14500 Coy Drive, Grass Lake, Michigan Vinyl Anaerobic Airlock Chamber Instruction Manual

Transcription

1 14500 Coy Drive, Grass Lake, Michigan Vinyl Anaerobic Airlock Chamber Instruction Manual

2 1.0 DESCRIPTION 1.3 CHAMBER ASSEMBLY 2.0 ERRORS MESSAGES FROM AIRLOCK 2.5 AUTOMATIC AIRLOCK (CIRCUIT BOARD) 3.0 MANUAL AIRLOCK 4.0 OPERATIONS OF MANUAL AIRLOCK 5.0 AIRLOCK MAINTENANCE 6.0 VACUUM PUMP DIAGRAM 1. OPERATION OF COMPONENTS 6.2. STANDARD EQUIPMENT 1. PLUG STRIP 2. CATALYST BOXES 3. GAS LEAK DETECTOR 4. GAS PRESSURE REGULATOR 5. MANUAL AIRLOCK 6. AUTOMATIC AIRLOCK 7.0 OPTIONAL EQUIPMENT 1. OXYGEN/HYDROGEN ANALYZER 2. INCUBATOR INCANDENCENT FLAMING DEVICE 4. STACK PAK 5. RECIRULATING ATMOSPHERE FILTER 6. GAS INJECTION SYSTEM 7. INTERIOR SHELVES 8.0 THEORY OF DESIGN 1. PALLADIUM CATALYST/GAS REACTION 8.1. OXYGEN ENTERING THROUGH AIRLOCK 8.2. AUTOMATIC AIRLOCK 8.3 MANUAL AIRLOCK 8.4. MOISTURE CONTROL 9.0 CARE AND MAINTENANCE 10.0 FREQUENTLY ASKED QUESTIONS 11.0 REPLACEMENT PARTS Vinyl Anaerobic Chamber Instruction Manual - 2 -

3 1.0 DESCRIPTION WARNING DO NOT USE PURE HYDROGEN IN ESTABLISHING YOUR CHAMBER ENVIRONMENT. USE ONLY PRE-MIXED GASES. THE USE OF PURE HYDROGEN, OR PRE-MIXED GASES WITH AN HYDROGEN CONTENT OF GREATER THAN 4%, MAY CAUSE AN EXPLOSIVE MIXTURE TO EXIST IN YOUR CHAMBER. 1.1 WARRANTY THE ELECTRONIC COMPONENTS CONTAINED IN THIS CHAMBER ARE WARRANTED AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP DURING THE FIRST 12 MONTHS AFTER ORIGINAL DATE OF SHIPMENT. THE VINYL BAG PORTION OF THE ENVIRONMENTAL CHAMBER IS WARRANTED AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP DURING THE FIRST 90 DAYS AFTER ORIGINAL DATE OF SHIPMENT. THE FACTORY WILL, AT ITS OPTION, REPAIR OR REPLACE DEFECTIVE MATERIALS WITHIN THE ABOVE PERIODS AT NO CHARGE FOR PARTS AND LABOR. ALL RETURNS OR EXCHANGES MUST FIRST BE AUTHORIZED BY COY LABORATORY PRODUCTS, INC. PHONE: FAX: COY LABORATORY PRODUCTS, INC COY DRIVE, GRASS LAKE, MICHIGAN THE RESPONSIBILITY OF COY LABORATORY PRODUCTS, INC., IS LIMITED TO THE PURCHASE PRICE OF THIS PRODUCT, AND COY LABORATORY PRODUCTS, INC. WILL NOT BE RESPONSIBLE FOR ANY CONSEQUENTIAL DAMAGES. THIS WARRANTY DOES NOT COVER DAMAGE IN SHIPMENT OR DAMAGE AS A RESULT OF IMPROPER USE OR MAINTENANCE OF THE PRODUCT. THIS WARRANTY DOES NOT COVER DAMAGES CAUSED BY EXCESSIVE LINE TRANSIENTS ON THE AC SUPPLY LINE

4 1.2 GENERAL INFORMATION 1. This manual is designed to provide you with basic knowledge of a Coy Environmental Chamber and the components supporting the Chamber. It will provide insight on how to assemble, operate, and maintain the Chamber. 2. The Coy Environmental Chamber is available in three standard sizes (Type A, B, and C) and is constructed of flexible PVC vinyl. The seams are sealed together using a radio frequency welding technique. A tubular aluminum frame supports the Chamber on a 3/4" plywood base, covered with foam and vinyl surface. The Chamber has two entry ports, one of which is used to install large equipment before the Chamber is initially purged. After large equipment has been installed, this entry port is sealed with a large plastic disc and taped. The other entry port is the airlock, and is used by the operator to enter the Chamber on a routine basis. Catalyst Boxes are supplied with the Chamber to ensure an anaerobic environment. Catalyst Boxes circulate the Chamber's atmosphere through palladium catalyst to remove oxygen. It should be noted here that HYDROGEN must be pres ent in order for the palladium catalyst to properly remove oxygen. We strongly recommend that all personnel and users read this manual to become familiar with the assembly, operation, theory of maintaining anaerobic conditions, and use and care of the Chamber. 3. The Automatic Airlock version has the following power requirements: 110 volt 60 hz 15 amp Type 3 AB Fuse 220 volt 50 hz 15 amp Type 3 AB Fuse VINYL REPAIR KIT ROLL OF YELLOW TAPE 1Pr. NEOPRENE RUBBER GLOVES PLASTIC CUFF 1/8" ALLEN WRENCH (For Chamber assembly) 5/32" ALLEN WRENCH (For Chamber assembly) - 4 -

5 Figure #1 Legend 1. Left Side Support 2. Straight Aluminum Hanger Pole 3. Right Side Support 4. Cup, 36 /91 cm Above Chamber Base 5. Front Side Support Cups 6. Chamber Base 7 7. Slight Angle on Side Support (front side only) 8. Rear Side Support Cups 2. Once you have found a suitable place to set the Chamber, insert the side supports (1,3) in their cups (screwed to the Chamber base 5,8). As you will notice in Figure 1, and by inspection, the side supports are not symmetrical. At the bottom of each support, one side is bent at a slight angle (7). This bend allows the Chamber to slant away from the user's face when it is fully assembled. The side that is bent is inserted in the cup closest to the front of the Chamber (5). Side support cups are located on all four corners of the Chamber. DO NOT TIGHTEN THE SETSCREWS THREADED IN THE CUPS, YOU WILL DO THIS LATER. 3. Next, insert the two straight aluminum poles (2) into the PVC hangers (The PVC hangers are sleeves that are connected to the vinyl bag and are located near the top of the Chamber). DO NOT FORCE THE POLES THROUGH THE HANGERS. Slide them through, with a rotating motion, which will help guide them. Then, lift one pole (either in front or back of the Chamber) and insert it in the cups (4). You may have to spread the side supports slightly to insert the aluminum poles. Now, install the other aluminum pole in the same manner as the first. 4. With the 5/32" Allen wrench tighten the setscrews located on ALL of the cups. Tightening the setscrews will make the Chamber's frame ridged and self-supporting. The Chamber should now be standing and ready for large equipment installation. 1.4 COMPONENT PLACEMENT 1. This section contains information on placement of the Plug Strip, Catalyst Boxes, and Shelving Units. Figure 3 will illustrate a popular floor plan and may be used as a guide to help you choose a floor plan to maximize your work area. NOTE: It is recommended that you read the Theory of Operation (section 2.0) before proceeding further with a special consideration on section

6 Figure #3 Standard Equipment Layout Figure # 3 Legend 1. 6 Outlet Plug Strip 2. Work Pad 3. Padded Base 4. Airlock 5. Catalyst Boxes 6. Large Equipment Entry Port 7. Utility Nipple 8. Optional Shelving or Incubator 2. Before you install large equipment, you must first insert the electrical plug strip (Figure #3 Standard Equipment Layout). Slide the plug strip through the large nipple located at the bottom rear on either side of the Chamber, usually the side opposite the airlock unless specified differently at time of the order. When the plug strip is completely inside the Chamber, forcefully push the plug strip's stopper into the nipple. Wetting the stopper with water will help you push it into the nipple. The best location for the plug strip is in back of the Chamber. 3. Now you are ready to install large equipment through the large equipment entry port (6). Large equipment is defined as anything too big to fit in the airlock (4), such as a Coy Incubator (8), Catalyst (Fan) Boxes (5), Work Mat (2), and Shelving Units (8). Arrange the items to provide maximum work area. Coy recommends placing the work mats in front of the gloves and Catalyst Boxes at opposite ends of the Chamber. If your Chamber is equipped with one Catalyst Box, placement should be next to the airlock, since this will more efficiently extract any oxygen entering the Chamber through the airlock. Also, make sure the Catalyst Boxes fan cages are facing the center of the Chamber (catalyst box laid horizontally) or with the Catalyst Tray Holder facing the center see (Figure #4); Catalyst Box efficiency is sharply decreased when the fan cage or the catalyst trays rests against any of the walls or are placed under a shelf

7 Figure #5 Large Equipment Entry Port Taped into Position 1. Once large equipment has been installed, and arranged to your satisfaction, and plugged into the power strip, seal the large equipment entry port with the plastic disc. To do this, orientate the disc so that COY can be read from inside the Chamber. If you have the disc oriented correctly, COY will read backward when you stand outside the Chamber. Next, push the disc through the large opening and begin the sealing process by grasping the outside of the disc with both hands and pulling it through the hole until about 2" of PVC is resting on the sides of the disc. With one hand, hold the PVC in place; and with the other used as a lever, stretch the PVC over the disc. After the PVC has been stretched over the disc, seal the junction where the PVC and disc meet with yellow tape (supplied with your Chamber Care Kit). Taping the PVC and disc together is an important procedure and should be done with care so the tape does not wrinkle. Coy recommends 6 revolutions of tape to ensure an adequate seal. The first revolution of tape should be very flat and straddle the PVC and disc. This first revolution of tape actually seals the large equipment port. The remaining revolutions ensure a complete seal by overlapping the first revolution on both sides. When you complete step 4, there should be a band of yellow tape (created by the overlapping tape) about 3" wide. (See Figure #5)

8 AUTOMATIC AIRLOCK SET-UP FIGURE 1 AUTOMATIC AIRLOCK REAR VIEW FIGURE #1 LEGEND AMP FUSE 2. MANUAL VACUUM SWITCH 3. MANUAL NITROGEN SWITCH 4. MANUAL GAS SWITCH 5. GAS MIX PORT (ATTACH GAS LINE HERE) 6. NITROGEN PORT (ATTACH LINE HERE) 7. MAGNETIC SWITCH WIRE HOUSING 8. VACUUM PORT (ATTACH VACUUM TUBING HERE) 9. POWER CORD 10. VACUUM PUMP (POWER OUTLET) 1. Plug the vacuum pump into the outlet marked VACUUM PUMP POWER (10) and the vacuum hose is attached with a hose clamp to the port marked TO VACUUM (8). Place the vacuum pump on secure surface either below the chamber or behind the airlock. Make sure the space is well ventilated to prevent overheating. 2. Now install the gas lines from your 2 tanks of gas See Figure #2 Gas Regulator Assembly. Each Gas Line comes from the factory with ¼ compression fitting around a copper line. Securely fasten your Nitrogen tank tubing to the NITROGEN (6) inlet on the back of the airlock. NOTE: This tank can be any inert gas you choose. Do the same for the GAS MIX (5) inlet. As shown by the sketch below, the Vacuum Airlock has independent gas lines going to the supply tanks and airlock. When the tank valves are opened, the primary pressure gage (3) will display the amount of gas remaining in the tanks. By turning the pressure gage valve (7), you can regulate gas flow to the airlock (secondary pressure gage (5)) to be 20 psi (1.4 Kg/sq.cm). When the supply tanks and ball valves (2) are turned on, gas will flow to the solenoid valves in the rear of the Airlock

9 FIGURE 2 GAS REGULATOR ASSEMBLY FIGURE #2 LEGEND 1. NITROGEN PRESSURE REGULATOR 2. BALL VALVE (NITROGEN & GAS MIX) 3. PRIMARY PRESSURE GAGE (NITROGEN & GAS MIX) 4. GAS MIX PRESSURE REGULATOR 5. SECONDARY PRESSURE GAGE (NITROGEN & GAS MIX) 6. PRESSURE REGULATOR VALVE (NITROGEN & GAS MIX) 7. ¼ COMPRESSION FITTING FOR CONNECTION TO THE AIRLOCK 2. Next, turn the gasses on and set both regulators to 20 psi (1.4 Kg/sq.cm) THE GAS REGULATORS MUST NOT EXCEED 60 PSI (4.2 Kg/sq.cm). NOTE: Before proceeding further, all gas fittings should be checked for leaks. To do this, simply make a soap/water solution. Brush the solution on all fittings. It will bubble when a leak is present. Tighten fitting to stop leak. DO NOT OVER TIGHTEN THE FITTINGS AS THIS MAY MAKE THE LEAK WORSE. 1.6 PURGING THE CHAMBER & ESTABLISHING INITIAL ATMOSPHERE This section will explain how to purge the Chamber and establish an anaerobic environment. See the "Airlock Manual" for proper connection of vacuum and gas supply to either your Automatic or Manual Airlock. NOTE! DO NOT INTRODUCE CATALYST INTO THE CHAMBER UNTIL THE PURGE OPERATION IS COMPLETE. 1. To purge the Chamber, close the outer door of the Airlock and open the inner door. Plug the Plug Strip into a wall outlet, and Catalyst Fan Box will turn on. The Catalyst Box fans should be the only thing operating in the Chamber. If you have heated Catalyst Boxes be sure the "Set Point" is lower than ambient temperature so the heater cones do not come on. If you have an Incubator, slide one door to open position to allow oxygen evacuation during Chamber purge. All Equipment except for Catalyst Boxes and the optional Model 10 Gas Analyzer should be turned off. 2. Using the manual control switches (on the rear of the Automatic Airlock or in the Airlock Menu switch to manual controls to operate the controls using just the front buttons), vacuum the Chamber's atmosphere (See the "Airlock Manual"). When you do this, the Chamber will collapse. While the Chamber is collapsing, make sure it is protected from sharp objects which may puncture the PVC. Continue vacuuming the Chamber until the bag becomes inverted and tight. Then manually inflate the Chamber with nitrogen gas until the bag starts to protrude out from the Chamber. CAUTION! DO NOT OVER INFLATE THE CHAMBER! Repeat the vacuum/nitrogen gas procedures AT LEAST 3 MORE TIMES. 3. After the vacuum/nitrogen gas procedure is completed, repeat 2 more times, except use gas mix rather than nitrogen. 4. Now, introduce the palladium Catalyst to the Chambers atmosphere. To do this, close the airlock inside door and place the palladium Catalyst inside the airlock. Operate airlock to anaerobic conditions. At cycle completion open the inside door and - 8 -

10 remove the palladium Catalyst Stak Pak from the airlock and place it perpendicular in the Catalyst Box so that only a portion of the palladium Catalyst is in direct contact with the air flow created by the fan. IF YOU ARE USING CATALYST THAT IS NOT CONTAINED IN A COY STAK PAK, MAKE SURE IT DOES NOT SPILL ONTO THE CHAMBER FLOOR. 5. When palladium Catalyst is introduced to an environment rich in oxygen and hydrogen, the palladium coated pellets generate heat as the 3 components (palladium Catalyst, oxygen, and hydrogen) react with each other. After about 15 minutes, you can correctly arrange the tray in the Catalyst Boxes. In about 2 hours or less (depending on chamber size), the oxygen content in your Chamber should be low enough to begin routine tasks. 6. During the next hours, you should monitor the oxygen content in your Chamber using Coy's Model 10 Oxygen/ Hydrogen Analyzer. After the first 24 hours of operation, you should manually vacuum your Chamber about half way and manually re-inflate it with gas mix, to allow more hydrogen to enter the Chamber's atmosphere. If the Chamber is left unattended for several days, it may lose anaerobic condition due to lack of hydrogen. For this reason, Coy recommends using the Model 10 Oxygen/Hydrogen Analyzer (part # ) to monitor your Chambers hydrogen content as well. 1.7 AUTOMATIC AIRLOCK (MANUAL MODE) The DAALC may be operated manually using three toggle switches located on the back panel (see Figure 1), or through the Manual Menu on the front panel display. For easier operation through the Manual Menu on the front panel see section If the airlock PC Board is not working or removed the switches on the rear will still operate the system however if the Board is removed there will be no Vacuum Display levels. For this reason it is advised in the first week of operation to time the cycles of the airlock in the automatic mode with the airlock empty and noted here for future reference. NOTE: the gas pressure on the gas regulators will determine time as well so that should be noted as well. Cycle #1 Background Cycle #2 Vacuum Cycle #3 Gas Mix Gas Pressure The three switches are: 1. VACUUM (Vacuuming the airlock) 2. NITROGEN (Filling the airlock with nitrogen) 3. GAS MIX (Filling the airlock with gas mix) Changes in elevation will also affect the vacuum pump performance. These three switches are located just above their respective ports on the back panel. The airlock can be operated in the manual mode with the printed circuit board either installed or removed AUTOMATIC AIRLOCK (MANUAL OPERATION) 1. Close both doors. 2. Turn the power switch on Front Panel OFF. *All numbers referring to parts correspond to Figure 1 for the rest of the manual operation procedure. 3. Depress and hold the vacuum toggle switch (2) for the time listed under Cycle #2 Vacuum in section Release the switch. 4. Depress and hold the nitrogen toggle switch (3) for the time listed under Cycle #1 Background in section Release the switch. 5. Repeat 3 & 4 for a second time. 6. Depress and hold the vacuum toggle switch (2) for a third time for the time listed under Cycle #2 Vacuum in section Release the switch. 7. Depress and hold the gas mix toggle switch (4) for the time listed under Cycle #3 Gas Mix in section Release the switch. 8. The airlock is under anaerobic conditions; the inside door may be opened

11 1.8 MENU S To enter the Menu s the outer Airlock door must be closed. After closing the door press and release the Enter Menu key. This will take you to the following display. Up-Prof. Dn-Conf. Start-Mmode Menu-Exit You can choose between 4 Menu s (listed Below). NOTE: there is no time limit placed for choosing a menu. The controller will maintain the display until you are finished scrolling thru the menu or you cycle the power ON/OFF. The new Values are not stored in the controller s memory until after the Enter Menu button is pressed and released Profile Menu (Up-Prof.) The Menu is entered by pressing and releasing the up key. 1) Enter Profile number that you want to edit. Using the up & down keys select the profile that you want to edit 1 thru 9. After you have changed the profile to the profile number that you want to edit press and release the Enter Menu key. 2) Enter the number of Gas mix cycles. Using the Up and down key to change the number of cycles to 0 to 9. If you enter 0, when running the profile the program will skip over the Gas mix portion of the program. When you change your entry to the number of cycles that you want press and release the Enter/Menu key to go to the next item in the menu. 3) Enter the number of Purge gas cycles. Using the Up and down key to change the number of cycles to 0 to 9. If you enter 0, when running the profile the program will skip over the Purge gas portion part of the program. When you change your entry to the number of cycles that you want press and release the Enter/Menu key to go to the next item in the menu. 4) Enter time out for the vacuum in sec. Using the Up and Down key to change the time out value form 45 to 120 seconds in increments of 5 seconds. When you have changed your entry to the seconds that you want press and release the Enter/Menu key to go to the next item in the menu. When running the profile if the time it takes to reach your vacuum limit then the time you just entered an alarm will sound. NOTE: When you change the vacuum level limit above the 20 in hg standard from the factory, you may need to increase this setting. If your lab operates at a high altitude you may also need to increase this setting. 5) Enter time out for the purge in sec. (For both Gas mix and Purge Gas.) Using the Up and Down key to change the time out value form 45 to 120 seconds in increments of 5 seconds. When you have changed your entry to the seconds that you want press and release the Enter/Menu key. When running the profile if the time it take to reach your o in hg then the time you just entered an alarm will sound. 6) Set vacuum limit The display will display in inhg (inches of mercury) or mbar (milli bars) depending how the display in mbar is set in the Configuration Menu. Using the up and down keys to change the vacuum limit. The limit can be change from 5 (169 mbars) to 29.9 inhg (1012 mbars). The limit will change only after the key is pressed and released. The limit is change in increment of.1 increments. After you have changed your entry to the limit that you want press and release the Enter Menu key this will take you out of the profile menu. Note: If you enter 0 cycles for both Gas Mix and Purge cycle the controller will display an error massage and sound an alarm. After a couple of seconds the controller will take you to the being of the Profile Menu. The error message will read (You have Entered 0 cycles for both Gas & Purge) - 9 -

12 1.8.2 Configuration (Dn-Conf.) Settings The Menu is entered by pressing and releasing the Down key. 1) Display in mbars (inches of mercury) Pressing and releasing the up key with instruct the controller to display the vacuum reading in mbars. Pressing and releasing the Enter Menu key will instruct the controller is display the vacuum reading in inches of mercury (in Hg). Once you have pressed and released either the up or the Enter Menu key the controller will go to the next item in the menu. 2) Setting pressure limit Enter 1 to 40 Using the up and down key to change this value 1 to 40. This limit sets the amount of gas that is aloud into the airlock after the controller reaches 0 inhg or 0 mbar. By adding 1 about.0043 PSI (.296 mbar) where 40 will add.172 PSI (5.825 mbar) to the airlock. If you are unable to open your airlock doors after a cycle you may have to increase this number to relieve the excess vacuum left from the automatic cycle. If you excess gas purges out of the airlock door (either inside or outside) then you may need to decrease the number, however if the next number leaves a vacuum on one of the doors go back to the higher number and tighten the door (see section) that is allowing the excess gas. Default setting is 20 however the settings from the factory may differ as each airlock has variations. To adjust change the number select a profile to cycle through the purge gas (background gas) 1 time (see section 2.1 for creating this profile) and 0 Gas Mix cycles and then run a cycle to see if the adjust pressure limit will operate correctly with your airlock. 3) Factory Setting Press and release the up key will change the Profile 9 to the factory default setting. The display will change to Factory setting have been restored. The controller comes from COY Labs with the following default setting All profiles Number of Gas mix cycle 1 Number of Purge gas cycles 2 Vacuum time out 45 seconds 45 seconds Purge Gas time out (both Gas mix and Purge) Vacuum limit 20.0 in Hg Configurations setting are set to. (See Configuration Menu for more information) Display in mbars No Pressure Limit 20* Factory Setting Yes Sensor Zero Cal Yes * NOTE This number may vary based on testing from the factory Pressing and releasing the Enter Menu key will not change to the default setting and take you to the next item in the menu. 4.) Sensor Zero Calibration Press and release the Enter Menu key will exit out Configuration menu. Press and release the up key will display the instruction Close inner door and Open outer door. The controller will stay here until the outer door is opened. Warning the controller does not know if the inner door is opened or closed. After the controller senses the outer door is open the controller will display the following numbers on the top line. XXX YYYYY AA XXX YYYYY AA is the Analog to Digital reading is the sum of the total samples taken is the number of samples taken After the zero is calculated the controller exits the Configuration menu

13 1.8.3 Manual Mode(Start-Mmode) The Menu is entered by pressing and releasing the Start key. The controller will display Manual Mode and key functions for about 3 seconds, after the 3 seconds another screen will display the rest of the key functions for 3 second. The display will display in inhg or mbar depending how the display in mbar is set in the Configuration menu is set. 1) Pressing and holding the Up key will turn on the vacuum pump until the key is released. 2) Pressing and holding the Down key will turn on the purge gas until zero inhg or 0 mbar is reached. 3) Pressing and holding the Start key will turn on the gas mix until zero inhg or 0 mbar is reached. 4) Pressing and releasing the Enter Menu start key will exit out of the Manual Mode. Warning: In the Manual Mode the controller does not monitor the front door switch. You can vacuum and purge with the front door open. Manual switches are supplied on the rear of the airlock that will perform the same functions as those noted above. See Figure #1 for details on the switches. If the Electronic board fails these switches on the rear will continue to operate unless there is power failure on the unit. Please note that the vacuum level display will not work without the electronics functioning. As a reference the standard 3 cycle airlock is described below. A COMPLETE AIRLOCK CYCLE CONSISTS OF: 1. Vacuum airlock to 20" Hg (677 mbar). 2. Back fill airlock with nitrogen gas. 3. Vacuum airlock to 20" Hg (677 mbar). 4. Back fill airlock with nitrogen gas. 5. Vacuum airlock to 20" Hg on (677 mbar Torr). 6. Back fill airlock with pre-mixed gas Cycle complete, airlock is now anaerobic Exit Menu (Menu-Exit) Takes you out of the menu listing mode

14 PH. (734) WEB: START MENU ENTER OFF ON WARNING: DO NOT USE PURE HYDROGEN. EXPLOSIVE POTENTIAL EXISTS, USE ONY NON - FLAMMABE GAS MIX 1.9 AUTOMATIC OPERATION Figure 3 can be used as an aid to locate components on the front panel. Begin operation by closing both the inside and outside doors. FIGURE 3 AUTOMATIC AIRLOCK FRONT VIEW AUTOMATIC MODE When the Airlock is first turn on the controller will display Coy Lab Products and AAL Rev (level) and then enters the automatic mode. The display will be displaying Ready Px on the first line and the second will be blank if the outer door is closed. The x next to P will be the last Profile that was entered or edited. The controller can store and run 9 different profiles (1 to 9). On the second line the controller will display X.X inhg or X mbar depending on the setting in the configuration menu. If the outer airlock door is opened the display will read Open door, vacuum reading, Aerobic. Note the vacuum reading will not be display during time out Errors and when in the Menu s Running a Profile in the Automatic Mode Close outer airlock door. The display will be displaying Ready Px on the first line and Aerobic will be displayed on the second line. The x next to P will be the last Profile that was entered or edited. If you want to run this profile press and release the start key. The controller will run the selected profile automatically Changing Profile Selection Using the up and down key change the profile number to the profile that you want to run. The profile number will only change after releasing the key. After you have entered the profile you want to run see for running a profile End of Profile The controller will sound an alarm and display Ready Px and Anaerobic. 2.0 Errors Note: each error will sound an audible alarm 1 Error 01 The profile that you are tried to run has both 0 cycle for both Gas mix and Purge gas. To clear the error you must cycle the power off then back on again. Then edit the profile that you where trying to run. Most likely cause was a power failure when entering a profile. 1. Time out Error Vacuum NOTE: you can determine the version of your airlock by turning the system OFF then ON again, displayed first will be the Rev # of your airlock

15 Rev. 1.3 or earlier: During the running of a profile the airlock did not reach the vacuum limit set in the profile in the specified time (factory default is 45 seconds). To clear the error Press and release the Start key this will open the purge gas solenoid and being the vacuum to 0. The display will display Time out error See Manual at this point cycle the power off the back on again. If the vacuum pump turned on check the profile that you were trying to run and look at the vacuum limit, you maybe trying reach a limit that the vacuum pump cannot reach. The other common problem is a door left open. Rev. 1.5 or later: During the running of a profile the airlock did not reach the vacuum limit set in the profile (factory default is 45 seconds). To clear the error turn the power switch OFF/ON and manual purge the airlock back to 0 Hg. If the vacuum pump turned on check the doors to make sure they are closed and the profile you were trying to run and look at the vacuum limit. You may be trying to reach a limit that the vacuum pump cannot reach. HIGH ALTITUDE OPERATION: If operating the system at high altitudes the vacuum pump will take longer to reach the same levels at sea level, you may have to increase the amount of time for the appropriate vacuum levels to be reached. 3 Time out Error Purge Gas During the running of a profile the airlock did not return to 0 in the specified time set in the profile. The display will display Time out error Purge Gas, See Manual, at this point cycle the power off the back on again. Check the profile that you were trying to run and look at the purge time out limit, you maybe trying 0 to fast for your pressure setting on the gas tank regulator. Also check your tank regulator setting, see if tank have gas and values. 4 Time out Error Gas Mix During the running of a profile the airlock did not return to 0 in the specified time set in the profile. The display will display Time out error Gas Mix, See Manual, at this point cycle the power off the back on again. Check the profile that you were trying to run and look at the purge time out limit, you maybe trying 0 to fast for your pressure setting on the gas tank regulator. Also check your tank regulator setting, see if the tank is empty. 2.5 AUTOMATIC AIRLOCK (CIRCUIT BOARD SERVICE) 1. Below is a step by step procedure for removing and installing the airlock printed circuit board. Coy Laboratory Products, Inc. is not responsible for any field calibrations or adjustments unless performed by factory authorized personnel. If you have any questions please contact the factory PROCEDURE 1. Turn off the airlock power switch (Figure 3 (15)). UNPLUG the airlock power supply cord (Figure 1 (10). If you do not unplug the power cord, live electrical current is present for possible electric shock. 2. Remove 8 screws (Figure 2 (12), Figure 3 (6)) securing the airlock cover. Do not remove the screw in the bottom center of each panel. These screws secure the panels to the airlock body. The Center screw on the front panel will be done last. 3. Remove the Power switch on the front panel. Warning: It is recommended that you do not remove wires from the switch. It is also recommended that you take a look at how the bezel is mounted to the switch before removing it, this will help when reinstalling the switch. A. From the back push the power switch thru the front panel. B. Remove the bezel (frame around the switch). Grip the switch in the center. Grab the mounting tab of the bezel (either side is OK). Pull tab away from the switch this unlocks the bezel from the switch. C. After the bezel is removed from the switch, push the switch back thru the front panel. D. Now disconnect the wiring by pulling the 3 pin connector off the switch, and wrap electrical tape around the connector pin and tape down to the airlock top. E. Remove the 2 single blue connectors that connect the magnetic door switch. To do this you will need a very small screw driver. Insert screw into opening above where the wires connect. Twist the screw driver up gently while gently pulling the wires free. F. Remove the clear plastic tubing connecting the airlock nipple to the pressure transducer on the printed circuit board. This will simply pull off from the pressure transducer. If the board is not replaced immediately, close off tube to prevent leaks in airlock

16 G. Locate the 3-wire device bolted through the bracket welded to the airlock. Remove the nut and gently slide the device out of the bracket. This device is called the Triac and is connected to the printed circuit board with 3 wires (red, white, and black) and has to be sent back with the PC board. H. Loosen the 6 screws holding the fanning strip on the right side of the PC board. NOTE The screws do not have to be completely removed. I.. J.. Now remove the center screw on the front panel and remove the entire panel from the airlock. Pack the airlock board in a plastic bag and return to COY Labs with the appropriate return authorization number (RMA#). Installation of New/Repaired Circuit Board 1. Installation of the replacement board is in the reverse order of the steps given above. After the fanning strip is secured to the terminal block (step 7). At step 5, the clear tubing is re-attached to the airlock nipple. To do this, lubricate the airlock's nipple with soapy water and CAREFULLY, with a direct force, push the tubing back into place. 2. With the replacement printed circuit board fully mounted, visually inspect the entire top area of the airlock for any pinched wires and correct any problems found. 3. Plug the airlock into an outlet. DO NOT TOUCH ANY INTERNAL PARTS AS HAZARDOUS VOLTAGES ARE NOW PRESENT. 4. Check for normal airlock operation. Make sure both doors open freely after completion of a full cycle. 5. Due to variations from unit to unit, slight adjustment of the vacuum or pressure levels may be necessary. After cycle completion, if the door is hard to open or gas escapes from the airlock door, the pressure level needs adjustments see section 2.1 (Pressure Limit adjustment). Adjust the pressure limit down if gas is escaping from the door (over pressurizing) at the end of the airlock cycle. Or adjust the pressure limit up if you are unable to open the door (vacuum left on the door). 6. Secure the airlock top cover when proper operation had been confirmed. 3.0 MANUAL AIRLOCK 1. Before operating the Manual Airlock, you must make a basic decision; how hard to vacuum the Airlock. The type of vacuum pump you are using may dictate this decision for you. If you have a vacuum pump that will attain 29" Hg on gauge (10 Torr), then you only have to back fill the Airlock once with gas mix. If not, then you will have to cycle the Airlock 3 times, each time vacuuming the Airlock to at least 22" Hg on gauge (200 Torr), back filling the Airlock 2 times with nitrogen gas and once with gas mix. Vacuuming the Airlock once to 29" Hg on gauge (1.0 Torr) will remove more oxygen than vacuuming 2 times to 22" Hg on gauge (200 Torr). 2. Use Figure 4 as an aid to preparing the Airlock for operation. 3. Plug the vacuum pump into a convenient electrical outlet so as to allow easy access to its on/off switch. 4. Attach the vacuum hose from your pump to the appropriate nipple (Figure 4 (5)). 5. Attach the gas supply assembly (Figure 2 (8)) to the Airlock (Figure 4 (1)) and to the appropriate supply tanks. 6. SLOWLY open the supply tank valves so you can adjust both regulators to 20 psi (1.4 Kg/sq.cm). This is he recommended setting with the 3 ft. (1 m) gas lines supplied by Coy Labs. If your gas lines are longer, you may need to set the gas regulators at a higher setting to produce the same flow of gas. Alternatively, you may install larger diameter tubing. THE GAS REGULATORS MUST NOT EXCEED 60 PSI (4.2 Kg/sq.cm). NOTE: BEFORE PROCEEDING FURTHER, ALL GAS FITTINGS SHOULD BE CHECKED FOR LEAKS. To do this, simply make a soapy water solution. Brush the solution on all fittings. If it bubbles, a leak is present. Tighten fittings to stop leak. DO NOT OVER TIGHTEN THE FITTINGS AS THIS WILL MAKE THE LEAK WORSE

17 Gas Mix Off Gr ass Lake, MI www. coylab. com BG (N2) CLOSED MANUAL VACUUM BALL VALVE OPEN TOP VIEW 4.0 OPERATION OF MANUAL AIRLOCK 1. All instructions refer to Figure 4 except at noted. See Paragraph for discussion of number of times to repeat sequence. 2. Close both doors. 3. Open vacuum ball valve and start pump until gauge attains appropriate reading (Min. 22" Hg. on gauge (200 Torr)). Close vacuum ball valve. 4. SLOWLY open nitrogen ball valve to replenish atmosphere in airlock until gauge returns to "0". Close nitrogen ball valve. 5. Open vacuum ball valve and start pump until gauge attains appropriate reading (Min. 22" Hg on gauge (200 Torr)). Close ball valve. 6. Depending upon efficiency of pump you may now either replenish the atmosphere with your gas mix by opening gas mix ball valve until gauge returns to "0". Repeat steps 6.1.4, 6.1.5, and finish with The Airlock is under anaerobic conditions; the inside door may now be opened. FIGURE 4 MANUAL AIRLOCK FRONT VIEW Gas Inlet Ball Valves Gauge 6. Vacuum Ball Valve ZERO 5.0 AIRLOCK MAINTENANCE 1. The Coy AALC is preset and adjusted at the factory to obtain optimum performance. However, during normal everyday use, the airlock may require adjustment or routine maintenance. The next section will detail solutions to common problems you may experience during normal operation. Please familiarize yourself with this section. Normal care and preventive maintenance will help avoid these problems. If a problem persists or you experience an uncommon problem, consult the factory. The other sections under AIRLOCK MAINTENANCE concentrate on replacing major components of the airlock. NOTE: The airlock is designed to hold a vacuum, not pressure. The airlock doors are spring loaded, if the airlock is pressurized the doors will open slightly so the gas can escape

18 5.1 FIGURE 5 MANUAL AIRLOCKFRONT 17 Front Figure 5 can be followed to locate different parts of the airlock and the terminology associated with these parts. 5.2 COMMON PROBLEMS AND SOLUTIONS 1. DIRT ON THE DOOR OR SEAL, SCRATCHES ON THE DOOR 1-A. Dirt on a door (11) or its seal (7) can cause the airlock to leak. Always keep the doors and seals clean. Scratches on any part of the door coming in contact with the seal may create leaks. If you scratch the door, try polishing it out or continuously apply a heavy grease to the scratched area. If the scratch is very deep, door replacement is necessary. 2. AIRLOCK LEAKS BETWEEN THE AIRLOCK BODY & DOOR FRAME 2-A. Leaks between the airlock body and door frame (17) or chamber usually result from an absence of sealant between frame and body. The absence of sealant generally occurs near a door mounting screw (8), and is caused by stresses put on the door frame while the airlock is cycling. To fix this type of leak, locate the mounting screw closest to the leak; remove it and fill the threaded hole with silicone caulk. Then replace the mounting screw. If the leak is between two mounting screws, apply a small bead of silicone around the leaking area and manually apply a vacuum on the airlock to 14" Hg on gauge (400 Torr). This will draw the silicone into the void. After 15 minutes, manually back fill the airlock with nitrogen to 0" Hg. In both cases, allow the silicone to cure for 24 hours before operating the airlock. 3. DOOR PUSH PIN WEAR 3-A. Door Handle and Push Pin (16) wear is caused from not lubricating the Pin. Lubricating the push pin must be part of your routine maintenance plan. The door cam is best lubricated with a light silicone or lithium grease

19 4. BENT LOCK STUD 4-A. Over the course of time the Lock Stud (5) may become bent preventing the door from closing securely or easily. The Lock Stud is a pin the Door Bar engages to when the door is locked in place. The Lock Stud is screwed into the bottom of the door frame. If a the stud is bent, it can be bent back into place with a 12" (30 cm) crescent wrench, or replaced. 7. DOOR ADJUSTMENTS 7-A. Before making any airlock door adjustments, look at how the door closes. The door only needs to collapse the lip of the seal (7) all the way around to ensure proper door adjustment. This can easily be observed by wiping the seal with a wet cloth, closing the door and looking at the seal through the clear acrylic. If the lip is not collapsed all the way around, the door needs to be adjusted. Door adjustments should be done with the Lock Stud (5) only. To adjust the airlock door use a crescent wrench to turn the lock nut (2) of the lock Stud in very small increments 1/16 of a turn is usually all it takes to tighten the door and collapse the seal. Making larger adjustments should not be necessary, if so it may indicate a problem with another area of the airlock. 8. MAGNET ON OUTSIDE DOOR FALLS OFF 8-A. This is the most common problem with the airlock. Typically, the reason the magnet (29) falls off is because the user grabs it to open the door. THE MAGNET IS NOT A HANDLE, the door handle should be used to open and close the airlock door. This magnet signals the printed circuit board when the door is closed. If the magnet falls off, use double face picture mounting tape to reinstall in original position. 5.3 REPLACE DOOR LOCK MECHANISM 1. Replacing the door lock mechanism requires you to be familiar with parts of the airlock and their terminology. Figure 5 can be used as an aid to replace the door lock mechanism. A list of procedures follows that will step you through the process. 5.3 PROCEDURE 1. Place a piece of tape on the upper right corner of the door. The tape is used to designate the top portion of the door. This step will be used later when you orientate the new lock mechanism. 2. Open the door. 3. Use the 5/32" Allen wrench supplied with your chamber care kit. While holding the door, remove the two bolts (21) holding the lock mechanism on the door (26). When the bolts are removed, the door can be set aside. At this point, the lock mechanism should be the only thing attached to the airlock. 4. With your small 1/8" Allen wrench, remove the setscrew found in the hinge bolt (18). The setscrew holds the 1/2" (13 mm) metal dowel (33) in place. The lock mechanism pivots up and down on the 1/2" (13 mm) dowel. 5. Loosen the very top Phillips head screw found on the right side plate (Figure 2 (20)). 6. Free the lock mechanism by pushing the 1/2" (13 mm) metal dowel through the hinge bolt and metal spacer (32, shaped like a washer). If you have trouble getting the 1/2" (13 mm) dowel through the hinge bolt, try gently tapping on it with a punch hammer. The lock mechanism should be free. 7. Loosen the lock nut (34) so the hinge bolt (18) may be removed. On units manufactured prior to June, 1987, setscrews (19) secure both the hinge bolt and catch bolt. Use the small 1/8" Allen wrench to remove both setscrews located on the right hand side of each bolt. 8. Remove the catch pin and hinge bolt. To remove the catch pin (28) loosen the setscrew, grip the catch pin perpendicular to the catch pin's shaft with a pair of pliers, and rotate counterclockwise until the catch pin is removed. To remove the hinge bolt, loosen the lock nut, insert a screwdriver through the hole left by the 1/2" (13 mm) metal dowel, and rotate counterclockwise until the hinge bolt is removed. Record the number of turns it takes to remove the catch pin and hinge bolt, it will be helpful when you re-install them. 9. The lock mechanism removal process is now complete. The remaining steps will guide you through the installation process. 10. Install the catch pin and hinge bolt. Use step 8 as a guide except rotate the pliers and screwdriver clockwise. Recall the number of turns needed to remove the catch pin and hinge bolt, and turn them that number of times when installing. That will put them in approximately the same place

20 11. Install new lock mechanism. To do this, line up the spacer (shaped like a washer) and new lock mechanism with the hinge bolt. Now, push the 1/2" (13 mm) metal dowel through the lock mechanism and spacer. Center the metal dowel between the side plates (12,21). 12. Attach the door to the lock mechanism. Locate the top of the door (marked with tape) and position it behind the lock mechanism. Slide the springs (39) over the bolts that hold the door on the lock mechanism. With your 5/32" Allen wrench, tighten the bolts until they are snug. 13. Close and lock the door. Check the contact between the door and black rubber seal (27); the door should collapse the lip of the seal all the way around. If the door does not collapse the seal, it may need adjustment. See section 2.2 paragraph 7-A for door adjustments. 14. Adjust the door drag. See section 2.2 paragraph 7-B for adjustment. Tighten all setscrews and lock nuts previously loosened. 15. Now, the lock mechanism should be in place. If you have any problems or questions please contact the factory. 5.4 REPLACE DOOR 1. Replacing the door requires you to be familiar with parts of the airlock and their terminology. Figure 3 can be used as an aid to replace the door. A list of procedures follows that will step you through the process. 5.4 PROCEDURE 1. Note the top of the door, labeled on the new door with a marker. 2. Open the door. 3. Use the 5/32" Allen wrench supplied with your chamber care kit. While holding the door, remove the bolts (21) holding the lock mechanism on the door. When the bolts are removed, the door can be set aside. At this point, the lock mechanism should be the only thing attached to the airlock. 4. Attach the new door to the lock mechanism. To do this, locate the top of the door and position it behind the lock mechanism. Make sure the springs (39) are still on the lock mechanism bolts. With your 5/32" Allen wrench, tighten the bolts until they are snug. 5. The new door should now be in place. Close and lock the door. Check contact between the door and black rubber (27); the door should collapse the lip of the seal all the way around. If the door does not collapse the seal, it may need adjustment. See section 2.2 paragraph 7-A for door adjustment. 6. Check door drag. See section 2.2 paragraph 7-B for door drag adjustment. 7. If you are installing an outside door, you will need to transfer the magnet (29) from the old door onto the new one. To do this, pull the magnet off the old door, clean the double face tape off, apply new double face tape, and stick it on the new door. The double face tape is picture mounting tape. The magnet should be installed in the same place on the new door, directly across from the magnetic switch (35) located on the airlock body. 8. The new door installation is complete. If there are any problems or questions, please contact the factory. 5.5 REPLACE DOOR FRAME (INCLUDING DOOR AND LOCK MECHANISM) 1. Replacing the door frame requires you to be familiar with parts of the airlock and their terminology. Figure 6 can be used as an aid to replace the door frame. A list of procedures follows that will step you through the process. 5.5 PROCEDURE 1. STEP 1-4 FOR REMOVING OUTSIDE DOOR FRAME ONLY With a 90 degree Phillips screwdriver, remove the two screws holding the magnet switch (35) in place. The magnet switch is located on the bottom of the outside door frames. If a 90 degree screwdriver is not available, remove the cap nuts holding the airlock to the chamber base. CAREFULLY, tilt the airlock up just far enough to remove the screws with a regular Phillips screwdriver. 2. Remove 10 Phillips screws (22) securing the door frame to airlock body

21 3. Remove setscrew holding catch pin (28) in place. Remove the catch pin by gripping a pair of plier s perpendicular to the shaft and rotating counterclockwise. 4. Install a 1/2-13 X 2" bolt in the hole left by the catch pin. Rotate the bolt clockwise, this will pry the door frame away from the airlock body. 5. FOR INSIDE DOOR FRAME ONLY. Remove 10 Phillips screws (22) with large screwdriver. Remove the door frame by pulling it away from the PVC, the door frame should separate easily. DO NOT USE ANY SHARP OBJECTS TO SEPARATE THE DOOR FRAME AND PVC. 6. Using a putty knife, scrape silicone off the airlock body. Pull the silicone off the PVC. You MUST have clean mating surfaces when you install the new door frame. 7. You are now ready to install new door frame. Get rags and alcohol ready, they will be needed to clean silicone off the airlock body or PVC. 8. Apply a 1/4" (6 mm) bead of silicone to the airlock body. The silicone must go all the way around the airlock body. Insert the alignment pins (one in each corner) in the holes left by the door frame mounting screws. If you are replacing an inside door frame use the alignment pins to line up the holes in the PVC and airlock body. 9. Apply a 1/4" (6 mm) bead of silicone on the new door frame. The silicone must go all the way around the door frame. Line the door frame up with the airlock body and push the door frame on the airlock. 10. Loosely insert 6 door frame mounting screws. Then remove the alignment pins and replace them with the remaining mounting screws. Tighten the mounting screws in a pattern alternating from side to side to ensure uniform pressure between the door frame and airlock body. DO NOT OVER TIGHTEN THE MOUNTING SCREWS. 11. Quickly wipe the excess silicone off with rags and alcohol. You must wipe the silicone off before it cures. 12. DO NOT USE THE AIRLOCK YET. ALLOW THE SILICONE TO CURE 24 HOURS BEFORE USING. Applying a vacuum too soon may suck the silicone into the airlock and leave a leak. 13. This completes the door frame replacement procedure. If there are any problems or questions, please contact the factory. 5.8 FACTORY SERVICE INFORMATION 1. Please have the following information available before you call or write Coy Laboratory Products, Inc. 1. Model and serial number of your airlock. 2. Approximate date of purchase. 3. Nature of problem(s). 4. Name and phone number of person to be contacted by Coy Lab Products with service instructions or return authorization. * The person who assists you at the factory might ask you if you have a new or old style airlock. A new style airlock emits a high frequency tone when the airlock is turned on, an old style airlock does not. 2. DO NOT 1. Attempt to repair unit with power applied. Before trying to make any repairs disconnect the power cord. 2. Return the automatic airlock or parts until a return is authorized. WARNING!! HAZARDOUS VOLTAGES ARE PRESENT WHEN THE AIRLOCK COVER IS REMOVED