NEW BRUNSWICK SCIENTIFIC AS-10 User manual

AS-10
Agar Sterilizer
Models M1189-0010 & M1189-0011
MANUAL NO: M1189-0057
Revision K
May 12, 2003
NEW BRUNSWICK SCIENTIFIC CO., INC.
BOX 4005 •44 TALMADGE ROAD •EDISON, NJ 08818-4005
Telephone: [phone] •1-800-631-5417
Fax: [phone] •Telex: 4753012 NBSCO
Internet: http://www.nbsc.com •E-mail: [email protected]

2
AS-10 Agar Sterilizer M1189-0057 User’s Guide

3
New Brunswick Scientific Co., Inc. User’s Guide
INTERNATIONAL OFFICES:
BELGIUM
New Brunswick Scientific NV-SA
Stationsstraat 180/4
3110 Rotselaar
België/Belgique
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
GERMANY
New Brunswick Scientific GmbH
In Der Au 14
D-72622 Nürtingen
Deutschland
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
CHINA
New Brunswick Scientific Co., Inc.
Room 1501, Xiangjiang Building, No. 18
Lane 1265, Zhongshan Road (W)
Shanghai 200051, P.R. China
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
THE NETHERLANDS
New Brunswick Scientific BV
Kerkenbos 1101, 6546 BC Nijmegen
P.O Box 6826, 6503 GH Nijmegen
Nederland
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
FRANCE
New Brunswick Scientific SARL
3, rue des Deux-Boules
75001 Paris
France
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
UNITED KINGDOM
New Brunswick Scientific (UK) Ltd.
163 Dixons Hill Road
North Mymms, Hatfield, Herts. AL9 7JE
United Kingdom
Tel: [phone] or 0800 581331
Fax: [phone]
E-mail: [email protected]
Web: www.nbsuk.co.uk

4
AS-10 Agar Sterilizer M1189-0057 User’s Guide
THIS PAGE IS INTENTIONALLY BLANK

5
New Brunswick Scientific Co., Inc. User’s Guide
CAUTION!
This equipment must be operated as described in this
manual. If operational guidelines are not followed,
equipment damage and personal injury can occur.
Please read the entire User’s Guide before attempting to
use this unit.
Do not use this equipment in a hazardous atmosphere or
with hazardous materials for which the equipment was not
designed.
New Brunswick Scientific Co., Inc. (NBS) is not responsible
for any damage to this equipment that may result from the
use of an accessory not manufactured by NBS.

6
AS-10 Agar Sterilizer M1189-0057 User’s Guide
THIS PAGE IS INTENTIONALLY BLANK

7
New Brunswick Scientific Co., Inc. User’s Guide
Copyright Notice
New Brunswick Scientific Company, Inc.
Box 4005 44 Talmadge Road
Edison, New Jersey 08818-4005
Copyright 2003 New Brunswick Scientific Co., Inc.
All Rights Reserved.
Reproduction, adaptation, or translation without prior written permission from
New Brunswick Scientific is prohibited.
Disclaimer Notice
New Brunswick Scientific Co., Inc. reserves the right to change
information in this document without notice. Updates to information in this
document reflect our commitment to continuing product development and
improvement.
Manual Conventions
#NOTE:
CAUTION!
WARNING!
Bold Text in bold face type emphasizes key words or
phrases.
Caution messages appear before procedures
which, if caution is not observed, could result
in damage to the equipment.
Notes contain essential information that
deserves special attention.
Warning messages alert you to specific
procedures or practices which, if not followed
correctly, could result in serious personal
injury.

8
AS-10 Agar Sterilizer M1189-0057 User’s Guide
THIS PAGE IS INTENTIONALLY BLANK

9
New Brunswick Scientific Co., Inc. User’s Guide
Every Instrument manufactured by the New Brunswick Scientific
Co., Inc. is warranted to be free from defects in material and work-
manship. This apparatus with the exception of glassware, lamps and
electrodes (where supplied), is warranted for 1 year against faulty com-
ponents and assembly and our obligation under this warranty is limited
to repairing or replacing the instrument or part thereof, which shall
with-in 1 year after date of shipment, prove to be defective after our
examination. This warranty does not extend to any NBS products
which have been subjected to misuse, neglect, accident or improper
installation or application; nor shall it extend to products which
have been repaired or altered outside the NBS factory
without prior authorization from the
New Brunswick Scientific Co., Inc.
W A R R A N T Y

10
AS-10 Agar Sterilizer M1189-0057 User’s Guide
THIS PAGE IS INTENTIONALLY BLANK

11
New Brunswick Scientific Co., Inc. User’s Guide
TABLE OF CONTENTS
1OVERVIEW.....................................................................................................................................................13
1.1 SPECIFICATIONS ........................................................................................................................................14
1.2 VESSEL TEST CERTIFICATES .....................................................................................................................15
2INSPECTION...................................................................................................................................................17
2.1 INSPECTION OF BOXES...............................................................................................................................17
2.2 PACKING LIST VERIFICATION....................................................................................................................17
3INTRODUCTION............................................................................................................................................19
3.1 PREPARING THE LOCATION .......................................................................................................................19
3.2 PHYSICAL LOCATION ................................................................................................................................19
3.3 ENVIRONMENT ..........................................................................................................................................19
3.4 FRONT PANEL FEATURES ..........................................................................................................................20
3.4.1 Process Indication ...............................................................................................................................21
3.4.2 Operational Indication ........................................................................................................................21
3.4.3 Keypad/Display Functions...................................................................................................................22
3.5 STERILIZER FEATURES ..............................................................................................................................24
3.5.1 Rear Panel ...........................................................................................................................................24
3.5.2 Vessel Cover ........................................................................................................................................26
3.5.3 Over-Temperature Safety Thermostat..................................................................................................28
3.5.4 Pressure Limit Test Port ......................................................................................................................28
4MAKING CONNECTIONS............................................................................................................................29
4.1 PLUMBING CONNECTIONS .........................................................................................................................29
4.2 ELECTRICAL CONNECTION ........................................................................................................................31
4.3 LEVELING THE UNIT..................................................................................................................................31
5OPERATION ...................................................................................................................................................33
5.1 PREPARATION............................................................................................................................................33
5.2 INITIAL POWER-ON AND SELF-TEST .........................................................................................................37
5.3 STERILIZER OPERATION ............................................................................................................................38
5.4 DISPENSING...............................................................................................................................................38
5.5 REMOVING THE VESSEL COVER................................................................................................................39
6COMMUNICATIONS & OUTPUT PORTS.................................................................................................41
6.1 DATA OUTPUT...........................................................................................................................................41
6.2 DIP SWITCH SETTINGS FOR RS-232/RS-422.............................................................................................41
7OPTIONAL EQUIPMENT.............................................................................................................................43
7.1 DUAL TEMPERATURE PROBE.....................................................................................................................43
7.2 GLASS WOOL FILTER CONVERSION KIT....................................................................................................44
8MAINTENANCE.............................................................................................................................................47
8.1 ROUTINE CLEANING ..................................................................................................................................47
8.2 CLEANING THE EXHAUST LINE .................................................................................................................47
8.3 PERIODIC INSPECTION ...............................................................................................................................48
8.4 O-RINGS....................................................................................................................................................48
8.5 AGITATION SHAFT BEARING (BELOW VESSEL).........................................................................................48
8.6 FILTER.......................................................................................................................................................49
8.7 HARVEST VALVE ASSEMBLY SEALS .........................................................................................................49
8.8 AGITATION SYSTEM ..................................................................................................................................49

12
AS-10 Agar Sterilizer M1189-0057 User’s Guide
9TROUBLESHOOTING ..................................................................................................................................51
9.1 INITIAL POWER-ON...................................................................................................................................51
9.2 ERROR MESSAGES.....................................................................................................................................51
9.2.1 Controller Error Messages..................................................................................................................51
9.3 WARNING MESSAGES................................................................................................................................52
9.4 TROUBLESHOOTING GUIDE .......................................................................................................................54
10 REPLACEMENT PARTS & ACCESSORIES .............................................................................................57
10.1 REPLACEMENT PARTS AND PART NUMBERS .............................................................................................57
10.2 ACCESSORY INFORMATION .......................................................................................................................59
11 DRAWINGS .....................................................................................................................................................61
11.1 LIST OF DRAWINGS ...................................................................................................................................65
12 TIMING CHART.............................................................................................................................................67
13 INDEX...............................................................................................................................................................69

13
New Brunswick Scientific Co., Inc. User’s Guide
1
1 O OV
VE ER RV VI IE EW W
The AS-10 Agar Sterilizer was initially developed to sterilize agars, hence its name.
Although it can be used to sterilize a variety of solutions, merely for the sake of simplicity
this manual may, from time to time, refer to “agar” only.
The AS-10 Agar Sterilizer automates the sterilization of various agars and nutrient broths.
Sterilization is carried out under precisely controlled conditions of time and temperature.
Volumes of one to ten liters can be sterilized and cooled to the dispense temperature in less than
90 minutes. This is accomplished without an external steam supply. Sterilization, temperature,
time and dispense temperature are readily adjustable for preparation of different agars. For
safety and durability, all vessels are constructed in accordance with ASME (American Society of
Mechanical Engineers) Boiler and Pressure Vessel Code, Section VIII.
A solid-state temperature controller and a water-jacketed sterilization vessel provide accurate
regulation. This, along with a large impeller operating at slow speed, provides optimum heat
transfer without local hot spots or introducing air bubbles into the media. After sterilization, an
automatic solenoid valve permits tepid water to circulate through the water jacket, quickly
cooling the nutrient to a pre-set dispense temperature that is maintained until the contents are
emptied. Dispensing is made easy through the harvesting valve assembly. A quick-connect
fitting is supplied to ensure a quick, aseptic connection of a sterilized dispense tube.
Unique AS-10 features ensure quality product time after time. An absolute sterile filter is
sterilized in place each time the AS-10 is run. Automatic venting eliminates foaming during
sterilization and maintains positive pressure during cool-down and dispensing. The top-mounted
dispense valve and vessel design combine efficiently to reduce hold-up volume.
The AS-10 has numerous safety features. The ASME-coded vessel has a rear exhausting
pressure relief valve. Multiple clamps ensure lid security. The protective see-through hood
protects operators from contact with hot surfaces. Safety interlocks prevent the dispensing of
excessively hot or pressurized liquids.

14
AS-10 Agar Sterilizer M1189-0057 User’s Guide
1.1 Specifications
AS-10 Agar Sterilizer
Cover Closed Cover Open
Height 26 inches 35 inches
Depth 20 inches 29 inches
Overall Dimensions
Width 24 inches
Weight Approx. 160 lbs
Total Volume 12 liters
Working Volumes 1 to 10 liters
Vessel
Operating Pressure 0 to 25 PSIG
Agitation Rate 48 rpm at 50 Hz / 57 rpm at 60 Hz
208V 60 minutes
220V 54 minutes
Heat-Up Time* per
Line Voltage
240V 45 minutes
Sterilization Temperature &
Time Adjustability
Sterilization cycles adjustable from 0 to 120 minutes
at 50°C to 125°C. Automatic cool-down to
dispensing temperature (front panel set)
Sterilization Temperature Control
Accuracy
User-set temperature ±0.5°C at 121°C (±2°C below
121°C).
Cool-Down Time From 121°C to 55°C in 15 minutes using water at
20°C, 30 PSIG.
Dispensing Temperature Control
Accuracy
Accurately maintained from 45°C to 75°C (±2°C)
(front panel set).
Electrical 208V, 1 Phase, 10 Amps, 60 Hz
220V - 240V, 1 Phase, 11 Amps, 50 or 60 Hz
Services Required
Water Tap water supply, tepid.
Minimum pressure required 30 PSIG
Maximum pressure 40 PSIG.
Flow rate: 5 gpm / 19 lpm at 30 PSIG
Drain Open gravity type drain.
Ambient/Environmental
Operating Conditions
• Altitude: up to 2000m / 6,560 ft for optimal
performance.
• Temperature: 5°C to 40°C
• Relative Humidity: 80% up to 31°C decreasing
linearly to 50% at 40°C.
• Voltage Fluctuation: ±10% maximum.
• Overvoltage Category II (UK only)
• Pollution Degree 2 (UK only)
*Time to sterilization temperature varies with actual line voltage, initial agar temperature, and
sterilization temperature. To a lesser degree, heat-up time also depends on liquid volume and
ambient temperature.

15
New Brunswick Scientific Co., Inc. User’s Guide
1.2 Vessel Test Certificates
Vessel test certificates are available upon request. To obtain copies, the inner and outer
vessel serial number must be specified at time of request. The serial number for the outer
vessel is stamped on the outer circumference of the vessel flange. The inner vessel serial
number is stamped on a label located on the outside diameter. The inner vessel must be
removed to view the label.

16
AS-10 Agar Sterilizer M1189-0057 User’s Guide
THIS PAGE IS INTENTIONALLY BLANK

17
New Brunswick Scientific Co., Inc. User’s Guide
2
2 I IN
NS SP PE EC CT TI IO ON N
2.1 Inspection of Boxes
After you have received your order from New Brunswick Scientific, inspect the boxes
carefully for any damage that may have occurred during shipping. Report any damage to
the carrier and to your local NBS Sales Order Department.
2.2 Packing List Verification
Verify against your NBS packing list that you have received the correct materials.
Save all packing materials and the User’s Guide. If any part of your order was damaged
during shipping, is missing pieces, or fails to operate, please fill out a Customer
Satisfaction Form 6300 (copy the form packed with your AS-10) and return it by fax or
mail.

18
AS-10 Agar Sterilizer M1189-0057 User’s Guide
THIS PAGE IS INTENTIONALLY BLANK

19
New Brunswick Scientific Co., Inc. User’s Guide
3
3 I IN
NT TR RO OD DU UC CT TI IO ON N
3.1 Preparing the Location
3.2 Physical Location
The AS-10 Agar Sterilizer should be placed on a smooth, level and sturdy surface that
can support both the sterilizer and its contents when in use. It must also be near suitable
electrical, water and drain services. Leave enough clearance to allow easy access to the
rear panel, and ensure that the lid and vessel cover are clear from any obstructions that
might hinder their proper operation.
3.3 Environment
The AS-10 functions optimally in an environment with the following ambient conditions:
• Temperature: 5°C to 40°C
• Relative Humidity: 80% up to 31°C, decreasing linearly to 50% at 40°C.
• Altitude: up to 2000m (6,560 ft.)
WARNING!
The AS-10 Sterilizer weighs 160 lbs. Do not attempt to lift or
move the unit by yourself. Note, too, that the unit should be
lifted only from the base.

20
AS-10 Agar Sterilizer M1189-0057 User’s Guide
3.4 Front Panel Features
Acquaint yourself with the location (see Figure 1) and features (see Figure 2 on the
following page) of the front panel, which is the primary user interface to control your AS-
10.
Figure 1: Front Panel Location (top view)
FRONT
PANEL