Pall Allegro 200 L User manual

USD 2883
Instructions for Use
Allegro™ 200 L and 500 L Plastic Totes, Lids
and Trolleys
For u e with Allegro 3D biocontainer y tem and bag y tem
from other manufacturer (100L, 200L and 500 L)
(Part number LGRPTTE200L, LGRPTTEL200L, LGRPTRL200L,
LGRPTTE500L, LGRPTTEL500L and LGRPTRL500L)

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Table of Contents
1. Introduction..................................................................................................................................................3
2. Warnings ......................................................................................................................................................3
3. Materials of Construction and Operating Limits........................................................................................4
4. Receipt of Equipment – Allegro Plastic Totes and Allegro Single-use Systems......................................4
4.1 Receipt of Allegro Plastic Totes and Accessories ....................................................................................4
4.1.1 Allegro Tote ....................................................................................................................................4
4.1.2 Allegro Tote Trolley..........................................................................................................................4
4.1.3 Allegro Tote Lid ..............................................................................................................................5
4.1.4 Packaging Retention ......................................................................................................................5
4.2 Receipt of Allegro Single-use Biocontainer Systems ................................................................................5
5. Installation and Operation ..........................................................................................................................5
5.1 Preparation of the Allegro Plastic Tote and Accessories ..........................................................................5
5.1.1 Tote Trolley Preparation ..................................................................................................................7
5.1.2 Tote Preparation ............................................................................................................................9
5.2 System Preparation, Installation and Use of Allegro Single-use Biocontainer Systems
in an Allegro Plastic Tote ........................................................................................................................11
5.2.1 Installation of a Single-use Biocontainer System in the 200 L tote ................................................11
5.2.2 Installation of a Single-use Biocontainer System in the 500 L tote ................................................13
5.2.3 Using the Allegro Plastic Totes with Other Suppliers’ Single-use Systems ....................................17
5.3 Filling an Allegro 3D Biocontainer System ..............................................................................................18
5.4 Using the Tote Lids ................................................................................................................................20
5.5 Moving Filled Totes ................................................................................................................................20
5.6 Dispensing from the Allegro Tote System ..............................................................................................20
5.6.1 Dispensing from the Bottom ........................................................................................................20
5.6.2 Dispensing from the Top ..............................................................................................................21
5.7 Removing a 3D Biocontainer System from the Tote ..............................................................................21
6. Allegro Tote Stacking.................................................................................................................................21
7. Maintenance and Spare Parts...................................................................................................................23
8. Troubleshooting Guide and Useful Tips ...................................................................................................23
9. Warranty .....................................................................................................................................................23
10. Allegro System Disposal .........................................................................................................................24
11. Other Allegro Tote Accessories...............................................................................................................24
12. Scientific and Laboratory Services (SLS) ...............................................................................................24

1. Introduction
The following procedures are provided for receiving, preparing, installing and storing Allegro 200 L and
500 L plastic totes, trolleys and lids. Additionally, installation and use of Allegro single-use 3D systems
with capacities of 100 L or 200 L in the Allegro 200 L plastic tote, or 500 L in the Allegro 500 L plastic
tote is described. Pall Allegro 3D biocontainer systems can also be used in association with purpose-
built Allegro hardware and qualified hardware from other suppliers. Certain bag systems from other
manufacturers may also be used in Allegro 200 L and 500L plastic totes.
The instructions contained in this product documentation should be read thoroughly because they
contain valuable information gained by extensive experience. It is very important that all instructions are
carefully followed and, where appropriate, that they be incorporated into the user’s standard operating
procedures. If some of the procedures do not suit your needs, please consult Pall or your local distributor
before finalizing your system.
OTE: Illustrations in this document are of the Allegro 200 L plastic tote LGRPTTE200L or 500 L plastic
tote LGRPTTE500L.
2. Warnings
Use of this product in a manner other than in accordance with Pall’s current recommendations may lead
to injury or product loss. Pall cannot accept liability for such injury or loss.
Allegro plastic totes have warning markings concerning handling. Please familiarize users with these
markings and, as necessary, include them in any Standard Operating Procedures (SOPs) based on this
Instruction for Use (IFU) that is used in your facility.
Figure 1
Warning la els for Allegro (a) 200L and ( ) 500L plastic totes
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DO OT STACK TWO
TOTES O A TROLLEY
DO OT OPE THE
ACCESS DOOR WHILST
BAG IS I USE
DO OT STACK TWO
TOTES O A TROLLEY
(a)
(b)

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3. Materials of Construction and Operating Limits
Allegro plastic totes are designed to be used in manufacturing facilities for fluid handling, storage, and
transport inside buildings. They are not recommended for long term use or storage outside as direct
sunlight results in UV degradation of polypropylene over time. Intermittent exposure to sunlight, or use
in facilities with glass-protected natural light is acceptable.
Table 1
Materials of Construction and Operating Limits
Mate ials of Const uction
otes Polypropylene reinforced with stainless steel
Latch mechanism Polypropylene
Hinge Polypropylene with stainless steel hinge rod
Accessories - Lids, trolley base and outlet Polypropylene
support plate
rolley casters Nylon and 304 stainless steel
Ope ating Tempe atu e Range
-40 ºC to 60 ºC
Stacking Specications
Allegro 200 L plastic totes Empty (closed/collapsed) x 5
Full x 3
Allegro 500 L plastic totes Empty (closed/collapsed) x 5
Full x 2
Note: Totes should not e stacked on trolleys
4. Receipt of Equipment – Allegro Plastic Totes and Allegro ingle-use ystems
4.1 Receipt of Allegro Plastic Totes and Accessories
The Allegro 200 L and 500 L plastic totes, accessory trolley and accessory lid are individually
packaged.
Assembly of components together is covered in Section 5.
4.1.1 Allegro Tote
Lift tote from packaging by holding underneath the tote base. As shipped, the tote
is in the collapsed position. Do not lift by grasping any of the folded side panels.
The 200 L tote weighs approximately 30 kg when wrapped. The 500 L tote weighs
approximately 60 kg when wrapped. Two people should lift the tote, one at each end.
If mechanical handling equipment is used (such as a fork lift truck) ensure that the
blades are spread to support the tote just inboard of the triangular leg gussets.
Note that the totes are supplied and fitted with Allegro port bracket (part number
LGRPFBP200L or LGRPFBP500L).
4.1.2 Allegro Tote Trolley
Remove from packaging and place on wheels. Wheels are taped for protection.
Position the trolley as close to point of use as possible before removing tape from
wheels. Carefully peel away tape (do not cut with a knife as this might damage the
nylon castors).

4.1.3 Allegro Tote Lid
Remove from packaging. Note that the Allegro 500 L tote lid is in two sections.
4.1.4 Packaging Retention
Retain all packaging as a minimum until the products have been inspected and
received into the area where they are to be used. Please recycle or reuse packaging
materials where possible.
4.2 Receipt of Allegro ingle-use Biocontainer ystems
Allegro 3D biocontainers are provided as part of an Allegro single-use system that has been
sterilized by gamma irradiation. In addition to the part number, each Allegro single-use
biocontainer is identified by a unique identification batch number.
1. Upon receipt, store the Allegro 3D single-use biocontainer system in clean, dry conditions
between 0 and 30 °C without exposure to radiation sources such as direct sunlight and,
wherever practical, in the original external packaging as delivered.
2. Check that the internal packaging is undamaged prior to use.
3. Do not remove the Allegro systems from packaging until just before use.
OTE: Allegro 200 L and 500 L plastic totes have a base port which is fitted with Allegro Port
Bracket (Part number LGRPFBP200L and LGRPFBP500L). The tote orifices are 100 x 100 mm
(200 L tote)and 100 x 200 mm (500 L tote); all system components attached to the base outlet
port of the biocontainer must be able to fit readily through this opening. It is recommended that
systems are designed with a short section of outlet tubing terminating in a connection device
such as a Pall leenpak™ sterile connector to which the rest of the system downstream of the
tote can be attached after the biocontainer system is placed in the tote.
5. Installation and Operation
5.1 Preparation of the Allegro Plastic Tote and Accessories
The Allegro plastic totes may be used with or without the accessory trolley and lid according to
process requirements.
OTE: Many manufacturing facilities are designed with floors that gently slope to a floor drain.
In this case, ensure that trolley brakes are always applied, and that when moving a tote on a
trolley, enough operators are provided to maintain control of the tote when moving; the weights
of the 200 L and 500 L totes may exceed 250 kg and 600 kg respectively.
Figure 2
Allegro 200 L plastic tote and accessories
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Tote lid
Latches
Collapsible side
panels (left & right)
Collapsible front &
back panels
Brakes and
trolley castors
Trolley

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Table 2
Allegro 200 L Plastic Tote and Accessories
Desc iption Allegro 200 L Allegro trolley for Allegro port bracket Allegro lid for
plastic tote Allegro 200 L for Allegro 200 L Allegro 200 L
plastic tote plastic tote plastic tote
Pa t Numbe LGRP E200L LGRP RL200L LGRPFBP200L1LGRP EL200L
Weight 29 Kg 16.3 Kg 0.1 Kg 4 Kg
Maximum 700 Kg (3 full Allegro 388 Kg ––
Load 200 L totes stacked)
Nominal 835 x 665 x 900 mm 855 x 665 x 212 mm 100 x 106 x 20 mm 770 x 635 x 75 mm
Dimensions 835 x 665 x 560 mm2
(LxWxH)
Figure 3
Allegro 500 L plastic tote and accessories
Table 3
Allegro 500 L Plastic Tote and Accessories
Desc iption Allegro 500 L Allegro trolley for Allegro port bracket Allegro lid for
plastic tote Allegro 500 L for Allegro 500 L Allegro 500 L plastic
plastic tote plastic tote tote (2 sections)
Pa t Numbe LGRP E500L LGRP RL500L LGRPFBP500L1LGRP EL500L
Weight 55 Kg 27.4 Kg 0.25 Kg 9 Kg (4.5 Kg per
section)
Maximum 1400 Kg (2 full 747.5 Kg ––
Load Allegro 500 L
totes stacked)
Nominal 1220 x 870 x 974 mm 1250 x 870 x 260 mm 100 x 208 x 20 mm 1155 x 835 x 75 mm
Dimensions 1220 x 870 x 447 mm2
(LxWxH)
1 A single port racket is supplied with each Allegro plastic tote. Spares are availa le to order in packs of 5.
2 Collapsed dimensions
Tote lid
(two sections)
Latches
Collapsible side
panels (left, right,
front & back)
Access door
with latches
Brakes and
trolley castors
Trolley

5.1.1 Tote Trolley Preparation
Where a trolley is being prepared, apply both brakes (one brake on each rear wheel)
prior to use (Figures 5, 6, 7).
Do not unfold tote panels prior to installing on a trolley. The empty tote can be in-
stalled on a trolley manually with at least two operators lifting from the base of the
tote, or using lifting equipment.
Do not lift the tote using the folded side panels or the lateral structural bars.
CAUTIO : Pall does not recommend lifting or otherwise placing an already filled tote
onto a trolley.
The legs of the tote locate into raised pockets at the corners of the trolley. Ensure that
all 4 legs are correctly located.
Figure 4
Leg correctly located in pocket on trolley
Figure 5
Position to apply rakes on trolley
Figure 6
Apply rakes
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Figure 7
Brake engaged
Trolleys are recommended to be used only for moving single totes (full or empty), or
collapsed totes in stacked or non-stacked positions (see section 5.5). In order to
move empty or full totes, release the brakes (Figure 8 and Figure 9).
Figure 8
Release rakes
Figure 9
Brake released

5.1.2 Tote Preparation
The procedure for opening the collapsible totes (200 L and 500 L) is as follows:
Figure 10
Open the first side panel
Figure 11
Open the second side panel
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Figure 12
Open the ack panel
Figure 13
Open the front panel
Figure 14
Engage the latches to lock the panels into position
CAUTIO : the panels can fold back if they are not secured with the latches.
Ensure that the internal surfaces of tote are undamaged, clean, dry, and free from
particulate matter. If required clean internal surfaces and bottom port as per the
procedures followed at your facility. Any cleaning agents used should be compatible
with the materials of construction (See Section 3).

5.2 ystem Preparation, Installation and Use of Allegro ingle-use Biocontainer ystems
in an Allegro Plastic Tote
1. Inspect the Allegro single-use system packaging. Verify that it is free from visible damage
that might compromise the integrity or sterility of the system.
2. Remove the system from its packaging. Carefully remove by hand any ancillary packaging
materials such as bubble wrap that might be present to protect system components. Do not
unfold the biocontainer.
CAUTIO : Avoid the use of sharp blades or pointed instruments that could damage the Allegro
3D biocontainers and other system components. Do not open the bag by forcing any of the
system components through the sealed end because this can generate particulate
contaminants and may damage or dislodge components.
3. Detach and discard any existing attached adapter plates from the Allegro system, if present.
OTE: Allegro 3D Biocontainers may be supplied with an adapter fitted to the outlet port,
which should be removed and may be discarded prior to the installation of Allegro systems in
plastic totes. This adapter is only used to locate Allegro 3D Biocontainers in Allegro stainless
steel totes.
5.2.1 Installation of a Single-use Biocontainer System in the 200 L tote
1. Confirm that the selected 3D single-use system is suited for the 200 L tote and has
the correct size of biocontainer (100 L or 200 L capacity).
2. Before inserting the single-use system into the tote, attach the port bracket
provided with the Allegro plastic tote to the hexagonal section of the bottom outlet
port (Figures 15 and 16). This secures the system bottom port when installed.
CAUTIO : Guide the clips to the hexagonal section. Ensure no lateral stress is placed
on the outlet port while attaching the port bracket. Do not hold the outlet port pipe
connection or attached tubing while attaching the bracket. Only apply opposing force
if necessary at the point marked in Figure 16 with a red dot.
Avoid using the inlet ports to support the biocontainer while sliding the port bracket
into position.
Figure 15
200 L Bottom port racket fixing position
Figure 16
Fixing the 200 L ottom port racket to the hexagonal section of the ottom outlet port
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3. Hold the Allegro 3D biocontainer with the base port and port bracket facing down
and closest to you and the top multi-port system uppermost. eep the side panels
on the uppermost face of the Allegro 3D biocontainer.
4. Prepare to place the Allegro 3D biocontainer into the base of the tote from above.
Do not unfold the bag.
OTE: The unfolded side panels of the 100 or 200 L single-use biocontainer should
be positioned at the front and rear of the tote when empty.
5. Lower the system into the tote. Align the base port and port bracket close to the
orifice in the tote (Figure 17). Pass any tubing or system components attached to
the bottom port through the orifice in the tote and gently pull the tubing while
guiding the port bracket to the locating ledges. Ensure that no tension is exerted
on tube connections to the biocontainer ports, and that there is sufficient slack for
any other tube connections to system components.
Figure 17
Locating the port racket in the orifice of the tote and feeding the system tu ing
through the locating slot
6. Align the corners of the Allegro 3D biocontainer with the corners of the tote, with-
out unfolding the biocontainer. Confirm that the bottom bracket is securely located
in the retaining/locating ledges by holding the outlet port from underneath without
putting strain on the tubing. Lock the port bracket in place as shown by twisting
the latches provided on the underside (Figure 18) of the port bracket, which secure
it to the bottom of the tote in the locating orifice.
Figure 18
Latches on the underside of port racket of the 200 L tote
7. Perform a final positioning check. Place the tubing and hardware connected to the
top ports in the center of the flattened bag, so the tubing and hardware do not
snag or catch during filling (Figure 19).

Figure 19
Final position of secured 200 L tote port racket with a single-use iocontainer system
8. Close all clamps on outlet lines.
9. Check that inlet lines are open prior to filling.
OTE: A correctly installed Allegro 3D biocontainer system will have a gap of
approximately 20 – 25 mm between the system and the walls of the tote to allow
for movement and expansion of the single-use system as it forms during filling.
5.2.2 Installation of a Single-use Biocontainer System in the 500 L tote
1. Confirm that the selected 3D single-use system is suited for the 500 L tote and has
the correct size of biocontainer (500 L capacity).
2. For installation of a single-use biocontainer system in the 500 L tote, open and
remove the front access door of the tote. Opening and removing the front access
door on the 500 L tote is performed by disengaging the front access door latches
(Figures 20, 21).
3. Install the single-use biocontainer system through the front access after removing
the door (Figure 22) in the non-stacked or stacked arrangement (Figures 23, 24).
TIP: When removing the front access door of the Allegro 500L tote, the door can be
temporarily clipped to the side of the tote.
4. Before inserting the single-use system into the tote, attach the port bracket to the
hexagonal section of the bottom outlet port (Figure 25).
OTE: The Allegro 3D single-use biocontainer system is prepared for installation in
the plastic tote by attaching the port bracket provided with the Allegro plastic tote.
This secures the system bottom port when installed.
CAUTIO : Guide the clips to the hexagonal section. Ensure no lateral stress is placed
on the outlet port while attaching the port bracket. Do not hold the outlet port pipe
connection or attached tubing while attaching the bracket. Only apply opposing force
if necessary at the point marked in Figure 25 with a red dot.
Avoid using the inlet ports to support the biocontainer while sliding the port bracket
into position.
Figure 20
Opening or disengaging the front door top latches
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Figure 21
Opening or disengaging the front door side latches
Figure 22
Remove the front access door
Figure 23
Removing the 500 L tote front access door when the totes are stacked
Figure 24
Feeding the 500 L system through the front access door when the totes are stacked

Figure 25
Fixing the 500 L ottom port racket to the hexagonal section of the ottom
outlet port
Figure 26
Feeding the 500 L system through the front access door
Figure 27
500 L single-use system position in the 500 L tote
5. Hold the Allegro 3D biocontainer with the base port and port bracket facing down
and closest to you and the top multi-port system uppermost. eep the side panels on
the uppermost face of the Allegro 3D biocontainer. Do not unfold the biocontainer.
6. Align the base port and port bracket close to the orifice in the tote (Figure 30). Pass
any tubing or system components attached to the bottom port through the orifice
in the tote and gently pull tubing while guiding the port bracket to the locating
ledges. Ensure that no tension is exerted on tube connections to the biocontainer
ports, and that there is sufficient slack for any other tube connections to system
components.
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Figure 28
Locating the port racket in the orifice of the tote and feeding the system tu ing
through the slot, following the closure of the clamp
7. Align the corners of the Allegro 3D biocontainer with the corners of the tote, with-
out unfolding the biocontainer. Confirm that the bottom bracket is securely located
in the retaining/locating ledges by holding the outlet port from underneath without
putting strain on the tubing. Lock the port bracket in place as shown by twisting
the latches provided on the underside (Figure 29) of the port bracket, which secure
it to the bottom of the tote in the locating orifice (Figure 30).
Figure 29
Latches on the underside of port racket of the 500 L tote
Figure 30
Position of the 500 L fixed ottom port racket

8. Perform a final positioning check. Place the tubing and hardware connected to
the top ports in the center of the flattened bag, so the tubing and hardware do
not snag or catch during filling (Figure 31).
OTE: A correctly installed Allegro 3D biocontainer system will have a gap of
approximately 20 – 25 mm between the system and the walls of the tote to allow
for movement and expansion of the single-use system as it forms during filling.
Figure 31
Final position of secured 500 L tote port racket with a single-use iocontainer system
9. Check clamps are closed as indicated in figure 28.
10. Check that inlet lines are open prior to filling.
5.2.3 Using the Allegro Plastic Totes with Other Suppliers’ Single-use Systems
The Allegro plastic tote can also be used with the systems from other suppliers by
rotating the port bracket, as shown in Figure 32 and 33.
Figure 32
Orientation of the port racket for (a) 200 L and ( ) 500 L totes for use with Pall
Allegro single-use systems
(a) (b)
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Front of Tote

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Figure 33
Reversed orientation of the port racket for (a) 200 L and ( ) 500 L totes for use with
other suppliers’ single-use systems
(a) (b)
For further information regarding the installation of other supplier’s single-use systems
into Pall hardware, or Pall single-use into non-Pall hardware, please contact a local
Pall representative.
5.3 Filling an Allegro 3D Biocontainer ystem
WAR I G: Do not overfill the Allegro 3D biocontainer above its maximum volume specification.
WAR I G: Do not open the access panel when the system is fully or partially filled.
OTE: Allegro 3D biocontainer systems can be filled from either the top or bottom ports. The
system will naturally move during filling. When filling through the top ports, position the tubing in
the center of the system, so it does not become snagged or pulled during the filling operation.
1. Check that the outlet lines are closed (Figure 34)
Figure 34
Clamp the outlet lines
2. Open the filling lines.
3. Commence filling. When properly installed, the Allegro 3D biocontainer system is self-aligning
and will require no manipulation during filling (Figures 35 to 37).
OTE: If manipulation is required e.g. when using other manufacturer’s single-use systems,
then use of the access panel on the 500 L tote is possible, as long as the liquid level is below
the panel.
Front of Tote

Figure 35
Commence filling
Figure 36
Allegro iocontainer self-aligning while filling in progress
4. Fill the container to the desired level.
Figure 37
Fill up to recommended volume specification
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Figure 38
Do not open the access panel when the system is fully or partially filled
5. Upon completion of filling, turn off the pump and close the filling line. Disconnect the filling
line in accordance with the requirements of the connection device and your own site
procedures.
5.4 Using the Tote Lids
The lids for the plastic totes are primarily used for protecting the biocontainer system in the tote
when used for storage, while being moved, and as protection for the biocontainer at any time
when not filling and dispensing. When used with a trolley, the lid may be stored on the trolley
underneath the tote.
5.5 Moving Filled Totes
When moving totes on a trolley, guide the tote assembly using the 4 corner uprights. Do not
push the tote by using the side or end panels. If using a mechanical moving device such as
a tote tug, engage only the trolley, not the tote. Move slowly without sudden starts or stops
to avoid liquid surges in the biocontainer.
When moving filled totes that are not on a trolley, use a suitable device capable of safely lifting
the entire weight of the tote and its contents. Lifting should be straight up and down.
Movement must be done slowly and without sudden starts or stops to avoid liquid surges in
the tote. Move only one tote at a time.
It is generally preferable to use dedicated Allegro Transportation Totes if totes are to be moved
extended distances, or between facilities.
TIP: During storage and whenever the tote is being moved on a trolley, the outlet port tubing
and any attached components can be stored in the port tunnel directly underneath the base
of the tote.
5.6 Dispensing from the Allegro Tote ystem
5.6.1 Dispensing from the Bottom
1. Connect the dispensing line tubing in accordance with the requirements of the
connection device and your own site procedures.
2. Open the clamp on the selected dispensing line.
3. Commence the dispensing operation. The Allegro system will self-collapse as the
fluid is drained.
4. Position any additional tubing to prevent it from snagging or being pulled during
dispensing operations.
X