shelf. The shelf holdingthe spray pump is tilted, this is intentional.

    5) Connect the outlet of the pump to the longtriclamp pipe, and connect the far end ofthis pipe to the Optical Density sensor, andfinally connect the optical density sensor tothe bottom of the tank.

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    6) Connect the drain line to the drainsolenoid. Bolt down the tube to theedge of the machine using the strainrelief bracket.

    7) Connect the electrical lines to thesensors and actuators. Everyconnection should be labeled. Thereare 2 rectangular holes below theelectrical box for cords. The right holeis for sensor cords, the left hole is forpower cords. Separating the power andsensor cords reduces signal noise.There are 7 cords that do not use these2 square holes: spray pump, mainpower, top LED, UV, Stir Motors(2) andair pump.

    The 4 cords for the T5 fluorescent lights (7A, 11A, 7B, 11B) connect to the 4 lights at the front of the machine (2 on each side of the viewing window).

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    8) Connect the CO2 from a regulator to theCO2 solenoid using john guest fittings andtubing provided.

    9) Connect the inlet watersolenoid, pre-filters, and UVsterilizer: Connect the blackline from the blue prefilter(10-1um Hydronix, SDC-45-1001) to the prefilter white(0.2um Shellco, MAS0.2-10S3S-B). Ensure there arefilters in the housings thenconnect white prefilter to thepressure gauge, then thepressure gauge to the bottomof the UV.

    10) Attach the three Pall micron filters and corresponding tubing.

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    11) Install the chiller. Water moves from thechiller's outlet (embossed lettering on the chillerlabeled OUT) to the inlet of the reactor's heatexchanger (labeled In). The outlet of thereactor's heat exchanger (labeled Out)connects to the top of the transparent watercistern. The bottom of the water cisternconnects to the inlet of the pump, and the outletof the pump connects to the inlet of the chiller(embossed lettering labeled IN). Dipping the endof the black tubing in hot water for 10 secondsmakes it easier to push onto the barbs.

    Ensure that the Temperature probe from the chiller is fully inserted into the Temperature probe housing. The housing is located above the pump to the right on the bottom dome of the PBR. There are two holes: one for the PBRs Probe and one for the chillers.

    Before plugging in the chiller, fill the cistern with water to the level of the blue metal plate. The cap on the cistern slides off, but fits tightly to avoid evaporation, so may need to be tapped upwards with a block of wood to loosen it. When the pump turns on the 1st time, air pockets will move to the cistern, and it requires topping up.

    12) If the chiller option was declined, a 3 way ball valve will be supplied. Connect yourfacilitys cold water supply to the AB barb of the valve. Connect the A barb to theinlet of the heat exchanger and its outlet to return to the reservoir/drain. Connect theB barb to the reservoir/drain. When the machines temperature increases beyond theset point in culture settings, it will open and allow cool water to chill the reactor.

    13) Install the 8 black wooden blocks underneath thereactor's pallet. Spacing is show in blue on the pictureto the right. These are used to providing support to thepallet to avoid sagging. If the floor is not level,additional shims should be used to level the pallet andwooden blocks and provide even support for the tank.

    14) Install the UV bulb into the UV sterilizer by plugging inthe 4 prong bulb to the UV ballasts receptacle. Do nottouch the bulb with bare hands. Tighten the nut on topof the housing, then the cord grip. Do not drop the bulbinto the UV sterilizer, as it will break the quartz sleeve.

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    15) Electrical requirements are on the side of the control box. For North American unit, thecord is wired to North American Standards: Black is live, White is Neutral, and Green isGround. Reactors in North America require a 120V AC 30 amp plug (L5-30).

    Plug in the reactor, it will automatically boot into the program. If the reactor does notstart after being plugged in, unplug it, then open the control box to ensure the breakerslocated at the bottom left of the box are flipped to on (L).

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    Cleaning and sterilizing the system between cultures is done in 2 steps: biofilm removal, followed by a bleach pressure wash.


    A. Disconnect the air inlet quick disconnect fitting(QDC), located below the tank. Leave all otherQDCs` intact and filters in place. Do not run thespray pump without disconnecting this QDC, orwater can be pushed back into the air pump.

    B. Turn the handle of the Brass 3-way valve to pushair through the upper branch of air tubing.


    C. If the tank isn't empty, drain it from the Manual Controls screen bypressing stop, then drain valve. If your software is up to date thetank will automatically drain before starting a cleaning cycle.

    D. On the Cleaning and Sterilization screen, Press Rinse X2. Confirmthe air inlet is disconnected (see Step A) and air lever turned todirect air through the upper branch of the tubing (Step B), beforeproceeding. The program will then execute 2 cycles of filling,rinsing, and draining the tank.

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    E. Gently, remove the pH probe on the outlet side of the spray pump by holding down theplastic ring of the John-Guest fitting and pulling the probestraight out. Replace the probe with the red (or gray) plasticpH-Blank. This is to protect the probe from the cleaningagents. Do not insert the blank or the probe all the way downto the flange as it makes it very hard to remove. If the pH-Blank is not in place, water will spray out during thecleaning cycle and could damage personnel orequipment.

    F. Place the pH probe in pH 7.01 buffer and 4.01. If thetransmitter (Eutech Instruments panel) is reading off of theexpected values, calibrate the probe following the eutechalpha 500 manual:(http://www.eutechinst.com/manuals/english/ts_alpha_controllers/ts_alpha_ph500.pdf).

    Biofilm Removal


    CIP 100 is a caustic cleaner, once diluted it is harmless and can be added directly to waterways, but DO NOT add CIP 100 laden water directly to your recirc system or holding tank. Ensure the water draining from your reactor is leaving your facility.

    Use appropriate protection when handling CIP 100, it can damage eyes and skin.

    G. On the Cleaning & Sterilization page,change wash time to 2 hours, and pressthe Chemical Clean button. Water willdrain if the tank is not already empty,then a prompt to: remove pH probe,replace with the red plug, disconnectlower air QDC and direct air flowupwards will appear. The program willask which water is hooked up to the PBR:salt or fresh. If Freshwater is selectedwater will automatically be added forcleaning. If Saltwater is selected theuser will need to add 30-40L offreshwater manually through thetriclamp port in the lid (pictured to theright), because CIP 100 does not work insaltwater. Hit okay on this screen toreturn to the Cleaning and Sterilization page and fill through the port . The progress of thewater addition is displayed in the text box at the bottom of the screen.


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    H. A prompt to check that the dome is mostly full of water and to Add XYZml of Steris CIP 100will appear on the screen, where XYZ is calculated for the set rinse volume. Visually confirmthe water level, then add CIP 100 through the triclamp port in the lid. Ensure not to spill it.Hit Okay after adding the cleaning agen