NuAire NU-5500 User manual

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OM0133 1
Air-Jacketed Automatic CO2Incubator
Models
NU-5500
NU-5500E
Operation and Maintenance Manual
October, 2010
Revision 9
(Series 14)
For 115 Vac, 60 Hz Only
Manufactured By:
NuAire, Inc.
2100 Fernbrook Lane
Plymouth, MN 55447
Toll-Free: 1-800-328-3352
In Minnesota: (763)-553-1270
Fax: [phone]
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OM0133 2
Air-Jacketed DH
Autoflow Automatic CO2Incubator
NU-5500/E
Operation & Maintenance Manual
TABLE OF CONTENTS
Section No. 1........................................................General Description
Section No. 2........................................................Performance Parameters and Features
Section No. 3........................................................Models & Features
Section No. 4........................................................Test Performance & Procedures
Section No. 5........................................................Warranty
Section No. 6........................................................Shipments
Section No. 7........................................................Installation
Section No. 8........................................................DH Autoflow Operation
8.1 ..................................................................... Sterility
8.2 ..................................................................... Humidity
8.3 ..................................................................... Control System
8.4 ..................................................................... Front Control Panel Description
8.5 ..................................................................... Rear Panel Detail
8.6 ..................................................................... Run Mode Operator Interactions
8.7 ..................................................................... Setup Mode Operator Interactions
8.8 ..................................................................... Diagnostic and Checkout Procedures
8.8.1............................................................ Diagnostic Mode
Section No. 9........................................................Calibration
9.1 ..................................................................... Chamber Temperature Calibration
9.2 ..................................................................... Door and Perimeter Temperature Calibration
9.3 ..................................................................... Setting Air Injections
9.4 ..................................................................... CO2Calibration
Section No. 10......................................................Maintaining Your DH Autoflow
Section No. 11......................................................Error Indicators & Troubleshooting
Section No. 12......................................................Remote Alarm Contacts
Section No. 13......................................................Electrical/Environmental Requirements
Insert ....................................................................Replacement Parts List
MANUAL DRAWINGS
BCD-09441 .................................NU-5500/E Direct Heat CO2Incubator
BCD-09409 .................................Plenum/Shelf Installation
BCD-09439 .................................Front Control Panel
BCD-09440 .................................Rear Panel
ASSEMBLY DRAWINGS
BCD-09403 .................................Front Panel Assembly
BCD-09408 .................................Chamber Assembly
BCD-14139 .................................Component Layout
BCD-06782 .................................Door Heater & Switch Assembly
BCD-09420 .................................Rear Panel Assembly
ACD-14140.................................NU-5500/E Tubing Configuration
BCD-09376 .................................Circuit Board Assembly Dimensions
ELECTRICAL SCHEMATICS
BCD-09366 .................................NU-5500/E Electrical Schematic
BCD-09444 .................................Direct Heat Control Board Schematic
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OM0133 3
DH Autoflow Air-Jacketed
Automatic CO2Incubator
Models:
NU-5500
NU-5500E
Operation and Maintenance Manual
1.0 General Description
The NuAire DH Autoflow Automatic CO2Air-Jacketed Incubator has been designed to provide a reliable
controlled in-vitro environment for optimum tissue cell culture growth. The chamber also provides an
environment for the storage and preservation of embryos, gametes and animal tissue cell cultures at on near body
temperature. There are five parameters that contribute to optimum growth conditions. These are:
1. Humidity
2. Precise temperature control
3. Precise CO2control
4. Sterility
5. Reliability
Like all NuAire equipment, this incubator has been designed to provide the highest quality standards of
performance with matching computer technology, precise temperature control, and CO2gas control system
combining state-of-the-art technology with years of design, quality, and manufacturing experience.
In order to accomplish the foregoing objectives, this incubator features the following:
1.1 Incubator Chamber
The design and size of the DH Autoflow inner chamber provides a large capacity, and ease of use. The
chamber walls are directly heated by physically attached foil heating elements on the sides, bottom, top,
and back of the chamber, providing a temperature uniformity of +0.3C. A space-age high-density
insulation that has a high "R" rating covers the complete outer surfaces of the incubator inner chamber.
1.2 Incubator Blower Fan & HEPA Filter
A continuous operating fan motor drives a blower wheel within the upper air plenum and sidewall duct
system. Air is constantly re-circulating within the chamber keeping every cubic inch of volume at a
uniform temperature. This airflow is distributed uniformly and at very low velocity, so as not to influence
culture growth. A large replaceable HEPA filter cartridge continually filters the air that circulates in the
chamber.
1.3 Incubator Control Electronics
The NuAire Incubator Control Electronics is a state-of-the-art microcomputer based control system
specifically designed to service the precise control requirements of the chambers environment, providing
optimum programmable conditions for culture growth. The microcomputer is “user-friendly” with status
indicators, LED display of control parameters and five touch control keypads to permit efficient operator
entry of data.
The microcomputer is supported with Read Only Memory ROM) containing executable software,
Random Access Memory RAM) for temporary storage, and Electronically Erasable Programmable Read
Only Memory EEPROM) for control set points and parameters. The
EEPROM provides for indefinite storage of these values during periods of power off or power
interruption power fault tolerant). The microcomputer includes a complete internal diagnostic software
package that permits fault isolation detection down to the failed component.
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OM0133 4
1.4 Incubator CO2Control
The NuAire direct heat incubator incorporates a microprocessor-based, non-dispersive infrared CO2
induction sensor. The amount of energy received at the detector is an approximate logarithmic function
of the CO2concentration in the gas between source and detector. The wavelengths used are absorbed
only by CO2making the measurement insensitive to other components, such as water vapor. Detector
linearization is performed with 32 bit digital accuracy. Advanced design provides a very stable output
minimizing drift and requiring less frequent calibration. The output is digital, alleviating tolerances
brought about by analog signals. The sensor is within the chamber air plenum so very accurate CO2
control is achieved. The CO2sensor consists of a control board and a detector assembly connected by a
cable. Calibration of this control is accomplished through the front of the unit where there is a CO2test
port.
1.5 Incubator Construction
The outer shell of the air-jacketed incubator is cold-rolled steel with a powder coat paint finish. The front
frame surface of the outer shell is heated with a foil type heater directly attached behind the front
perimeter opening.
The front frame perimeter heater, as well as the outer front door heater is duty cycle controlled manually
adjusted for specific ambient conditions to balance the heat that reaches the chamber and thus reduces the
possibility of condensation forming on the inner glass door and the inner chamber walls.
The inner chamber is 16-gauge, type 304L polished stainless steel using crevice-free construction, which
provides an easily cleanable inert surface that does not in itself promote biological growth. In addition,
all shelves, shelf supports, guide rails and the air plenum are easily removable and can be autoclaved to
remove contamination.
Remember: The chamber is not selective. The growth environment is applied equally to all
microorganisms within the chamber.
1.6 Incubator Humidity
A relative humidity level of up to 95% is achieved in the incubator by the use of a stainless steel pan
filled with distilled water no purer than 1 mega ohm, and placed on the bottom of the chamber. It is
necessary to set the duty cycle 0-100% of the door and front perimeter heater in proper proportions to
reduce the possibility of condensation forming on the glass inner door and the chamber walls. It is also
important to thoroughly wipe the walls and the glass door clean before adding the humidity water pan.
Condensation will occur more readily at contamination points. There is no electronic sensing and thus no
automatic control of the humidity level in the air jacketed incubator. An air pump continuously
introduces fresh air into the chamber at a variable rate to reduce condensation forming on the chamber
walls and front glass door.
1.7 Cabinet Ventilator Fan
An axial fan is mounted to the bottom cover panel of the incubator and runs continuously when the unit is
switched on. This fan pulls air into the cabinet shell thru the top panel louver openings and discharges it
out of the bottom of the unit. The operation of this fan is necessary to assure accurate chamber
temperature control over the 60F to 85F ambient temperature range that the equipment may see.
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OM0133 5
2.0 Performance Parameters and Features
2.1 Both the interior and exterior of the DH Autoflow are constructed of 16-gauge material. The interior is
highly polished type 304L stainless steel, using crevice-free construction. All exposed edges are deburred
to insure no sharp edges. The exterior is cold rolled steel finished in a powder coated polyurethane finish,
which is resistant to chemicals and easily cleaned using mild household detergents.
2.2 The DH Autoflow's microcomputer temperature control system has two temperature sensors located in
the chamber. The temperature sensors compare the values to a setpoint and execute a differential control
algorithm that energizes a solid-state switch, supplying power to the heaters.
2.3 Up to 17 shelves can be placed inside the chamber (4 supplied).
2.4 Space-age high density CRL crosslink material is used to insulate the inner chamber walls.
2.5 Foil heaters are directly attached to the chamber walls and the top and bottom surfaces of the inner
chamber.
2.6 Incubators can be stacked for space saving, and can still be serviced from the front.
2.7 Easily removable inner chamber plenum, shelves and rails for sterilization.
2.8 Most electronics, motors, pumps, and valves are fully accessible from the front of the unit.
2.9 A thru-wall access port is provided for operating electrical appliances, such as roller apparatus, rockers,
etc.
2.10 A CO2sample port is provided on the front panel to check the concentration of CO2in the chamber.
2.11 The CO2percentage is controlled by a solid-state gas infrared sensor, which provides accurate monitoring
of CO2regardless of changes in temperature or humidity levels in the chamber.
2.12 Automatic recovery of the CO2level after a 15 second door opening to 5.0 + 0.2% is within a 4-1/2
minute period.
2.13 The outer door includes an internal radiant heater in order to minimize condensation on the inner glass
door. A magnetic outer door gasket helps to insure a tight seal against the cabinet.
2.14 The inner glass door is 3/16” (4.7mm) tempered with smooth-ground edges and seals are tight against a
U-grooved silicone rubber gasket. The door latch is cam action. An all solid-state magnetic switch
monitors door motion.
2.15 All control electronics are protected with a circuit breaker that may trip at 110% of loading rating but will
trip at 145% of load rating in less than 2 seconds. Should the circuit breaker open pop-out button will
appear), merely depress to reset.
2.16 The incubator has factory-installed adjustable leveling legs to compensate for uneven laboratory surfaces.
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OM0133 6
3.0 Models & Features
NuAire offers a basic Model NU-5500/E Air-Jacketed DH Autoflow CO2Incubator.
3.1 Dimensions see also Specification Drawing BCD-09441)
Overall Dimensions - inches (mm): Model NU-5500/E
Height: Exterior: 39.5 Inches (1003.3mm)
Width: 25.5 Inches (647.7mm)
Depth: 26.5 Inches (673.1mm)
Height: Interior: 25.5 Inches (647.7mm)
Width: 21.5 Inches (546.1mm)
Depth: 21.0 Inches (533.4mm)
3.2 Performance Parameters
Temperature Range: 18C to 55C 5C above ambient to 30C ambient max.
Temperature Uniformity: +0.3C @ 37C.
Temperature Accuracy: +0.1C.
CO2Range: 0.1 to 20%.
CO2Accuracy: +0.1%
CO2Recovery: up to 5% +0.2% in 4 minutes.
Temperature Recovery: 0.3C/min. Average
Temperature Display Resolution: 0.1C
CO2 Uniformity: +0.1%
CO2Display Resolution: 0.1%
Door and Perimeter Heater Control Logic: Proportional 0-100% adjustable
Door & Perimeter Heater Duty cycles are processor controlled.
Temperature Sensor Type: Precision Integrated Circuit
CO2Control Logic: Fixed Algorithm/Manual Environmental Adaptable.
CO2Sensor Type: Infrared
Connectors on rear panel are provided for chart recorder, remote alarm, and printer connection.
NOTE: RATINGS APPLY ONLY AT DEFAULT CONTROL AND OPTION SETTINGS
3.3 Standard Items Packed With Unit
Four (4) stainless steel shelves
Eight (8) stainless steel shelf brackets
Two (2) sidewall plenums installed
One (1) blower plenum installed
One (1) water pan
Gas tube and filter
Access port plug with breather holes installed
Outer shell plastic hole ring installed
2 Meter electrical cord
Operation and Maintenance Manual
Operating Instructions
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OM0133 7
3.4 Accessories (Ordered Separately)
Model NU-1550 Automatic Tank Switch External ( 115 VAC)
Model NU-1550E Automatic Tank Switch External ( 230 VAC)
Model NU-1552 CO2Tank Alarm 115 VAC
Model NU-1551E CO2Tank Alarm 230 VAC
Model NU-1557 Additional Shelves
Model NU-1559 CO2Analyzer Fyrite Kit Dry 0-20% replacement fluid required)
Model NU-1561 Replacement Fluid for CO2Analyzer two bottles/carton**
Model NU-2568 Surge Protector 115 VAC
Model NU-1564 CO2 Regulator (2 Stage)
**Fyrite Replacement Fluid may only be ordered when shipment is possible by UPS Ground Service.
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OM0133 8
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OM0133 9
4.0 Test Performance & Procedures
All equipment is thoroughly inspected at the NuAire Factory at the time of shipment. Quality control is
maintained by constant surveillance over the product, beginning at the receipt of purchased material and
concluding with a final inspection, which certifies the incubator performance to the specifications. In all instances
where product quality cannot be easily assessed on the end item, the product is inspected during sub-assembly
fabrication. The following test procedures are conducted on each cabinet and a copy of the test report is included
with each unit.
4.1 Visual Inspection
4.1.1 Each incubator is visually inspected to insure that the interior is clean and free from scratches,
nicks, and burrs and that all welds, both interior and exterior are ground and polished smooth.
4.1.2 Painted surfaces are inspected to be free of scratches, nicks, insufficient covering, and runs.
4.1.3 The doors open and close freely without binding of the hinges. The gasket seals the inner glass
door tightly. The glass door is free of scratches.
4.2 Electrical Tests
4.2.1 Electrical Leakage Test
All incubators are required to have primary-circuit filtering to meet EMC electromagnetic
compatibility regulations. Electrical leakage may exceed 0.5 milliampere provided the leakage
current does not exceed 1.0 milliamperes.
4.2.2 Dielectric Voltage - Withstand
1770 volts VDC ONLY is applied between dead metal parts and the hot/neutral power source
lead with no electrical breakdown using an Associated Research Model 4045AI or 3560D for 115
VAC units. 2100 volts VDC ONLY is applied for 230 VAC units.
4.2.3 Grounding Continuity
The resistance between the green bonding conductor of the supply cord and any dead metal part
of the cabinet shall not exceed 0.10 ohms.
4.3 Functional Tests
The following functional tests are performed on every unit at the end of a continuous 48-hour burn-in
period.
4.3.1 Control Systems
All diagnostic functions are exercised to insure proper operation of control systems, components
and alarms.
4.3.2 CO2Control
Each unit is calibrated to function at a 5% CO2level. The concentration is checked with an
independent instrument. Each unit is monitored during the 48-hour burn-in period and only
accepted with zero failures.
4.3.3 CO2Recovery
Each unit is exercised for CO2recovery time at the end of the 48-hour burn in period. The door is
opened for 1 minute to deplete the CO2. After the door is closed, the unit shall recover to 5%
+0.2% within a 4-minute period.
4.3.4 Temperature
Each unit is monitored for stable temperature control over the 48-hour burn-in period 37C.
4.3.5 Humidity
Each unit is subjected to the highest achievable RH during the 48-hour burn-in period and any
condensation problems corrected. Door and perimeter duty cycles are set at 40% and 45%
respectively for this test. These are the default settings from the factory.
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