User’s Manual PuriCare™ Vertical Flow Stations Models 3830000 3830020 Register your product online at www.labconco.com/productreg.html or return the attached card and receive FREE LabbyWear™! Labconco’s Mascot, Labby the LABster LABCONCO CORPORATION 8811 PROSPECT AVENUE KANSAS CITY, MO 64132-2696 800-821-5525, 816-333-8811 FAX 816-363-0130 E-MAIL labconco@labconco.com HOME PAGE www.labconco.
Copyright Information Copyright © 2003 Labconco Corporation. All rights reserved. Labconco Corporation 8811 Prospect Avenue Kansas City, Missouri 64132 The information contained in this manual and the accompanying product are copyrighted and all rights are reserved by Labconco Corporation. Labconco Corporation reserves the right to make periodic design changes without obligation to notify any person or entity of such change. PuriCare™ is a trademark of Labconco Corporation.
TABLE OF CONTENTS CHAPTER 1: INTRODUCTION About This Manual Typographical Conventions 1 2 3 CHAPTER 2: PREREQUISITES Location Requirements Exhaust Requirements Electrical Requirements Space Requirements Overhead Clearance 5 6 6 7 8 8 CHAPTER 3: GETTING STARTED Unpacking Your Vertical Flow Station PuriCare Components Preparing the Station for Operation Exhaust System Requirements Initial Certification 9 10 11 11 12 12 CHAPTER 4: THEORY OF OPERATION AND SAFETY PRECAUTIONS HEPA Filters Directional Airflo
Downflow Velocities Downflow Velocity Grid Patterns Inflow Velocity Calculation – Primary Method Inflow Velocity Calculation – Secondary Method Speed Control Adjustments Supply HEPA Filter Replacement Exhaust HEPA Filter Replacement Impeller and Motor/Blower Maintenance & Replacement Diffuser Removal Storage 30 30 30 31 32 33 35 36 38 39 CHAPTER 7: MODIFYING YOUR VERTICAL FLOW STATION Installing a Shelf 40 40 CHAPTER 8: TROUBLESHOOTING 42 APPENDIX A: VERTICAL FLOW STATION COMPONENTS 44 APPENDIX B: V
CHAPTER 1 INTRODUCTION Congratulations on your purchase of a Labconco PuriCare Series Vertical Flow Station. Your PuriCare product is designed to protect you, your product and your laboratory environment from aerosols. It is the result of Labconco’s years of experience manufacturing laboratory equipment, and many of its features were suggested to us by users like you. The PuriCare offers many unique features to enhance safety, performance and ergonomics.
Chapter 1: Introduction About This Manual This manual is designed to help you learn how to install, use, and maintain your Vertical Flow Station. Instructions for installing optional equipment on your station are also included. Chapter 1: Introduction provides a brief overview of the Vertical Flow Station, explains the organization of the manual, and defines the typographical conventions used in the manual.
Chapter 1: Introduction Appendix A: Vertical Flow Station Components contains labeled diagrams of all of its components. Appendix B: Vertical Flow Station Dimensions contains comprehensive diagrams showing all of the dimensions for the PuriCare model. Appendix C: Vertical Flow Station Specifications contains the electrical requirements for the Vertical Flow Station. Wiring diagrams for both the 115V and 230V models are also included.
Chapter 1: Introduction • ! • ) 115V 4 230V • • Critical information is presented in boldface type in paragraphs that are preceded by the exclamation icon. Failure to comply with the information following an exclamation icon may result in injury to the user or permanent damage to your Vertical Flow Station. Critical information is presented in boldface type in paragraphs that are preceded by the wrench icon. These operations should only be performed by a trained certifier or contractor.
CHAPTER 2 PREREQUISITES Before you install your Vertical Flow Station, you need to prepare your site for installation. Carefully examine the location where you intend to install your station. You must be certain that the area is level and of solid construction. In addition, a dedicated source of electrical power must be located near the installation site. Carefully read this chapter to learn: • • • • the location requirements for your installation site.
Chapter 2: Prerequisites Location Requirements ! The PuriCare should be located away from traffic patterns, doors, fans, ventilation registers, fume hoods and any other air-handling device that could disrupt its airflow patterns. All windows in the room should be closed. Figure 2-1 shows the optimum location for the PuriCare. Figure 2-1 Exhaust Requirements ) 6 THE VERTICAL FLOW STATION DISCHARGES ITS FILTERED EXHAUST AIR UNDERNEATH THE UNIT.
Chapter 2: Prerequisites Electrical Requirements The different PuriCare models have the following electrical requirements: Table 2-1 Model # 38300- 00-09 38300- 20-29 Requirements 115 VAC, 60 Hz, 12 Amps 230 VAC, 50 Hz, 6 Amps All PuriCare Stations with model numbers ending in – 00 to –09 are designed for operation at 115 volts, 60Hz, alternating current. PuriCare Stations with model numbers ending in –20 to –29 are designed for operation at 230 +/- 20 volts, 50 Hz alternating current.
Chapter 2: Prerequisites Space Requirements The dimensions for the different models are shown in Appendix B: Vertical Flow Station Dimensions. Overhead Clearance In order for the Vertical Flow Station to operate properly, at least six inches (150 mm) clearance from any overhead obstructions is required when the station is in its final operating position.
CHAPTER 3 GETTING STARTED Now that the site for your Vertical Flow Station is properly prepared, you are ready to unpack, inspect, install, and certify it. Read this chapter to learn how to: • • • • unpack and move your PuriCare. set up the station. connect the electrical supply source. arrange certification. Depending upon which model you are installing, you may need common tools in addition to a 3/4" wrench, a flat-blade screwdriver, and a Phillips screwdriver.
Chapter 3: Getting Started Unpacking Your Vertical Flow Station The United States Interstate Commerce Commission rules require that claims be filed with the delivery carrier within fifteen (15) days of delivery. Carefully unpack your PuriCare and inspect it for damage that may have occurred in transit. If your unit is damaged, notify the delivery carrier immediately and retain the entire shipment intact for inspection by the carrier. ) DO NOT RETURN GOODS WITHOUT THE PRIOR AUTHORIZATION OF LABCONCO.
Chapter 3: Getting Started PuriCare Components Labconco manufactures Vertical Flow Stations for use with 115 volts or 230 volts. Locate the station model you received in the following group of tables. Verify that the components listed are present and undamaged.
Chapter 3: Getting Started Exhaust System Requirements The Vertical Flow Station discharges its HEPA filtered exhaust air beneath the unit. Maintain at least 12 inches clearance between the station and any vertical obstruction on all sides of the unit. ! Initial Certification Prior to use, all PuriCare stations should be certified by a qualified certifier. Under normal operating conditions, the PuriCare stations should be recertified at least annually or when serviced.
CHAPTER 4 THEORY OF OPERATION AND SAFETY PRECAUTIONS The Vertical Flow Station operates using the following principles: • Filtration and retention of particulates by High Efficiency Particulate Air (HEPA) filters Directional airflow The major components in the Vertical Flow Station are: • • • • The HEPA filters The impellers and motor/blower to force air through the unit A speed controls for the impellers and motor Station air intakes (grilles) Product Service 1-800-522-7658 13
Chapter 4: Theory Of Operation And Safety Precautions HEPA Filters HEPA filters are disposable, dry-type particulate filters. The filter material or media is typically made of borosilicate microfibers that are made into a thin sheet, in a process similar to the production of paper. This sheet is folded, or pleated to increase its surface area. The pleats are held in place by aluminum diffusers or by beads of glue that add rigidity to the media pack.
Chapter 4: Theory Of Operation And Safety Precautions Figure 4-1 Directional Airflow Directional airflow plays a key role in the Vertical Flow Station’s performance. Sterile, HEPA filtered air flows downward throughout the work area, protecting the animals inside from external and cross contamination. All of this “supply” air and some room air is drawn into the front of the station at the grille.
Chapter 4: Theory Of Operation And Safety Precautions Figure 4-2 Impellers and Motor/Blower The Vertical Flow Station uses two air handling systems to direct air through it. In the top of the station twin motorized impellers draw room air in through prefilters and then force the air through the upper (supply) HEPA filter. Below the worksurface there are another set of prefilters, a heavy duty motor blower and the exhaust HEPA filter.
Chapter 4: Theory Of Operation And Safety Precautions The speed controls are electronic circuits that allow the certifier to set the speed of the motors by adjusting their voltage. The PuriCare speed controls are rated for 10 Amps current each, far in excess of the motor's normal current draw, to allow for greater reliability.
Chapter 4: Theory Of Operation And Safety Precautions ! HEPA filters are only effective for the entrapment of particulate matter. Manipulations which generate gases or vapors, i.e., toxic chemicals or radionuclides, should not be performed in this station. The PuriCare Vertical Flow Station should be certified by a qualified certification technician before its initial use. The station should be recertified whenever it is relocated, serviced or at least annually thereafter.
Chapter 4: Theory Of Operation And Safety Precautions Avoid the use of flammable gases or solvents in the PuriCare. Care must be taken to ensure against the concentration of flammable or explosive gases or vapors. An open flame should NOT be used in the PuriCare. Open flames may disrupt the airflow patterns in the station, burn the HEPA filter and/or damage the filter’s adhesive. Gases under high pressure should not be used in the PuriCare station, as they may disrupt the airflow patterns of the station.
Chapter 4: Theory Of Operation And Safety Precautions Proper operation of the station depends largely upon the station’s location and the operator’s work habits. Consult the Installation and Normal Operation sections of this manual for further details. ! ) WHEN SURFACE DISINFECTING THE PURICARE STATION: • • • AVOID SPLASHING THE DISINFECTING SOLUTION ON SKIN OR CLOTHING. ENSURE ADEQUATE VENTILATION.
CHAPTER 5 USING YOUR PURICARE Operating the Sash The sash of the Vertical Flow Station can be locked in the full open position. To lock the sash open: 1. Grasp the bottom edge of the sash, and pivot it up until the sash is fully opened. 2. Locate the sash locking bolt on the inside left side of the sash, as shown in Figure 5-1. 3. Restrain the sash by aligning the bolt with the hole in the left side wall of the station, and pressing the bolt to the left until it engages the hole. 4.
Chapter 5: Using Your PuriCare Figure 5-1 ! The sash must be completely closed for the PuriCare to contain properly. 5. Turn the blower and light switches to the 'On' position, as shown in Figure 5-2.
Chapter 5: Using Your PuriCare Figure 5-2 Working In Your PuriCare Planning • Thoroughly understand procedures and equipment required before beginning work. • Arrange for minimal disruptions, such as room traffic or entry into the room while the station is in use. Start-up • Turn on fluorescent light and station blower. • Check the return air grilles for obstructions, and note the pressure gauge reading. • Allow the station to operate unobstructed for 5 minutes.
Chapter 5: Using Your PuriCare Loading Materials and Equipment • Only load the materials required for the procedure. Do not overload the station. • Do not obstruct the grilles on the front, back or sides of the work area. • Large objects should not be placed close together. Work Techniques • Keep all materials at least 4 inches inside of the sash, and perform all contaminated operations as close to the center of the work area as possible. • Segregate all clean and contaminated materials in the work area.
Chapter 5: Using Your PuriCare Wipe-Down • Wipe down the interior surfaces of the station with 70% ethanol, or a suitable disinfectant, and allow to dry. • Periodically lift the work surface and wipe down the area beneath it. • Inspect the prefilters located beneath the work surface, beneath the work pan. Replace them if necessary • Dispose of rubber gloves appropriately, and have lab coat laundered properly. • Wash hands and arms thoroughly with germicidal soap.
CHAPTER 6 MAINTAINING YOUR PURICARE Now that you have an understanding of how to work in the Vertical Flow Station, we will review the suggested maintenance schedule and the common service operations necessary to maintain your PuriCare for peak performance. ! Many of the service operations should be performed only by trained and experienced certification technicians after the station has been properly decontaminated. DO NOT attempt to perform these operations if you are not properly trained.
Chapter 6: Maintaining Your PuriCare • • • Using an appropriate optical glass cleaner and cloth, clean the sash. Operate the station blowers, noting the pressure readings in an operational log. Lift the work surface and inspect the prefilters. Monthly (or more often as required) • Using a damp cloth, clean the exterior surfaces of the station, particularly the front, back and top of the unit, to remove any accumulated dust. • Disinfect and lift the work surface.
Chapter 6: Maintaining Your PuriCare Upper Prefilter Removal: 1. Loosen the nuts that secure the two upper prefilter brackets as shown in Figure 6-1. 2. Swing the upper prefilter brackets until the prefilters can be lifted out of the top of the units. 3. Replace the prefilter elements, ensuring the air flow direction arrow on the prefilter frame points down. Figure 6-1 Lower Prefilter Removal: 1. Remove the work surface as described earlier. 2.
Chapter 6: Maintaining Your PuriCare 4. Replace the prefilter elements, ensuring the air flow direction arrow on the prefilter frame points down. Figure 6-2 Changing the Fluorescent Lamp: 1. Unplug the station. 2. Swing up the sash. 3. Remove the fluorescent lamp by rotating it 90 degrees and pulling it straight down and out of its sockets. 3. Install the new lamp by reversing the removal procedure.
Chapter 6: Maintaining Your PuriCare ! The service operations listed in the rest of this chapter should only be performed by a qualified certifier. Downflow Velocities The average downflow velocity for all Vertical Flow Stations should be set at 50-55 FPM. Downflow Velocity Grid Patterns The downflow velocity test grid for all Vertical Flow Stations is as follows: The perimeter of the down test grid is 6.00 inches from the side walls and 6.00 from the rear of the work area.
Chapter 6: Maintaining Your PuriCare 5. Place the pattern with the hole over the other prefilter hole. Seal the pattern to the prefilter shelf if necessary. 6. Place the DIM upside down over the hole in the second pattern. Seal the DIM to the pattern with duct tape if necessary. 7. Start the Station and let it run for at least two minutes. Turn on the DIM and take at least 10 readings of the inflow volume. Average the readings. 8.
Chapter 6: Maintaining Your PuriCare 6. Using a thermal anemometer, measure the velocity at the center of each of the squares. 7. Average the readings. Multiply the average velocity by the correction factor 2.25 to obtain the average inflow volume. 8. The average inflow volume, corrected for local conditions, should be 650-670 CFM. Speed Control Adjustments The Vertical Flow Station blower speeds should only be adjusted by a qualified certification technician.
Chapter 6: Maintaining Your PuriCare Figure 6-4 Supply HEPA Filter Replacement ! The HEPA filters should only be serviced by a qualified certification technician. Following replacement of a HEPA filter, the station MUST be recertified by a qualified certification technician. 1. Unplug the station. 2. Remove the two upper prefilters as described earlier in this chapter. 3. Remove the five screws that secure the upper rear panel as shown in Figure 6-5. 4. Carefully swing the rear panel out.
Chapter 6: Maintaining Your PuriCare 5. Locate the four locking bolts that secure the upper plenum. They are located in each corner of the plenum, and they thread through the upper bracket and down onto the top of the plenum. Loosen each bolt at least ½ inch. 6. Locate the four plenum lift bolts that raise the upper plenum. They are located in each corner of the plenum, next to the locking bolts, and they thread into the top of the plenum.
Chapter 6: Maintaining Your PuriCare To Remove the Exhaust HEPA Filter: ! The exhaust HEPA filter is awkward to handle and heavy. Use appropriate lifting techniques to remove and handle it. Use two people to remove the filter if possible. Exhaust HEPA Filter Replacement 1. Remove the lower rear panel by removing the #2 Phillips screws on the perimeter of the panel. 2. Remove the work surface and two lower prefilters as described earlier in this chapter. 3.
Chapter 6: Maintaining Your PuriCare Figure 6-6 Impeller and Motor/Blower Maintenance and Replacement The motor/blower should be serviced by a qualified certification technician. ) The stations blower motor and impeller bearings are sealed and require no lubrication. DO NOT attempt to lubricate them. To replace an Impeller: 1. Unplug the unit. 2. Remove the two upper prefilters as described earlier in this chapter. 3. Remove the five screws that secure the upper rear panel as shown in Figure 6-5. 4.
Chapter 6: Maintaining Your PuriCare 5. Locate the four locking bolts that secure the upper plenum. They are located in each corner of the plenum, and they thread through the upper bracket and down onto the top of the plenum. Loosen each bolt as far as it will go. 6. Locate the four plenum lift bolts that raise the upper plenum. They are located in corner of the plenum next to the locking bolts, and they thread into the top of the plenum.
Chapter 6: Maintaining Your PuriCare 8. Plug in the station and have it recertified before use. Figure 6-7 Diffuser Removal ! Bending or distorting the diffuser may affect the airflow in the station. Use care when handling it. Upper Diffuser Removal 1. Swing the sash up until it is in the locked position. 2. Locate and remove the four acorn nuts that secure the upper diffuser brackets to the station. Support the diffuser when removing the brackets and lower the diffuser straight down.
Chapter 6: Maintaining Your PuriCare Storage If the PuriCare is to be left unused for more than one month, the unit should be prepared for storage. ! The station should not be stored in areas of excess humidity or temperature extremes. If the station is moved during storage, it must be recertified before use. 1. Lower the sashes completely and seal work area, the bottom edge and the exhaust outlet with plastic sheeting. 2. Unplug the unit. 3.
CHAPTER 7 MODIFYING YOUR VERTICAL FLOW STATION Installing a Shelf 1. Ensure that the shelf kit you have is the proper one. Kits for mounting on the operator’s left side are #3794900. Kits for mounting the shelf on the operator’s right side are #3794901. 2. Remove the four plastic plugs on the appropriate side of the lower panel, as shown in figure 7-1. 3. Lower the shelf brackets on the shelf and align them with the holes in the panel. 4.
Chapter 7: Modifying Your Open Access Station Figure 7-1 Product Service 1-800-522-7658 41
CHAPTER 8 TROUBLESHOOTING Refer to the following table if your Vertical Flow Station fails to operate properly. If the suggested corrective actions do not solve your problem, contact Labconco for additional assistance. PROBLEM CAUSE CORRECTIVE ACTION Station blower and lights won’t turn on Unit not plugged into outlet Plug the PuriCare into appropriate electrical service. Circuit breakers tripped Reset circuit breakers. Blower(s) wiring is disconnected Inspect blower(s) wiring.
Chapter 8: Troubleshooting PROBLEM CAUSE CORRECTIVE ACTION Slight increase in pressure reading HEPA filter loading The pressure reading will steadily increase as the unit is used. Prefilter loading Check the prefilters for obstruction(s). Clean if necessary. Blockage or restriction under the work surface Ensure that the plenum beneath the work surface is unobstructed. Blockage of the exhaust outlet Ensure that the exhaust outlet is not blocked or restricted.
APPENDIX A VERTICAL FLOW STATION COMPONENTS Illustration A-1 indicates the location of the following service parts: Vertical Flow Station Replacement Parts 44 Item Quantity Part No.
Appendix A: Purifier Components A-1 Product Service 1-800-522-7658 45
APPENDIX B VERTICAL FLOW STATION DIMENSIONS B-1 46 Product Service 1-800-522-7658
APPENDIX C VERTICAL FLOW STATION SPECIFICATIONS Electrical Data Station Model 3830000 to –09 Electrical Requirements 115 VAC – 60 Hz, 1 Phase – 12 Amps Station Model 3830020 to –29 Electrical Requirements 230 VAC – 50/60 Hz, 1 Phase – 7 Amps Impeller Specifications Station Model 3830000 to –09 Electrical Requirements 115 Volt – 60 Hz, 100 Watt, 2550 RPM Automatic Thermal Protection Station Model 3830020 to –29 Electrical Requirements 230 Volt – 50/60 Hz, 100 Watt, 2550 RPM Automatic Thermal Protectio
Appendix C: Vertical Flow Station Specifications Motor Specifications Station Model 3830000 to –09 Electrical Requirements 115 VAC – 60 Hz, 3.8 Full Load Amps 1/3 H.P. 1625 RPM Automatic Thermal Protection Station Model 3830020 to –29 Electrical Requirements 230 VAC – 50/60 Hz, 2.8 Full Load Amps 1/2 H.P. 1625 RPM Automatic Thermal Protection Environmental Conditions • • • • • • • 48 Indoor use only. Maximum altitude: 6562 feet (2000 meters). Ambient temperature range: 41° to 104°F (5° to 40°C).
Appendix C: Vertical Flow Station Specifications C-1 Product Service 1-800-522-7658 49
Appendix C: Vertical Flow Station Specifications C-2 50 Product Service 1-800-522-7658
APPENDIX D PURICARE ACCESSORIES Shelf Kit Shelf kits are available for either the left side (part number 3794900) or the right side (part number 3794901). The shelves are suitable for mounting on either side of the station. The shelves have a capacity of 20 pounds, a trigger to release the shelf, and fold down flat when not in use.
APPENDIX E QUICK CHART FOR THE PURICARE VERTICAL FLOW STATONS Model Sash Height (inches) Downflow (FPM) Approximate Settings for new Filters Mag Gauge Reading Supply Air Volume Displacement (CFM) Number of Laskin Nozzles Needed Exhaust Air Volume Displacement (CFM) Number of Laskin Nozzles Needed Supply HEPA Filter Dims. (in.) Exhaust HEPA Filter Dims (in.) Fluorescent Light(s) 38300 14 50-55 0.3-0.4 upper / 0.5-0.
APPENDIX F REFERENCES Many excellent reference texts and booklets are currently available. The following is a brief listing: Biosafety in Microbiological and Biomedical Laboratories. 4th Edition, May 1999. U.S. Department of Health, Education, and Welfare, National Institutes of Health, Division of Safety, Bethesda, MD 20892. Laboratory Safety: Principles and Practices. 2nd Edition 1995. American Society for Microbiology, Washington, D.C. The Foundations of Laboratory Safety. 1990. Stephen R. Rayburn.
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