User’s Manual Purifier® Filtered PCR Enclosures Models 3970202, 3970205, 3970222, 3970225, 3970302, 3970305, 3970322, 3970325, 3970402, 3970405, 3970422, 3970425 To receive important product updates, complete your product registration card online at register.labconco.com 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.com Please read the User’s Manual before operating the equipment.
Copyright © 2004, 2007, 2012, 2013, 2014, 2015 Labconco Corporation. All rights reserved. The information contained in this manual and the accompanying products are copyrighted and all rights 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. Warranty Labconco provides a warranty on all parts and factory workmanship.
ORIGINAL INSTRUCTIONS TABLE OF CONTENTS CHAPTER 1: INTRODUCTION ISO Class 5 Definition Polymerase Chain Reaction Definition About This Manual Typographical Conventions 1 2 2 3 4 CHAPTER 2: PREREQUISITES Support, Vibration & Movement Requirements Location and Air Current Requirements Airflow Specifications Electrical Requirements Space Requirements 5 5 6 6 7 7 CHAPTER 3: GETTING STARTED Unpacking Your Enclosure Installing the Filtered PCR Enclosure on a Supporting Structure and Work Surface Verifying HE
CHAPTER 6: MAINTAINING YOUR FILTERED PCR ENCLOSURE Routine Maintenance Schedule When to Replace HEPA Filters How to Install a New HEPA Filter HEPA Filter Leak Test Setting the Downflow Velocity with the Speed Control Adjustment Calibrate and Operate the Airflow Monitor Initial Certification Re-Certification Fluorescent Light Replacement UV Light Replacement Motorized Impeller Replacement Speed Control Replacement 24 25 25 26 28 29 29 33 33 33 33 34 36 CHAPTER 7: ACCESSORIZING & MODIFYING YOUR FILTERED PCR
CHAPTER 1 INTRODUCTION Congratulations on your purchase of a Labconco Purifier® Filtered PCR Enclosure. Your enclosure provides a particulate free environment for Polymerase Chain Reaction experiments. It is the result of Labconco’s more than 30 years experience in manufacturing filtered enclosures. These enclosures will effectively provide product protection from airborne particulate matter.
Chapter 1: Introduction ISO Class 5 Definition Airborne particulate cleanliness inside any PCR Enclosure is designated by ISO Class 5, which is equivalent to 3520 particles 0.5 µm or larger per cubic meter of air per ISO Standard 14644-1. ISO Class 5 cleanliness is illustrated in the table to follow and is equivalent to Class 100 air conditions as defined by Federal Standard 209E. Class 100 is equal to 100 particles 0.5 µm or larger per cubic foot of air.
Chapter 1: Introduction from the infectious agent’s DNA. See also nucleic acid. The Concise Columbia Encyclopedia is licensed from Columbia University Press. Copyright © 1995 by Columbia University Press. All rights reserved. About This Manual This manual is designed to help you learn how to install, use, and maintain your Filtered (PCR) Enclosure. ! If the unit is not operated as specified in this manual it may impair the protection provided by the unit.
Chapter 1: Introduction Appendix C: Filtered PCR Enclosure Specifications contains the electrical requirements for Filtered PCR Enclosures. Wiring diagrams are also included. Appendix D: References lists the various resources available addressing clean work stations and PCR Enclosures.
CHAPTER 2 PREREQUISITES Before you install the Filtered PCR Enclosure, you need to prepare your site for installation. You must be certain that the area is level and of solid construction. In addition, a dedicated source of electrical power should be located near the installation site to power the Filtered PCR Enclosure, and other apparatus. Additionally, the enclosure should be strategically placed in the lab to provide efficient workflow.
Chapter 2: Prerequisites Location and Air Current Requirements The Purifier Filtered PCR Enclosures have been designed to provide particulate free air meeting ISO Class 5 conditions by negating typical cross drafts and turbulence within the opening. However, as a precautionary safety measure and a higher level of quality management, it is recommended that the Filtered PCR Enclosure be placed in an area away from: High traffic areas where walking might cause an air disturbance or be a nuisance.
Chapter 2: Prerequisites Electrical Requirements Standard duplex electrical receptacles should be nearby for connecting the Filtered PCR Enclosure, or other equipment. The enclosure includes iris pass-throughs to allow electrical cords through the back of the enclosure without leaving a large hole. Space Requirements The dimensions for all the different models are shown in Appendix B: Dimensions.
CHAPTER 3 GETTING STARTED Now that the site for your Filtered PCR Enclosure is properly prepared, you are ready to unpack, inspect, install, and validate your enclosure. Read this chapter to learn how to: Unpack and move the enclosure. Set up the enclosure with the proper supporting structure and work surface. Verify HEPA filters integrity. Connect the electrical supply. Set the downflow velocity with the speed control adjustment. Validate enclosure airflow.
Chapter 3: Getting Started Unpacking the Enclosure Carefully remove the shrink-wrap or carton on the enclosure and inspect it for damage that may have occurred in transit. If 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. UNAUTHORIZED RETURNS WILL NOT BE ACCEPTED. IF ENCLOSURE WAS DAMAGED IN TRANSIT, YOU MUST FILE A CLAIM DIRECTLY WITH THE FREIGHT CARRIER.
Chapter 3: Getting Started Filtered PCR Enclosure Work Surface Installation 1. Level the base cabinet or stand and the work surface. See Figure 3-1. 2. Position the work surface in its intended location and with the front of the work surface towards you. (Rear mounting holes are located close to the rear edge.) 3. Secure the work surface to the base cabinet or stand with a structural adhesive or silicone sealant. 4. Insert the supplied mounting screws in the four holes.
Chapter 3: Getting Started Verifying HEPA Filter Integrity The HEPA filter is shipped installed with the gasket on the downstream side. The HEPA filter is leak checked at Labconco. A second leak check is recommended before using the enclosure and at least annually thereafter. Consult your Safety Officer and Chapter 6 for the HEPA Filter Leak Test. See Figure 4-2 for HEPA filter location, HEPA filter gasket, and filter clamp bolts. All seams downstream of the HEPA filter are jacketed by positive pressure.
Chapter 3: Getting Started Setting the Downflow Velocity with the Speed Control Adjustment of the speed control gives the correct downflow velocity and is located behind the front panel. The downflow velocity should be from 30-65 fpm for Class 100 (ISO Class 5) conditions. ISO Class 5 clean air conditions are maximized at a setting within this range. The Filtered PCR Enclosure is factory set at 40-55 fpm downflow velocity. (Consult your Safety Officer for airflow recommendations for your application).
Chapter 3: Getting Started The Purifier Filtered PCR Enclosures have been tested at Labconco before shipment and provide ISO Class 5 clean air conditions inside the enclosure. Labconco also performed extensive performance testing to validate the Filtered PCR’s for product protection under ISO Class 5 conditions. For copies of these validation reports, contact Labconco Customer Service.
CHAPTER 4 PERFORMANCE FEATURES AND SAFETY PRECAUTIONS The Purifier Filtered PCR Enclosure is designed to provide particulate free protection from airborne matter. During operation, room air is drawn from the top and filtered by the HEPA filter providing Class 5 conditions inside the enclosure. The Purifier Filtered PCR Enclosure delivers Class 5 air conditions when operating at downflow velocities of 30 to 65 feet per minute.
Chapter 4: Performance Features and Safety Precautions 6 10 9 Located Behind 12 4 2 15 5 3 1 6 Located Behind Control Panel Figure 4-1 Product Service 1-800-522-7658 15
Chapter 4: Performance Features and Safety Precautions 19 7 13 6 Airflow Switch with Adjustment Screw 11 18 15 UV Light (Not Shown) 4 16, (Not Shown) 1 17 Figure 4-2 Filtered PCR Enclosure Airflow Diagram 16 Product Service 1-800-522-7658
Chapter 4: Performance Features and Safety Precautions 16 Figure 4-3 UV Sash Closure Panel Product Service 1-800-522-7658 17
Chapter 4: Performance Features and Safety Precautions 1. Aerodynamic Lower Air Foil allows air to sweep the work surface and promote ISO Class 5 air conditions inside the enclosure. See Figure 4-1. 2. Ergonomic Slope of 10 degrees provides maximum visibility and comfort, reduces glare, thereby minimizing operator fatigue. See Figure 4-1. 3. Internal Depth of 25" provides necessary depth to work inside the enclosure. See Figure 4-1. 4.
Chapter 4: Performance Features and Safety Precautions PCR protocol. It is easily changed by, selecting the time necessary located on the control panel. To operate, simply select the UV light option on the light switch. 16. UV Closure Panel provides protection when the UV lamp is on. The panel must be in place for the UV lamp to work. See Figure 4-3. 17. Accessory Work Surface is dished and contoured to fit the dimensions of the enclosures to contain spills. 18.
Chapter 4: Performance Features and Safety Precautions 12. The HEPA filter provides Class 5 clean air conditions and only provides product protection inside the enclosure. Do not use the enclosure for personnel protection. 13. Never use flammable gases or solvents in the enclosure. Use of an open flame must be avoided in the enclosure. Open flames may disrupt the airflow patterns in the enclosure, burn the HEPA filter and damage the filter’s adhesive.
CHAPTER 5 APPROPRIATE APPLICATIONS FOR YOUR FILTERED PCR ENCLOSURE Now that the installation of your Filtered PCR Enclosure is completed, you are ready to use it. Read this chapter to learn about: 1. Routine Daily Work Procedures. 2. Suitable Applications. 3. Appropriate HEPA Filter Applications, Suitability and Guidelines. Routine Daily Work Procedures Planning Arrange for minimal disruptions, such as room traffic or entry into the room while the enclosure is in use. Start-up Turn on blower and light.
Chapter 5: Appropriate Applications for Your Filtered PCR Enclosure Loading Materials and Equipment Load only the materials required for the procedure. Do not overload the enclosure. Do not obstruct upper air diffuser screen. Large objects should not be placed close together. After loading, wait one minute to purge airborne contaminants from the work area. Work Techniques Keep all materials inside the lower air foil, and perform all operations as far to the rear of the work area as possible.
Chapter 5: Appropriate Applications for Your Filtered PCR Enclosure HEPA filters are only effective for entrapment of particulate matter. The surface of the HEPA filter is fragile and should not be touched. Care must be taken to avoid puncturing the HEPA filter during installation. If you suspect that a HEPA filter has been damaged, DO NOT use the enclosure. See Chapter 6 for Replacing the HEPA Filter. The HEPA filter will gradually accumulate airborne particulate matter from the room.
CHAPTER 6 MAINTAINING YOUR FILTERED PCR ENCLOSURE Monitoring airflow and changing the filters is the primary maintenance required. Certification and recertification is also reviewed in Chapter 6. Review this chapter on maintenance for the following: 1. Routine Maintenance. 2. Determination of when to replace the HEPA filters. 3. How to install a new HEPA filter. 4. HEPA filter leak test. 5. Speed control adjustment and setting the downflow velocity. 6. Operating and calibrating the airflow monitors. 7.
Chapter 6: Maintaining Your Filtered PCR Enclosure Routine Maintenance Schedule Weekly Wipe down the interior surfaces of the enclosure with a disinfectant or cleaner, depending upon the usage of the unit and allow to dry. Using a damp cloth, clean the exterior surfaces of the enclosure, particularly the front and top to remove any accumulated dust. Operate the exhaust system, noting the airflow velocity out the front of the enclosure using a source of visible smoke.
Chapter 6: Maintaining Your Filtered PCR Enclosure How to Install a New HEPA Filter NOTE: Only a qualified certifier should service the HEPA filter. After the HEPA filter is replaced, the enclosure MUST be certified. See Figure 6-1. 1. Unplug the enclosure and remove the prefilter located on top. 2. Remove the front panel by loosening the two screws that secure it. 3. Using a 9/16" deep socket, loosen the filter clamp bolts located on top. Refer to Figure 6-1. 4.
Chapter 6: Maintaining Your Filtered PCR Enclosure HEPA Filter Sealing Surface Prefilter HEPA Filter Filter Clamp Bolt Gasket Side Down as Shown Gasket Front Panel Speed Control Adjustment Screw Figure 6-1 HEPA Filter Changing Diagram & Filter Leak Test Diagram Product Service 1-800-522-7658 27
Chapter 6: Maintaining Your Filtered PCR Enclosure HEPA HEPA Filter Leak Test Purpose After installing the new HEPA filter, the HEPA filter should be leak checked. This test is performed to determine the integrity of the HEPA filter, the filter housing, and the filter seal. Leak testing must be done by a qualified technician with calibrated equipment. Remove the upper perforated diffuser located inside the enclosure by using a Phillips screwdriver to unfasten the screws (see Figure 61).
Chapter 6: Maintaining Your Filtered PCR Enclosure 8. If necessary, adjust the speed control of the enclosure to maintain the following downflow airflows at 55 fpm; 2' (230cfm), 3' (340 cfm), 4' (460 cfm.) 9. Position the aerosol generator discharge in the intake of the prefilter on top of the enclosure. 10. Start the aerosol generator (Pressure to be 10 +/- 1 PSIG). Ensure that one Laskin nozzle is in the “open” position. 11. Allow the generator to operate for a minimum of 15 seconds.
Chapter 6: Maintaining Your Filtered PCR Enclosure The circuit board provides power to the sensor and also contains a “safe (green)” and “alert (red)” airflow LED indicators, as well as a “SILENCE ALARM” button to quiet the audio alarm. When first powered up, the Printed Circuit Board (PCB) will light both red and green LED indicators and sound the alarm to indicate it is working. After 5 seconds, the air monitor will indicate either good or bad airflow based on what the connected airflow switch detects.
Chapter 6: Maintaining Your Filtered PCR Enclosure 5. Adjust the downflow velocity to the nominal operating point required. The green “safe” LED should light. 6. Over time the HEPA filter will load and eventually slow the downflow velocity. Once the alarm condition is met, simply increase the speed control as outlined in Chapter 6 or replace the HEPA filter if the speed control is maximized. 7. The table below lists typical alarm conditions based on normal operating conditions.
Chapter 6: Maintaining Your Filtered PCR Enclosure Speed Control Light Reflector Airflow Monitor LED Circuit Board Airflow Switch with Adjustment Screw Control Panel Green “Safe” LED Silence Alarm Button with Test/Reset Red “Alert” LED with Audible Alarm Figure 6-2 Guardian Airflow Monitor with Airflow Switch 32 Product Service 1-800-522-7658
Chapter 6: Maintaining Your Filtered PCR Enclosure Initial Certification The Purifier Filtered PCR Enclosure has been certified at the factory for an average downflow velocity of 40-55 fpm along with the HEPA Filter Leak Test. The Purifier Filtered PCR Enclosures should be certified for the proper downflow velocity required by your Safety Officer. It is also a conservative recommendation to perform the HEPA Filter Leak Test again should there be any damage caused during transport.
Chapter 6: Maintaining Your Filtered PCR Enclosure Motorized Impeller Replacement The motorized impeller must be replaced as a complete unit. When the motorized impeller is replaced, the capacitor should also be replaced. See Appendix A for Replacement Parts Diagram. See Figure 6-3 for an isometric view of the motorized impeller plenum assembly. The HEPA filter rests below the motorized impeller assembly. ! Do NOT contact blower wheel while still in motion.
Chapter 6: Maintaining Your Filtered PCR Enclosure 2' Model Mounting Screws for Motorized Impeller Motorized Impeller HEPA Filter Capacitor Mounted here on Electrical Subassembly located behind the Control Panel Wire Access Hole Impeller Mounting Bracket Hardware Front Panel Motorized Impellers Wire Access Holes 3' or 4' Models Figure 6-3 Motorized Impeller Replacement Product Service 1-800-522-7658 35
Chapter 6: Maintaining Your Filtered PCR Enclosure Speed Control Replacement 1. Remove the bracket that the speed control is attached to. See Figures 6-1, and 6-2. 2. Remove the two screws holding the speed control using a Phillips screwdriver. Refer to Appendix A for Replacement Parts Diagram. 3. Disconnect all wires leading to the speed control. Connect wires on new speed control in the same position as the old speed control. 4.
CHAPTER 7 ACCESSORIZING AND MODIFYING YOUR FILTERED PCR ENCLOSURE There are several ways to accessorize and modify the Filtered PCR Enclosure for your individual requirements. These include the addition of accessory work surfaces, airflow monitors, filters, and storage cabinets or stands. 1. Work Surfaces An optional dished work surface is available to attach to the Filtered PCR Enclosure. Dished work surfaces are contoured to fit the dimensions of the filtered enclosures to contain spills.
Chapter 7: Accessorizing and Modifying Your Filtered PCR Enclosure 2. Guardian™ Airflow Monitor The Guardian Airflow Monitor allows you to continuously monitor airflow through the enclosure. The Guardian monitor can be placed on any Purifier Filtered PCR Enclosure. Description Guardian Airflow Monitor 115V or 230V 1 ea. 1 ea. 2 ea. Order Part #’s Individual Parts Required 3811500 3910700 Airflow Monitor Printed Circuit Board Airflow Sensor w/ Connector #6-32 x .
Chapter 7: Accessorizing and Modifying Your Filtered PCR Enclosure 4.
CHAPTER 8 TROUBLESHOOTING AND SERVICER OPERATING LOG Refer to the following table if your Filtered PCR Enclosure fails to operate properly. If the suggested corrective actions do not solve your problem, contact Labconco for additional assistance. PROBLEM CAUSE CORRECTIVE ACTION Class 100 (ISO Class 5) air conditions are not present inside the enclosure. Improper user techniques for the enclosure. External factors are disrupting the enclosure airflow patterns. Enclosure has improper downflow velocity.
Chapter 8: Troubleshooting and Servicer Operating Log PROBLEM Blower won’t operate. Poor internal Class 5 air conditions. Blower and lights won’t operate. Light does not work. UV light timer does not work Airflow monitor malfunction CAUSE Circuit breaker(s) or Ground Fault Interrupter. Blower wiring is disconnected. Blower switch is defective. Motorized impeller or blower is defective. Enclosure sash not closed. HEPA filter clogged. Unit not plugged into outlet. Circuit breaker(s) tripped.
Chapter 8: Troubleshooting & Servicer Operating Log PROBLEM Airflow monitor malfunction (Continued) CAUSE Wrong alarm set point. Constant audible alarm. Continuous alarm. Monitor alarms; air way to airflow monitor sensor is blocked by insects, dust or debris. Audible disable will not stay operational. 42 CORRECTIVE ACTION Airflow monitor was not properly adjusted. Repeat calibration steps outlined in this manual in Chapter 6. Check airflow and calibration of airflow monitor. See Chapter 6.
Chapter 8: Troubleshooting and Servicer Operating Log Service Operating Record Log Customer Name Model Number Date Installed Serial Number Unit Location Date Comments Product Service 1-800-522-7658 43
APPENDIX A FILTERED PCR ENCLOSURE COMPONENTS AND REPLACEMENT PARTS The components that are available for your Filtered PCR Enclosure are listed. The parts shown are the most commonly requested. If other parts are required, please contact Product Service.
Appendix A: Components and Replacement Parts Item 1 2A 2B 2C 3A 3B 3C 4A 4B 4C 5A 5B 6 7A 7B 7C 7D 8 9A 9B 9C 10 11A 11B 12A 12B 12C 12D 12E 12F 12G 13A 13B 13C 13D 14A 14B 14C 15A 15B 16A 16B 16C Qty. 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 2 2 2 1.
Appendix A: Components and Replacement Parts Item 17A 17B 17C 17D 18A 18B 19 20A 20B 22A 22B 23A 23B 23C 23D 24A 24B 24C 24D 25A 25B 25C 25D 25E 25F 26A 26B 26C 27A 27B 27C 27D 28A 28B 29A 29B 29C 29D 29E 29F 46 Qty.
Appendix A: Components and Replacement Parts Item 30 31A 31B 31C 32A 32B 32C 35A 35B 35C 35D 36A 36B 40A 40B 40C 40D 40E 41A 41B 41C 42 43 Qty. 10 2 4 2 1 1 1 1 1 1 1 1 - (115V) 2 - (230V) 1 1 2 2 2, 1" Long 1 1 1 2 1 Part Number 1893712 1881196 1911018 1906925 3707900 3707901 3707902 1333800 1305800 1305900 1339200 1327204 1327200 1952500 3667400 1905617 1551700 3788200 3560510 3560511 3560512 1907002 1322800 Product Service 1-800-522-7658 Description Screw, #10 x .75 PH Phil. Thd.
Appendix A: Components and Replacement Parts 24 26 Fluorescent 35, 36 Not Shown 25 27 UV 28 23 31 15 32 7 14 13 8, UV Light Timer Located Behind Control Panel 20 40 29 18 30 43 11 17 19 16 9 10 5 41 6 3 1 2 22 4 12, Not Shown 5 42 Figure A-1 Replacement Parts, Purifier Filtered PCR 48 Product Service 1-800-522-7658
APPENDIX B DIMENSIONS Figure B-1 Purifier Filtered PCR Enclosure Product Service 1-800-522-7658 49
APPENDIX C FILTERED PCR ENCLOSURE SPECIFICATIONS This Appendix contains technical information about all Purifier Filtered PCR Enclosures including electrical specifications and environmental operating conditions. Electrical Specifications 5 Amps, 115V, 60 Hz 3 Amps, 230V, 50/60 Hz Environmental Conditions Indoor use only. Maximum altitude: 6562 feet (2000 meters). Ambient temperature range: 41° to 104°F (5° to 40°C).
APPENDIX D REFERENCES Many excellent reference texts and booklets are currently available. The following is a brief listing: Bryan, D., and R.C. Marback. 1984. Laminar-airflow equipment certification: What the Pharmacist needs to Know. American Journal of Hospital Pharmacy. 41.1343-1348. General Services Administration. 1988. FED-STD-209E Federal Standard – Clean Room and Work Station Requirements, Controlled Environment. Washington D.C. IES Recommended Practice: IES-RP-CC-001-86.
