Infors HT Labfors 5 Operating Manual

Infors HT Labfors 5 Operating Manual

Bench-top bioreactor - version for solid substrates and enzymatic bioprocesses
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Operating Manual
2019-01-22
Labfors 5
Bench-Top Bioreactor - Version for Solid Substrates and Enzymatic Bioprocesses
Dok-ID: 77767 / V.02.00 - Original

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Summary of Contents for Infors HT Labfors 5

  • Page 1 Operating Manual 2019-01-22 Labfors 5 Bench-Top Bioreactor - Version for Solid Substrates and Enzymatic Bioprocesses Dok-ID: 77767 / V.02.00 - Original...
  • Page 2 Infors GmbH Infors UK Ltd Infors Dachauer Str. 6 The Courtyard Business Centre Headoffice, Schweiz D-85254 Einsbach Dovers Farm, Lonesome Lane, Rittergasse 27 T +49 (0)8135 8333 Reigate CH-4103 Bottmingen F +49 (0)8135 8320 Surrey, RH2 7QT, UK T +41 (0)61 425 77 00 infors.de@infors-ht.com T +44 (0)1737 22 31 00 F +41 (0)61 425 77 01...
  • Page 3: Table Of Contents

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Table of Contents General Information ............... 8 About this Manual ............8 Explanation of Special Notices ........8 1.2.1 Warning Notices ..........8 1.2.2 Other Notices..........9 Equipment Identification (Standard Identification Plate) 9 Declaration of Conformity ..........
  • Page 4 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Table of Contents 3.1.10 Sensor Connections (Sensor Cables) ..25 3.1.11 Connections and Valve for Water Flow Regulation of the Exit Gas Cooler ....26 Operating Panel ............27 3.2.1 Monitor Keys ..........27 3.2.2...
  • Page 5 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Table of Contents Pocket for Temperature Sensor (Pt100) ...... 56 Blanking Plugs ............. 56 Addition Port Adapters ..........58 Inoculation Needles ............. 59 5.10 Septum Collars ............62 5.11 Probe Protection for pH Sensor ........63 5.12 Dip Tubes ..............
  • Page 6 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Table of Contents 8.1.4 Moistening/Filling the Culture Vessel ...92 8.1.5 Fitting the Vessel Top Plate ......93 8.1.6 Mounting a Threaded Adapter ......94 8.1.7 Mounting the Blanking Plugs ......95 8.1.8 Mounting Addition Port Adapters ....97 8.1.9...
  • Page 7 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Table of Contents 8.2.9 Connecting the pH Sensor ......122 8.2.10 Connecting the pO Sensor ......123 8.2.11 Polarising the pO Sensor (METTLER) ..124 8.2.12 Calibrating the pO Sensor ......124 8.2.13...
  • Page 8 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Table of Contents 10.6 Cleaning the Hoses and Pump Heads .......150 10.7 Cleaning the Super Safe Sampler ......150 10.8 Cleaning the Exit Gas Cooler ........151 10.9 Cleaning the Basic Unit and Operating Panel ...151 10.10 Maintenance Plan ............151...
  • Page 9 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Table of Contents 13.7.6 Pumps ............178 13.7.7 Sterile Filters..........179 13.8 Operating Conditions ..........179 13.9 Emissions ..............179 13.10 Utilities ............... 179 13.11 Auxiliary Supplies ............180 22 January 2019...
  • Page 10: General Information

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses General Information 1 General Information 1.1 About this Manual This manual enables the safe and efficient handling of the equip- ment. All the information and instructions in this operating manual comply...
  • Page 11: Other Notices

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses General Information WARNING The signal word “WARNING” indicates a potentially dangerous situation that may result in severe or even fatal injuries if not avoided. CAUTION The signal word “CAUTION” indicates a potentially dangerous situation that may result in minor injuries if not avoided.
  • Page 12: Declaration Of Conformity

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses General Information 1.4 Declaration of Conformity The equipment is in compliance with the essential requirements of the following Directives: Machinery Directive 2006/42/EC  EMC Directive 2014/30/EU  The Declaration of Conformity according to EC Machinery Directive 2006/42/EC, annex II 1 A is included in the general documentation supplied with the equipment.
  • Page 13: Safety And Responsibility

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Safety and Responsibility 2 Safety and Responsibility This section describes general considerations relating to user safety that must be taken into account when working with the equipment. In the remaining sections, warning notices are used only to high- light particular hazards directly arising from the actions being de- scribed in the section in question.
  • Page 14: Qualified Personnel

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Safety and Responsibility For use for special applications not covered by conventional, in- tended use, the equipment must be modified and certified accord- ingly by the manufacturer. Any use of the equipment outside of a biotechnology laboratory, i.e.
  • Page 15: Operator

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Safety and Responsibility Qualified personnel On account of their specific education, training and – in many cases – experience, the qualified personnel required for this work are able to recognise risks and respond accordingly to potential hazards.
  • Page 16: Unauthorised Persons

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Safety and Responsibility Technicians in training Persons in this group who are undergoing training or apprentice- ships are only permitted to use the equipment under supervision and in accordance with the instructions of a trained and qualified technician.
  • Page 17: Electrical Current

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Safety and Responsibility The following notices are general in nature. As such, with a few exceptions they are not repeated in the remaining sections. 2.5.1 Electrical Current The equipment runs on electrical power. There is an immediate risk of fatal injury if contact is made with live parts.
  • Page 18: Hot Surfaces

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Safety and Responsibility 2.6.1 Hot Surfaces For processes that are carried out with temperatures over 55 °C, there is a danger of burns on hot surfaces. Since the equipment is intended for applications at high tempera- tures, it is the responsibility of the users to ensure that they have sufficient protection.
  • Page 19: Bioactive Substances Or Pathogenic Organisms

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Safety and Responsibility 2.6.5 Bioactive Substances or Pathogenic Organisms The use or production of bioactive substances, pathogenic organ- isms or genetically modified cultures entails a significant health risk. As such, special measures must be taken to protect the users for such applications.
  • Page 20: Declaration Of Decontamination

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Safety and Responsibility 2.8 Declaration of Decontamination When returning the equipment for repair, disassembly or disposal, it is required for the safety of all parties involved and because of legal provisions that a lawful declaration of decontamination is pre- sent.
  • Page 21: Setup And Function

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3 Setup and Function 3.1 Basic Unit Holder for operating unit, manometers and Pumps pressure reduction valves Console Main switch Base plate Sensor cables Holder for gassing unit(s)
  • Page 22: Main Switch

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function The whole measuring and control technology of the bioreactor is integrated in the console of the basic unit. One operating unit with touchscreen software can be used to control up to six bioreactors (culture vessels) see also chapter „Operating Unit“.
  • Page 23: Identification Plate

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function The autoclavable pump heads are latched onto a mounting plate. The mounting plate is identically as the drive shafts labelled with the pump names. The pump heads together with the mounting plate can easily be plugged onto or pulled off the drive shafts.
  • Page 24: Water Connections

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3.1.5 Water Connections The two hose nozzles for connection of water inlet and outlet of the basic unit are situated on the rear side at the bottom of the con- sole.
  • Page 25: Signal Connections

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function Manometers are installed after each pressure reduction valve for pressure indication. They are labelled accordingly, e.g. Air etc. 3.1.7 Signal Connections The following signal connectors are situated above the mains...
  • Page 26: Connections For Vessel

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3.1.8 Connections for Vessel The water connectors for the vessel jacket are labelled with corre- sponding symbols. Water overflow vessel jacket Water outlet vessel jacket Water inlet vessel jacket...
  • Page 27: Gassing Connection (Sparger/Head Space)

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3.1.9 Gassing Connection (Sparger/Head Space) The hose nozzle for connection of the gassing hose (sparger or head space gassing) is located below the holder for gassing unit on the right side of the basic unit.
  • Page 28: Connections And Valve For Water Flow Regulation Of The Exit Gas Cooler

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3.1.11 Connections and Valve for Water Flow Regulation of the Exit Gas Cooler The water connections for the (optional!) exit gas cooler and the valve for the water flow regulation are located on the left front side of the basic unit.
  • Page 29: Operating Panel

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3.2 Operating Panel The operating panel has a 12" colour-touch screen with protection IP66. Up to six bioreactors (= culture vessels) can be individually or in parallel controlled by one operating panel.
  • Page 30: Operating Panel Connections

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function INFORMATION The ON/OFF key is locked when a bioreactor (fermentation) is running. A dialogue box with the appropriate message appears when pressing the ON/OFF key by mistake during fermentation.
  • Page 31: Culture Vessel

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3.3 Culture Vessel Handhold top plate Water inlet vessel jacket Water overflow vessel jacket Handhold vessel holder Water outlet vessel jacket Vessel holder Glass vessel Top plate...
  • Page 32: Top Plate

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3.3.1 Top Plate Four knurled screws are used to fixate the top plate to the glass vessel and the vessel holder. Drive hub and motor coupling are lo- cated in the middle of the vessel top plate.
  • Page 33: Ports In The Vessel Top Plate And Their Configuration

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3.3.2 Ports in the Vessel Top Plate and their Configuration The vessel top plate has different ports of different sizes to mount the different components such as sparger, blanking plugs, sensors etc.
  • Page 34: Temperature Control System

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3.4 Temperature Control System The temperature control takes place in the vessel jacket, which is connected to the basic unit. For heating, water is heated by means of an electrical heating element in the basic unit.
  • Page 35 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function The mechanical seal must be lubricated at any time. For this, two nozzles fitted with a piece of silicone hose are located on the drive hub. For details see chapter “Lubricating the Mechanical Seal” in the main chapter “Cleaning &...
  • Page 36 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function Fork blade impeller  Anchor impeller  Single helix impeller  Double helix impeller  ATTENTION The glass vessel, the impeller or the motor may be damaged when operating the stirrer at unauthorised excessive rotation speed or when using the wrong impellers.
  • Page 37: Gassing System

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function 3.6 Gassing System The basic unit is equipped with the appropriate gassing units (rota- meter or mass flow controllers) and configured according to the chosen gassing strategy.
  • Page 38: Ph Control

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function The exit gas cooler is separately available, it is NOT included in the standard package. Deviating the exit gas via exit gas cooler The exit gas cooler dries the exit gas by condensation so that hu- midity cannot block the exit filter.
  • Page 39: Calibration

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function Variant HAMILTON Traditional pH sensor (potential measurement against refer-  ence) with integrated electronics Type: Easyferm Plus ARC  Manufacturer: HAMILTON  HAMILTON pH sensors are preconfigured before dispatch by the equipment manufacturer INFORS HT.
  • Page 40: Measuring System

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Setup and Function reduction In anaerobic processes, the vessel can be gassed using nitrogen. This displaces the oxygen dissolved in the medium. For details about pO control refer to the separate operating man- ual of the touch screen software.
  • Page 41: Measurement And Calibration

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Options 3.9.2 Measurement and Calibration Generally speaking, the following applies: Unlike measurements such as pH, which are calibrated to absolute measurement values, the oxygen measurement is always calibrated to a relative refer- ence point.
  • Page 42: Servomotor (High Torque)

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Options 4.2 Servomotor (High Torque) For high speed requirements, a powerful servomotor is available and can be used instead of the standard brushless DC motor. A 3 : 1 ratio in the motor increases the torque of the motor in normal operation by a factor of 3 to 3 Nm.
  • Page 43 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Options ATTENTION A rotation speed higher than 300 min in combination with vis- cous medium or with a helix impeller can destroy the motor, the impeller or the vessel. –...
  • Page 44: Exit Gas Analysis

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Options 4.3 Exit Gas Analysis In order to allow the user to draw conclusions regarding the status of the culture while the bioprocess is still underway, the CO measurements are often taken and analysed in the exit gas flow of the bioreactor.
  • Page 45 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Options INFORS HT Gas Analyser Connection of the gas analysis equipment from the equipment manufacturer is described in details in its separate documentation. Gas sensors from manufacturer BlueSens The gas sensor must be connected to the sensor cable and the bioreactor’s exit gas must be led into the sensor via hose line.
  • Page 46: Calibration

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Options 4.3.3 Calibration INFORS HT Gas Analyser The display of measured values on the bioreactor should be cali- brated after the annual maintenance of the gas analyser has been carried out For details about maintenance of the gas analyser refer to its sepa- rate documentation.
  • Page 47: Permissive Measurement

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Options 4.5 Permissive Measurement The sensor with the corresponding transmitters must be purchased directly from the manufacturer ABER. INFORS HT offers a connec- tion to the transmitter on the basic unit.
  • Page 48 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Options Pressure control consists of a solenoid valve (proportional valve) and a piezo-resistive pressure sensor with fixed O-ring (the O-ring is not visible in the picture to the left). Depending on the equipment configuration, the solenoid valve is situated next to or below the gassing unit on the right side of the equipment.
  • Page 49 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Options Proceed as follows for the mounting: Procedure Fit a threaded adapter into the 19 mm port in the vessel top plate. Carefully remove the protective cap from the steel membrane of the sensor.
  • Page 50 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Options Plug the male plug of the sensor cable into the female plug on the sensor. To do so, the red mark on each plug must be aligned. Maintenance Basically, the pressure sensor is maintenance-free. The recalibra- tion interval depends on the operating conditions.
  • Page 51: Accessories

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5 Accessories The following table lists all accessories included in the standard package of the equipment. Accessories Quantity Base tray Single helix impeller Double helix impeller Anchor impeller Pitched blade impeller (45°) Fork blade impeller Pocket for temperature sensor in Ø...
  • Page 52: Reagent Bottle And Pump Holder

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5.2 Reagent Bottle and Pump Holder The culture vessel is autoclaved along with reagent bottles, hoses and pump heads. For easy handling, a holder for three 250 mL reagent bottles and pump heads is available.
  • Page 53: Sampling System Super Safe Sampler

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5.3 Sampling System Super Safe Sampler Basically different systems and also individual components are available for sampling. This operating manual describes the opera- tion and handling of the aseptic sampling system Super Safe Sam- pler combined with a dip tube.
  • Page 54 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Principle of function The sample valve on the side arm of the T-piece opens by putting the Luer connector of the syringe into the valve and closes by re- moving the syringe.
  • Page 55: Sparger With Sterile Sheath

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories sample has to be processed under sterile conditions. For sampling, the same non-sterile syringe can be used repeatedly, without fear of contamination of the culture vessel. Aseptic Sampling For each sample, use a new, sterile syringe with Luer Lock fitting, in order to ensure the sterility of the sample.
  • Page 56 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories To prevent the sparger from clogging up due to solids in the me- dium, the sparger is protected by a sterile sheath. Once the me- dium is liquified, the sparger can be extended and gassing can be started.
  • Page 57: Impellers

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories The sparger with sterile sheath consists of the following individual parts: Hand ring with grub screws Screw-mounted pin Sterile sheath cover with fixed O-ring and grub screw O-ring Sterile sheath...
  • Page 58: Pocket For Temperature Sensor (Pt100)

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5.6 Pocket for Temperature Sensor (Pt100) The pocket is a pipe with a sealed bottom end, and is used to in- sert the temperature sensor. Pocket Ø 10 mm Fitted with fixed O-ring.
  • Page 59 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Blanking plug, Ø 12 mm Must be fitted with an O-ring before being mounted in the 12 mm/Pg13.5 port. Mounted using a thread. Blanking plug Ø 19 mm Fitted with fixed O-ring.
  • Page 60: Addition Port Adapters

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Blanking plug Ø 40 mm Fitted with fixed O-ring. Two slotted screws are used for fixing in 40 mm port. 5.8 Addition Port Adapters Addition port adapters are used for liquid addition into the culture vessel.
  • Page 61: Inoculation Needles

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Addition port adapter Ø 12 mm Inside-Ø 3.0 mm Outside-Ø hose connection 5.0 mm Muts be fitted with O-ring. Thread is used for mounting in 12 mm / Pg13.5 port.
  • Page 62 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories pierced with the inoculation needle, which is screwed into the sep- tum collar. The septum may be wetted e.g. with an alcohol solution that is lit up before the piercing.
  • Page 63 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Inoculation needle, Ø 19 mm Inside-Ø 2.5 mm Outside-Ø hose connection 4.5 mm Fitted with fixed O-ring. Thread is used for mounting in septum collar in 19 mm port.
  • Page 64: Septum Collars

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Inoculation needle, double, Ø 19 mm Inside-Ø 2.0 mm Outside-Ø hose connection 4.0 mm Fitted with fixed O-ring. Thread is used for mouting in septum collar in 19 mm port.
  • Page 65: Probe Protection For Ph Sensor

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Septum collar, Ø 19 mm With inside thread. Septum must be inserted in port before mounting in 19 mm port. Threaded adapter is used for mounting. Multi-inlet septum collar, system Roussel, Ø 19 mm With inside thread, for inoculation with syringe.
  • Page 66: Dip Tubes

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5.12 Dip Tubes Dip tubes are open at both ends and are mounted in a vessel top plate port with a clamping adapter. Dip tubes are used for a variety of purposes: For filling the culture vessel after autoclaving.
  • Page 67 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Dip tube, curved with horizontal tip, Ø 6 mm Inside-Ø 4,0 mm Hose connection outside-Ø 6.0 mm The dip tube does reach to the vessel bottom. Dip tube, curved with frit, Ø 6 mm Inside-Ø...
  • Page 68: Clamping Adapters

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5.13 Clamping Adapters Clamping adapters are used for mounting the sparger, the various dip tubes and the antifoam/level sensors. The clamping adapter fixes the component part in place and can be used to adjust its mounting depth.
  • Page 69: Electrode Holder

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Clamping adapter Ø 8 mm / 12 mm Must be fitted with O-ring before mounting. Thread is used for mounting in 12 mm / Pg13.5 port. After loosening the hollow screw (A) the component part with Ø...
  • Page 70: Threaded Adapter

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5.15 Threaded Adapter The threaded adapter has an inside thread and is used for mount- ing blanking plugs or clamping adapters with Ø 19 mm in (thread- less) 19 mm ports in the vessel top plate.
  • Page 71: Exit Gas Cooler

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5.17 Exit Gas Cooler The exit gas cooler is fully equipped ex-factory. Exit gas cooler Rapid coupling Adjustable hose clamp Plug-in nozzle Exit gas filter The exit gas cooler is supplied with cooling liquid from the basic unit.
  • Page 72 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Exit gas cooler Ø 12 mm Must be equipped with O-ring Its thread is used for mounting in 12 mm / Pg13.5 Port Exit gas cooler Ø 19 mm With fixed O-ring.
  • Page 73: Reagent Bottles

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5.18 Reagent Bottles For addition of corrective reagent and feed solution (substrate) into the culture vessel, different sizes and models of reagent bottles made of borosilicate glass are available.
  • Page 74 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories The individual parts of the reagent bottle are: Threaded cap, PBT Plate with two hose nozzles, PVDF Flat gasket, silicone Laboratory bottle, Borosilicate The picture to the left shows the reagent bottle type with 3 + 1 hose connectors.
  • Page 75: Pump Heads

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5.19 Pump Heads The autoclavable pump heads are fitted with PharMed pump hoses prior to delivery. Three different hose diameters are available for different delivery rates: 1.0 mm (standard) ...
  • Page 76 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Ø 37 mm, marked green Application Exit gas Retention rate 0.3 µm dry 1.0 µm wet Ø 25 mm, not marked Application Super Safe Sampler Retention rate 0.2 µm...
  • Page 77: O-Rings And Gaskets

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories 5.21 O-Rings and Gaskets Description Ø mm Utilisation O-ring, EPDM 1.5 x 7.5 Gasket, port size 10 mm Gasket, port size 12 mm / O-ring, EPDM 2.62 x 10.77 Pg13.5...
  • Page 78: Inoculation Accessories And Tools

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Accessories Silicone hose, 60° 10 x 16 Water connections vessel Shore, jacket (double walled culture vessels) Attachment Ø mm Application Hose clamp, 1 screw, Attachment hose(s) gas in- INOX let(s).
  • Page 79: Transport And Storage

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Transport and Storage 6 Transport and Storage The following specifications are based on transport and storage of an unpacked equipment at the provider’s site. 6.1 Transport WARNING Improper transport, the use of incorrect auxiliary equipment and careless handling of the equipment may lead to injuries and se- vere property damage.
  • Page 80: Storage

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Transport and Storage 6.2 Storage Before each time they are put into storage, decontaminate,  thoroughly clean and dry the culture vessel and all accesso- ries Store the equipment and its components clean, dry and pro- ...
  • Page 81: Installation And Initial Operation

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Installation and Initial Operation 7 Installation and Initial Operation Installation and initial operation of the equipment may only be car- ried out by qualified personnel from the manufacturer or personnel authorised by the manufacturer.
  • Page 82: Minimum Distances

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Installation and Initial Operation 7.2 Minimum Distances To operate and maintain the unit it must be installed with a mini- mum spacing of 150 mm from walls, ceilings or other equipment.
  • Page 83: Gas Supply

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Installation and Initial Operation Hoses Only use pressure-resistant and intact hoses.  Only use appropriate hoses, use adaptors as necessary.  Secure hoses with the appropriate clamps.  7.5 Gas Supply...
  • Page 84: Exit Gas

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Installation and Initial Operation 7.6 Exit Gas On site, it must be ensured that: the exit gas is safely led away by means of a suitable, gas-  tight hose.
  • Page 85 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Installation and Initial Operation ATTENTION If the vessel top plate presses against long built-in components they may be distorted due to the weight of the top plate. Always position the vessel top plate so that it does not lie on top of components.
  • Page 86: Filling The Water Circuit

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Installation and Initial Operation INFORMATION In order that the hose connections can be disconnected easily again, slightly moisten the rapid couplings on the silicon hoses prior to connecting them. 10. Equip the sparger (if used) with a piece of silicone hose (D= 5 x 8 mm) for gassing and a dry, clean inlet air filter (accesso- ries, filter with red label).
  • Page 87: Stirring

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Installation and Initial Operation You should hear and see water flowing into the vessel jacket. If using an exit gas cooler: The water supply of the exit gas cooler is activated now.
  • Page 88: Gassing

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Installation and Initial Operation The temperature of the liquid (water) in the vessel jacket starts increasing. Wait until the temperature has adjusted to the setpoint. For the rest of the procedure, allow the bioreactor to run with the temperature switched on and the stirrer running.
  • Page 89 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Installation and Initial Operation CAUTION Risk of minor burns if the motor is touched during operation or its cooling phase! When the motor has cooled down: Uncouple the motor from the vessel and place it on a clean and dry work surface.
  • Page 90: Before Fermentation/Cultivation

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8 Before Fermentation/Cultivation The following chapters describe all the preparatory work before starting the fermentation/cultivation process. This essentially com- prises: Preparing and autoclaving the culture vessel:  Checking the gaskets (O-rings) on component parts and ...
  • Page 91: Mounting The Impellers

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Procedure Check the vessel seal (O-ring) for damage and on correct seat: it must rest firmly on the slightly prominent vessel rim within the metal ring. Place it correctly as necessary.
  • Page 92: Assembling And Mounting The Sparger

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation When mounting the impeller, observe the following: Only one helix impeller can be used at a time.  If an anchor impeller is to be used, it must be fitted at the bot- ...
  • Page 93 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Insert the O-ring into the sterile sheath from above. Place the sterile sheath cover onto the sterile sheath. In doing so, ensure that the grub screw in the sterile sheath cover and the indentation for affixing the grub screw on the sterile sheath are aligned on top of one another.
  • Page 94: Moistening/Filling The Culture Vessel

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Move the hand ring up to the stop (and no further) on the sparger. Ensure that the screw-mounted pin on the hand ring is placed in the direction of the sparger and does not touch the sterile sheath cover.
  • Page 95: Fitting The Vessel Top Plate

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation INFORMATION Development of steam is not possible when autoclaving an empty and dry culture vessel. Successful sterilisation is not guaranteed. Ensure that there is liquid in the culture vessel (approx. 10 mL of water per litre of total volume).
  • Page 96: Mounting A Threaded Adapter

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Tighten the knurled screws on the top plate by hand (no tool!) crossways. ATTENTION If the screws are tightened too much, components may be dam- aged, which can result in failure of the equipment. The screws may not be tightened with a tool under any circumstances.
  • Page 97: Mounting The Blanking Plugs

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.1.7 Mounting the Blanking Plugs For mounting the different blanking plugs, proceed as follows: Ø 10 mm Ports Procedure Insert the blanking plug with fixed O-ring into the port.
  • Page 98 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Ø 19 mm ports Procedure Screw the blanking plug with fixed O-ring into the threaded adapter. Tighten it by hand. Ø 40 mm Port Procedure Insert the blanking plug with fixed O-ring into the port.
  • Page 99: Mounting Addition Port Adapters

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.1.8 Mounting Addition Port Adapters Proceed as follows for mounting: Addition port adapter, quadruple, for Ø 19 mm port Procedure Insert the addition port adapter with fixed O-ring into the port.
  • Page 100: Mounting The Pocket For Temperature Sensor (Pt100)

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.1.9 Mounting the Pocket for Temperature Sensor (Pt100) Proceed as follows: Procedure Insert the pocket with the fixed O-ring into the 10 mm port. Fix it with both slotted screws.
  • Page 101: Equipping Port With Septum Collar And Septum For Inoculation

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.1.11 Equipping Port with Septum Collar and Septum for Inoculation A port in the vessel top plate must be appropriately prepared for later inoculation. For this, it must be equipped with septum collar and septum.
  • Page 102 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Mounting in Ø 19 mm port Equip the 19 mm port with a threaded adapter first and then screw the exit gas cooler (with fixed O-ring) into the threaded adapter by hand.
  • Page 103: Checking Lubrication Of The Mechanical Seal

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation If no exit gas cooler is used, close the manual control valve for water flow on the basic unit or close the hose connectors with the plugs provided with the equipment.
  • Page 104: Calibrating The Ph Sensor

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation sensor Mount the pO sensor in such a way that it has good access to the flow and there is no risk of bubbles collecting. (Calibration is car- ried out AFTER autoclaving!) pH sensor &...
  • Page 105: Fitting A Ph Sensor With A Probe Protection

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.1.14.2 Fitting a pH Sensor with a Probe Protection To avoid damage due to collision with solids, pH sensors are fitted with probe protection in a 19 mm port in the vessel top plate. To do...
  • Page 106 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Pull the support guide from the guide bar. Insert the sensor into the support guide and tighten it. Insert the sensor into the hollow screw with the thread pointing in the downward direction.
  • Page 107: Preparing The Super Safe Sampler

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Slide the O-ring onto the sensor and insert the sensor into the port. Adjust the sensor to the desired height. Screw the sensor on the hollow screw into the port and tighten 10.
  • Page 108 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Secure the hose with a cable tie. Tighten the sample valve carefully by hand in a clockwise di- rection. This ensures that the non-return valve/sample valve screw connection is tight.
  • Page 109: Mounting The Sparger Hose And The Inlet Air Filter

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.1.16 Mounting the Sparger Hose and the Inlet Air Filter The sparger (if used) must be equipped with the hose and inlet air filter before autoclaving. To do so, proceed as follows: Procedure Cut a short piece of silicone hose.
  • Page 110: Preparing The Gassing Hose Line On The Basic Unit

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Place the inlet air filter, marked in red, onto the hose end in the direction of the air flow. The nozzle with the red INLET marking remains exposed.
  • Page 111: Calibrating The Pumps

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.1.19 Calibrating the Pumps Not calibrated pumps show the duration in seconds and the num- ber of rotations. If the delivered volume (in mL) shall be indicated instead, the pumps must be calibrated before autoclaving.
  • Page 112 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Connect the silicone hoses and pump hoses of the pump heads with hose connectors. INFORMATION Note that the direction of rotation of the pumps is clockwise in operational state.
  • Page 113 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Depending on the application: Fill the reagent bottles with rea- gents and reclose them with their lid. ATTENTION Usage of the highly corrosive hydrochloric acid HCl as reagent leads to damage to components made of stainless steel such as e.g.
  • Page 114: Sterile Hose Connections

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.1.21 Sterile Hose Connections If additional vessels are needed and these can only be connected to the culture vessel after autoclaving, such as vessels for the inoc- ulum or bottles for sampling etc., rapid couplings (male/female), sterile connectors or –...
  • Page 115: Checklist Before Autoclaving

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Fit the mounting plate with the pump heads onto the reagent bottle and pump holder. 8.1.23 Checklist Before Autoclaving Check and ensure the following items before autoclaving: Culture vessel All necessary O-rings are fitted.
  • Page 116 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Super Safe Sampler The valve group is connected to the dip tube in the culture vessel by means of a hose. The valve group is lightly capped with aluminium foil.
  • Page 117: Autoclaving

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.1.24 Autoclaving Before cultivation starts, the culture vessel is autoclaved in accord- ance with the application in question. The culture vessel can be autoclaved with or without medium.
  • Page 118: Connecting The Culture Vessel And Preparing The Cultivation

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Ensure that the culture vessel and the accessories do not touch the inner wall of the autoclave. Ensure that the exit gas filter is open. Insert the temperature sensor of the autoclave into the pocket for the temperature sensor.
  • Page 119: Mounting The Pump Heads

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.2.2 Mounting the Pump Heads To mount the pump heads to the basic unit, proceed as follows: Procedure Pull off the mounting plate with the pump heads from the rea- gent bottle and pump holder.
  • Page 120: Connecting The Gassing

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Procedure Switch the equipment on at the main switch. Open the clamps on the reagent hoses. Fill the reagent hoses individually, successively and manually via the appropriate rocker switch.
  • Page 121: Connecting The Exit Gas Cooler

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.2.5 Connecting the Exit Gas Cooler To connect the exit gas cooler to the basic unit, proceed as follows: Procedure Remove the aluminium foil from the exit gas filter.
  • Page 122: Coupling The Motor

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.2.6 Coupling the Motor For routine operation, it is not necessary to plug in and unplug the motor cable. The motor connected during installation is merely connected using a bayonet lock prior to cultivation.
  • Page 123: Inserting The Temperature Sensor (Pt100) Into The Pocket

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation INFORMATION If the stirrer is turning on the surface of the medium, foam will be formed. For this reason, only switch on the stirrer if it is fully cov- ered by medium.
  • Page 124: Connecting The Ph Sensor

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation 8.2.9 Connecting the pH Sensor To connect the pH sensor, proceed as follows: METTLER pH sensor Procedure Remove the protective cap or the aluminium foil from the sen- sor.
  • Page 125: Connecting The Po 2 Sensor

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation HAMILTON pH sensor Procedure Remove the red protective cap from the sensor cable. Place the connector of the sensor cable onto the sensor head and screw into place.
  • Page 126: Sensor (Mettler)

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation Plug the cable connector onto the sensor. Turn the bajonet cap of the sensor cable clockwise und push gently towards the sensor. Ensure the cable is not twisted or buckled.
  • Page 127: Checking The Hoses And Hose Connections

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Before Fermentation/Cultivation A detailed description on the calibration can be found in the sepa- rate operating manual of the touch screen software. 8.2.13 Checking the Hoses and Hose Connections Check and ensure the following items before each cultivation: Hoses show no kinks and are not able to kink.
  • Page 128: Fermentation/Cultivation

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation 9 Fermentation/Cultivation The following sections describe the work necessary for the perfor- mance of and after the completion of a fermentation/cultivation, before the culture vessel with accessories is thoroughly cleaned and then prepared for another cultivation.
  • Page 129: Sampling

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation CAUTION If pressure equalisation does not take place via a top plate opening or the mounted exit gas cooler, overpressure in the cul- ture vessel may occur during cultivation as a result of warming, gassing or fermentation processes.
  • Page 130 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation WARNING Loose screws at components could lead to the penetration of unsterile air or contamination of the environment. Before and after autoclaving: Check that all screws are tightly screwed in and, if necessary, tighten them manually.
  • Page 131 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation Pull back the syringe plunger to remove the desired sampling volume. If the dip tube was rinsed with air, air is sucked in first. Remove it as follows: Unscrew the syringe from the valve.
  • Page 132 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation Procedure: Insert the syringe onto the hose at the sterile filter and push air through. The remaining liquid in the hose and in the dip tube is pushed back into the vessel.
  • Page 133: Inoculation

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation 9.3 Inoculation Check and ensure the following items before inoculation: Medium has been filled.  Heat-labile, separately sterilised substances are present.  The reagent bottles are connected with the pumps and the ...
  • Page 134: Inoculation With Inoculation Needle

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation 9.3.1 Inoculation with Inoculation Needle Proceed as follows for inoculation: Procedure Fill the inoculum under sterile conditions into the prepared container. Unscrew the blanking plug from the septum collar.
  • Page 135: Inoculation Using Dip Tube / Addition Port Adapter

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation Before piercing, drop a few drops of ethanol (70 %) on the septum. Pierce the septum and inject the inoculum. Remove the needle from the septum and close the septum collar with a blanking plug.
  • Page 136: Harvest

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation 9.5 Harvest The culture can be harvested at the end of the cultivation. To pre- vent possible sedimentation from the culture, the stirrer can be switched on during harvesting. If necessary, activate gassing for sensitive cultures.
  • Page 137: Emptying The Culture Vessel

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation 9.6 Emptying the Culture Vessel Depending on the user specifications, the culture vessel can be emptied either before or after autoclaving. A previously emptied and culture vessel filled only with water for autoclaving is easier to clean afterwards.
  • Page 138: Autoclaving The Culture Vessel After Fermentation/Cultivation

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation ATTENTION Switching the equipment off at the main switch without previ- ously stopping the bioreactor and shutting down the system on the operating panel may lead to damage of the operating panel! Close the supply lines (water, gas).
  • Page 139 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Fermentation/Cultivation Disconnect the water inlet / outlet /overflow hoses of the vessel jacket from the basic unit. Depending on the gassing strategy: Remove the gassing hose (emerging from basic ...
  • Page 140: Cleaning And Maintenance

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance 10 Cleaning and Maintenance The following sections describe in detail how the culture vessel and accessories and the basic unit are cleaned and, as required, stored. In addition, the section contains a maintenance plan and corre- sponding descriptions for the procedures to be performed by the operator.
  • Page 141 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance The following method describes a routine cleaning between two fermentations/cultivations. It takes place with the culture vessel completely assembled and the accessories completely mounted. This does not include the sensors, with the exception of antifoam or level sensors from the equipment manufacturer.
  • Page 142: Removing The Vessel Top Plate And Accessories

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance 10.3 Removing the Vessel Top Plate and Accessories All accessories must be removed for thorough cleaning of the indi- vidual parts of the culture vessel. This is described in the following sections.
  • Page 143: Removing Hoses, Filters And Pump Heads

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance INFORMATION This step is only necessary for the type of clamping adapter for 10 mm ports. All other clamping adapters can be directly un- screwed and pulled out from the port or threaded adapter in the port by hand.
  • Page 144: Removing Blanking Plugs

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance Dispose of the exit gas filter (see also chapter “Removing the Exit Gas Cooler”). 10.3.4 Removing Blanking Plugs Proceed as follows: Blanking plugs in 10/40 mm ports...
  • Page 145: Removing Addition Port Adapters

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance Remove the septum from the port and dispose of it. 10.3.7 Removing Addition Port Adapters Proceed as follows: Addition port adapter, quadruple, in 19 mm port Procedure Loosen the two slotted screws next to the addition port adapter.
  • Page 146 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance Carefully lift the top plate vertically upwards from the vessel until the stirrer shaft and other long built-in components can no longer come into contact with the glass vessel.
  • Page 147: Removing The Pocket For Temperature Sensor (Pt100)

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance 10.3.9 Removing the Pocket for Temperature Sensor (Pt100) Proceed as follows: Procedure Loosen both slotted screws next to the port. Ensure the screws do not get lost.
  • Page 148 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance Dismantling the sparger with the sterile sheath for cleaning Procedure Loosen the grub screw on the hand ring (2) (do not remove it). Pull the hand ring (1) off the sparger.
  • Page 149: Removing The Impellers

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance 10.3.11 Removing the Impellers Before removing the impellers, it is recommended to measure and record the positions to aid later mounting. Proceed as follows to remove: Loosen the grub screws on the impeller with an Allen key – do...
  • Page 150: Cleaning And Storing Individual Parts

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance Position an adjustable spanner on the two recesses on the up- per end of the stirrer shaft. Unscrew the stirrer shaft with the spanner counter clockwise from the drive shaft.
  • Page 151: Cleaning The Sensors

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance ATTENTION The mechanical seal is very delicate. No water/cleaning agent may enter it and the silicone hose on the bottom of the drive hub may not be pulled off during cleaning of the vessel top plate.
  • Page 152: Cleaning The Hoses And Pump Heads

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance 10.6 Cleaning the Hoses and Pump Heads Proceed as follows to clean the reagent hoses and pump heads: Procedure Thoroughly rinse the hoses with the pump heads with water.
  • Page 153: Cleaning The Exit Gas Cooler

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance 10.8 Cleaning the Exit Gas Cooler If the exit gas cooler is only lightly soiled, an ultrasonic bath for ap- prox. 15 minutes is sufficient to clean it.
  • Page 154 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance Contact the manufacturer for questions concerning maintenance. For contact details, see page 2. To be carried out by operator Interval Maintenance work Before each fermentation/cul- Check all hoses and hose connections. Replace hoses, if necessary. Sup- tivation ply hoses may be replaced by qualified personnel.
  • Page 155: Lubricating The Mechanical Seal

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance 10.11 Lubricating the Mechanical Seal The two-part silicone hose on the drive hub must always be filled with liquid (Glycerine, for details see the chapter “Operating Materi- als”...
  • Page 156 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance ATTENTION Inappropriate decalcifying of the equipment may lead to loss of property. Only decalcify the equipment AFTER CONSULTATION of the manufacturer or licensed dealer! INFORMATION A turbid or milky coloured appearance of the glass of the vessel jacket may be a sign of lime scale in the equipment with water temperature control system.
  • Page 157: Decalcifying Equipment Via Vessel Jacket

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Cleaning and Maintenance 10.13 Decalcifying Equipment via Vessel Jacket A turbid or milky coloured appearance of the glass of the vessel jacket may be a sign of lime scale in the equipment with water tem- perature control system.
  • Page 158: Interferences

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Interferences 11 Interferences The following section describes possible reasons for interferences and how to resolve them. Reduce the service intervals in corre- spondence with the actual loads if interferences become increas- ingly common.
  • Page 159: Drive System Faults

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Interferences 11.2 Drive System Faults Fault Stirrer does not start Possible cause Fault remedy Performed by The Stirrer parameter is not acti- Activate the parameter. Operator vated. Stirrer parameter setpoint = 0.
  • Page 160 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Interferences Interference No heating or inadequate heating. Possible cause Remedy Circulation not filled or air bubbles in Enter low setpoint for parameter temperature to Operator circulation are obstructing the open the cooling valve and to fill the circulation...
  • Page 161: Interferences Gassing System

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Interferences 11.4 Interferences Gassing System Interferences No gassing / air bubbles in the culture vessel. Possible cause Remedy The on-site gas supply has been in- Stop the bioreactor. Operator terrupted.
  • Page 162: Interferences Ph-System

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Interferences Interference Sudden increase in evaporation losses in the culture vessel. Possible cause Remedy The exit gas cooler does not cool. Open the control valve. Operator The control valve for water flow is closed.
  • Page 163: Interferences Po System

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Interferences Interference No pH control. Possible cause Remedy Parameter pH is not activated. Activate the parameter. Operator Incorrect dead band setting. Check the dead band (Dead Band in PID settings): Operator Switch off or enter a small value.
  • Page 164: Interferences Feed And Pump

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Interferences Interference No pO control. Possible cause Remedy The pO parameter and/or cascaded Activate parameters. Operator parameter is/are not activated. Check the cascade settings and change as neces- The cascade settings are incorrect.
  • Page 165: Returning For Repair

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Disassembly and Disposal 11.8 Returning for Repair The provider must return the equipment or the faulty component part(s) to the manufacturer if, after consulting the service depart- ment of the local dealer or the manufacturer, on-site diagnosis and/or repair is not possible.
  • Page 166: Disposal

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Disassembly and Disposal 12.2 Disposal Recycle disassembled components if no agreement is made con- cerning reclaim or disposal. Send metals for scrap.  Send plastic components for recycling.  Sort and dispose of the remaining components according their ...
  • Page 167: Technical Data

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data 13 Technical Data 13.1 Dimensions 1 Unit Front view Dimensions in mm To the left: equipment with operating unit, To the right: satellite unit, holder for up to 2 ...
  • Page 168 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data Top view and side view Dimensions in mm To the left: equipment with holder for up to 2 To the right: equipment with operating unit   gassing units and standard base tray...
  • Page 169: Dimensions Master Unit And Satellite Units

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data 13.2 Dimensions Master Unit and Satellite Units Front view master unit with 5 satellite units (with holder for up to 4 gassing units, 5 pumps and standard base...
  • Page 170: Dimensions Of Culture Vessels In Vessel Holder

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data 13.3 Dimensions of Culture Vessels in Vessel Holder Top view By way of an example, the figures above show top view of the cul- ture vessel with standard exit gas cooler and with swivelling exit gas cooler and, with / without reagent bottle und pump holder.
  • Page 171 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data Side view By way of an example, the figures show the culture vessel with standard exit gas cooler (left) and with swivelling exit gas cooler (right), both with reagent bottle and pump holder.
  • Page 172: Weights (Net)

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data 13.4 Weights (net) Description Value Unit Basic unit 25 kg Touch screen operating unit 5 kg Culture vessel Total volume L Diameter nominal Weight kg Empty weight of double walled culture vessels in delivery state (equipped with default mounting parts) 13.5 Connection Values...
  • Page 173: Water Out

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data 13.5.3 Water OUT Description Value Unit Connection pressure No back pressure Temperature up to 80 °C Connection: OD of hose nozzle 13.5.4 Gas(es) IN Description Value Unit Connection pressure 2 ±...
  • Page 174: Culture Vessel

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data 13.6.2 Culture Vessel Description Value Form Cylindrical with flat bottom and jacket Material Glass vessel Borosilicate glass Top plate and Stainless steel, AISI mounting 316L, electro polished parts...
  • Page 175: Impellers

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data INFORMATION Rotation speed is valid for viscosity similar to water, without aer- ation. 13.7.1 Impellers All the impellers are made of 316L stainless steel, electro polished and are included in the standard package.
  • Page 176 Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data Anchor impeller Position Dimension Ø A 140 mm 19 mm 25 mm Single helix impeller Position Dimension Ø A 140 mm Ø A1 118 mm 117 mm 161 mm...
  • Page 177: Temperature

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data Double helix impeller Position Dimension Ø A 140 mm Ø A1 118 mm 63 mm 136 mm 13.7.2 Temperature Description Value Sensor Type: Pt100 1/3 DIN-B Heating Water circulation in vessel jacket.
  • Page 178: Gassing

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data 13.7.3 Gassing The entire gas entry takes place via headspace or sparger. The specific gassing rate, calculated for the max. working volume is for sparger as well as for head space gassing 2 min...
  • Page 179: Po 2

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data Details on technical data, use and maintenance of the pH sensors can be found in the separate documentation of the sensor manu- facturer. 13.7.5 pO Description Value Control...
  • Page 180: January

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data 13.7.6 Pumps Description Value Type Peristaltic Standard Digital Acid (3 pieces) Base AF = Antifoam Analogue Feed (1 piece) Rotation speed Digital 74 min / fixed rotation speed...
  • Page 181: Sterile Filters

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data 13.7.7 Sterile Filters Description Value All filters Autoclavable Disposable Inlet air filter Retention rate: 0.2 µm (red label) Diameter: 37 mm Inlet air filter Retention rate: 0.2 µm...
  • Page 182: Auxiliary Supplies

    Labfors 5 – Version for Solid Substrates and Enzymatic Bioprocesses Technical Data 13.11 Auxiliary Supplies pH Buffers pH buffers are used to calibrate the pH sensors. 250 mL bags are available for the following buffers: pH 4.04  pH 7.01 ...

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