Vinyl Anaerobic Airlock Chamber Instruction ... - Wolf Laboratories

______________________________________________________________
14500 Coy Drive, Grass Lake, Michigan 49240
734-475-2200 E-mail: sales@coylab.com
www.coylab.com
Vinyl Anaerobic
Airlock Chamber
Instruction Manual

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 2000
3. 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
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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: 734-475-2200
FAX: 734-475-1846
COY LABORATORY PRODUCTS, INC.
14500 COY DRIVE, GRASS LAKE, MICHIGAN 49240
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.
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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)
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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 2.2.1
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Figure #3 Standard Equipment Layout
6
7
Figure # 3 Legend
1. 6 Outlet Plug Strip
2. Work Pad
3. Padded Base
4. Airlock
5
8
2
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.
1
5
4
3
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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)
1.5.1
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AUTOMATIC AIRLOCK SET-UP
FIGURE 1 AUTOMATIC AIRLOCK REAR VIEW
FIGURE #1 LEGEND
1. 15 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.
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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
1.6.1 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
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emove 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 24-48 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 # 6200000) to monitor your Chambers hydrogen content as well.
1.7 AUTOMATIC AIRLOCK (MANUAL MODE)
1.7.1 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 2.13. 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.
1.7.2 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 1.4.1. Release the
switch.
4. Depress and hold the nitrogen toggle switch (3) for the time listed under Cycle #1 Background in section 1.4.1. 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 1.4.1.
Release the switch.
7. Depress and hold the gas mix toggle switch (4) for the time listed under Cycle #3 Gas Mix in section 1.4.1. Release the
switch.
8. The airlock is under anaerobic conditions; the inside door may be opened.
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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.
Start-Mmode
Dn-Conf. 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.
1.8.1 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)
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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 is the Analog to Digital reading
YYYYY is the sum of the total samples taken
AA is the number of samples taken
After the zero is calculated the controller exits the Configuration menu.
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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.
1.8.4 Exit Menu (Menu-Exit)
Takes you out of the menu listing mode.
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1.9 AUTOMATIC OPERATION
1.9.1 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
PH. (734) 475-2200 EMAIL: SALES@COYLAB.COM WEB: WWW.COYLAB.COM
START
MENU
ENTER
WARNING: DO NOT USE PURE HYDROGEN. EXPLOSIVE
POTENTIAL EXISTS, USE ONY NON - FLAMMABE GAS MIX
1.9.2 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.
1.9.3 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.
1.9.4 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 3.2.1 for running a profile.
OFF ON
1.9.5 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.
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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.
2.5.1 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.
- 13 -

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.. Now remove the center screw on the front panel and remove the entire panel from the airlock.
J.. 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.
- 14 -

4.0 OPERATION OF MANUAL AIRLOCK
1. All instructions refer to Figure 4 except at noted. See Paragraph 1.6.1 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 6.1.6.
7. The Airlock is under anaerobic conditions; the inside door may now be opened.
FIGURE 4 MANUAL AIRLOCK FRONT VIEW
Gas Inlet Ball Valves
Gauge
5.0 AIRLOCK MAINTENANCE
Gas
Mix
Off
Gr ass Lake, MI www. coylab. com
BG
(N2)
15
20
10
25
30
ZERO
5
CLOSED
6. Vacuum Ball Valve
MANUAL VACUUM
BALL VALVE
OPEN
TOP VIEW
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.
- 15 -

5.1 FIGURE 5 MANUAL AIRLOCKFRONT
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
17
Front
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.
- 16 -

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.
- 17 -

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.
- 18 -

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.
- 19 -

OLD STYLE DOORS
5.9 FIGURE 5 DOOR FAME & LOCK MECHANISM
5.9 LEGEND
18. HINGE BOLT 31. MAGNETIC SWITCH MOUNTING SCREW
19. HINGE PIN LOCK NUT 32. WASHER/SPACER
20. LOCK MECHANISM SCREW 33. HINGE PIN BOLT
21. LOCK MECHANISM BOLT 34. HINGE BOLT LOCK NUT
22. DOOR FRAME MOUNTING SCREW 35. MAGNETIC SWITCH
23. LONG SIDE PLATE 36. DOOR HANDLE
24. DOOR CAM 37. DOOR CENTER BUTTON
25. DOOR CAM SETSCREW 38. CARRIER BLOCK
26. ACRYLIC DOOR 39. LOCKING MECHANISM BOLT SPRING
27. BLACK RUBBER DOOR SEAL 40. SHORT SIDE PLATE
28. CATCH PIN 41. DOUBLE SIDED TAPE
29. MAGENT 42. CATCH PIN SCREW
30. DOOR FRAME 43. PLASTIC KNOB
- 20 -

6.0 FIGURE 6 VACUUM PUMP DIAGRAM
Ref No. Description Qty. 0823-101Q
1. Body 1 AK517
2. Vane 4 AK513
3. Shroud 1 AK511
4. End Plate 1 AK514
5. Gasket 1 AK522
6. Muffler Box 1 AK520
7. O-ring 2 AK473
8. Felt 2 AK524
9. End Cap 2 AK510
10. End Cap Assembly 2 AK526
11. Filter/Muffler 1 AK840
12. Elbow 1
13. Nipple 2
Service Kit 1
Items 12 & 13 not include with this pump model.
6.1 OPERATION OF COMPONENTS
This section will briefly describe the operation of both standard and optional equipment that may have been supplied with your
Chamber. Standard Equipment are items included in the Chamber package.
Such as:
1. PLUG STRIP
2. CATALYST BOXES (HEATED/UNHEATED)
3. GAS LEAK DETECTOR
4. GAS PRESSURE REGULATORS
5. CATALYST STAK PAKS
6. MANUAL AIRLOCK
7. AUTOMATIC AIRLOCK
8. UTILITY NIPPLES w/RUBBER STOPPER
- 21 -

`Optional equipment are items not included in the Chamber package, but must be specified Such as:
1. MODEL 10 OXYGEN/HYDROGEN ANALYZER
2. MODEL 2000 INCUBATOR
3. INCANDESCENT FLAMING DEVICE
4. POP LOCK
5. STAK PAK, DESICCANT OR EMPTY
6. ATMOSPHERE FILTER
7. INTERIOR SHELVES
NOTE! The Oxygen/Hydrogen Analyzer, Incubator, Automatic and Manual Airlocks, have their own instruction manual detailing
their operation. Operation procedures are only briefly described here for convenience.
6.2 STANDARD EQUIPMENT
1. RECEPTACLE PLUG STRIP
The 6 receptacle plug strip supplies proper voltage to the Chamber interior. Six receptacles are used for continuously operating
equipment, such as Catalyst Boxes, Incubator, Gas Analyzer and miscellaneous lab equipment you may wish to provide. The Plug
Strip is sealed into the Vinyl Chamber wall through the Large Utility Nipple with the appropriate size rubber stopper installed on the
Plug Strip Cord from the factory.
2 CATALYST BOXES (HEATED/UNHEATED)
Catalyst Boxes circulate the Chamber's atmosphere through palladium catalyst, which, in the presence of hydrogen, removes
oxygen. The Catalyst Boxes perform other functions as well, such as provide a homogeneous mix of gases and temperature gradient
within Heated Chambers. If your Chamber is equipped with 1 Catalyst Box, it should be placed near the airlock with the fan cage
facing the center of the Chamber. If the Chamber has 2 Catalyst Boxes, they should be placed at opposite ends of the Chamber
with the fan cages facing toward the center of the Chamber. The Catalyst Boxes' efficiency decreases if the fan cage faces the wall
of the Chamber disrupting proper air flow. See figure 2 for proper Catalyst Box placement.
Note: On Type C Chambers (36”/91 cm Length) with Incubator option the Catalyst Box can be placed on top of the Incubator or on
the front side opposite the airlock.
The Catalyst Boxes are not equipped with cooling devices and cannot control the Chamber below room temperature. Following are
operating procedures for the heated and unheated Catalyst Boxes.
2A. HEATED CATALYST BOXES
The heated Catalyst Box consists of a power switch, 2 heating cones, and a variable controlled thermostat. The Heated Catalyst Box
can maintain the Chamber's temperature from ambient to about 40° Celsius (note optional High Range ability available up to 65°
C). Before operating the Catalyst Box, remove the heat shield, screw the heating cones into their sockets, and replace the heat shield.
When the Catalyst Box is plugged in to a suitable outlet, the fan will turn on and the controller display will light up showing the
ambient temperature. The thermostat will control the temperature by turning the heat cones "on" and "off". When the cones are
"on", a dot appears to the left of the temperature reading. The fan runs continuously while the power switch is "on" regardless of
temperature setting. The Sensor can be placed wherever the temperature is most critical.
2B. UNHEATED CATALYST BOX:
The unheated Catalyst Box consists of a fan that circulates the Chamber's atmosphere through palladium Catalyst to remove oxygen
and provide a homogeneous mixture of gases. When the unheated Catalyst Box is plugged into a suitable outlet, the fan will
immediately turn on and run continuously; there is no "On/Off" switch. The unheated Catalyst Box is not equipped with heating
devices, so it cannot control the Chambers temperature. As with the heated Catalyst Box, placement within the Chamber is
important. Position the Unheated Catalyst Box as described in 1.6.2.2. and see Fig. 2 (Sec 5).
3. GAS LEAK DETECTOR
- 22 -

The Gas Leak Detector senses hydrocarbons (hydrogen gas mix) and will detect leaks as small as a pin hole in the Anaerobic
Chamber. To operate the Gas Leak Detector, pull the black knob up to turn the unit on and listen for a fast, high frequency beeping
tone. Let the Gas Leak Detector warm up for 5 minutes on the maximum setting. After 5 minutes turn the setting down towards the
minimum setting, at which time the beeping tone will slow down. Rotating the black knob varies the speed of the beeping tone.
To detect leaks, turn the black knob so that the beeping tone is the slowest. Then turn the knob in the opposite direction so the
beeping tone is on the verge of speeding up. Now you are ready to detect leaks. The Gas Leak Detector is energized by a single size
"D" battery. Periodically you will have to replace the battery. To do this, remove 4 slotted screws securing the front panel. The
"D" battery is accessible for replacement.
4. GAS PRESSURE REGULATORS
Gas Pressure Regulators decrease the pressure exiting from you gas supply (primary pressure) to a pressure suitable for the Airlock
(secondary pressure). For each type of Airlock (manual and automatic) the secondary pressure must not exceed 60 psi
(4.2Kg/sq.cm). If the tanks are within approximately 10 feet (3 meter) of the airlock, 20 psi (1.4 Kg/sq.cm) is adequate for gas
lines supplied with your regulators. If you extend the gas lines, you may need to set the regulators higher than 20 psi (1.4 Kg/sq.
cm) to produce the same flow of gas. Both nitrogen and gas mix have their own Pressure Regulators. One end of the Gas Regulator
attaches directly to the supply tank. The nitrogen gas regulator has a male threaded coupler, and the gas mix regulator has a female
threaded coupler. The other end of the Gas Pressure Regulators are attached to copper tubing. At the other end of the copper tubing
is a Swage-lok fitting which screws into the airlock. The Gas Pressure Regulators are configured differently for the manual and
automatic airlock. Please see Airlock Manual for proper connections. Once the Gas Regulators are installed, slowly open the
supply tanks. The primary pressure gauge will now display the amount of gas remaining in the tank. Turn the pressure gauge valve
to regulate the gas flow to the airlock (secondary pressure gauge) to read 20 psi (1.4 Kg/sq. cm).
Figure #6 Gas Regulators
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
5. CATALYST STAK-PAK
The wire mesh container for the catalyst is called a stak-pak. Multiple units may be staked on top of each other (see
below) but the only Stak-Paks equipped with the anaerobic chambers are the ones filled with catalyst. The Catalyst works
with the hydrogen gas to remove oxygen (see section 2.0 Theory of Design). The catalyst will need to be regenerated at
least once a week. To regenerate place in an oven at 125-200 ° C for two hours. Included in the Chamber package are 2
sets of Catalyst Stak-Pak. Replace the Catalyst you rejuvenate with the extra set. Then your Chamber will always have
fresh Catalyst. If you have an extremely busy Chamber, you may need to rejuvenate the Catalyst more frequently.
- 23 -

Figure #7 Catalyst Stak-Pak
8. UTILITY NIPPLE w/RUBBER STOPPER
Utility Nipples provide an access point for cords, tubing and computer cable to be passed in/out of the glove box in an
airtight manner. Standard vinyl chambers are equipped with 2 Utility nipples mounted on the opposite side of the
chamber from the airlock on the lower rear of that side panel.
The Larger Nipple is used for the 6 Outlet Plug Strip and sealed around the cord at the factory. Extra Nipples may have
been purchased and are placed in locations specified on the order.
For modifying a utility nipple to fit around a cord/tubing use the following instructions.
1. Measure the cord diameter being passed through the glove box wall.
2. Mark the center of the rubber stopper.
3. See a drill bit slightly smaller in diameter then the cord diameter and drill a hole in the rubber stopper.
NOTE: The Rubber Stopper will get hot when drilling the hole.
4. Use a sharp Knife to cut the rubber stopper as shown on Figure #8
Figure # 8 Rubber Stopper
Pre Drilled Hole
Top View Side View
Note the Angle of the cut
5. “Peel open” the rubber stopper and place a small amount of silicone in the drilled hole.
NOTE: window a door silicone, available at most hardware stores is recommended.
6. Place the cord into the hole, careful to position the cord to the ideal length inside and outside of the glove box.
Squeeze the rubber stopper over the cord and clean up the excess silicone with alcohol and paper towels.
7. Place the Rubber Feed-Thru with the cord into the Feed-Thru Adaptor Body (Figure #9)
- 25 -

7.0 OPTIONAL EQUIPMENT
1. OXYGEN/HYDROGEN ANALYZER
Coy Labs Oxygen/Hydrogen Analyzer is designed to monitor the oxygen/hydrogen content inside an Anaerobic
Chamber. It has two independent digital readouts that display oxygen in parts per million (ppm) and hydrogen in percent.
To operate the Analyzer simply plug it into a suitable outlet (plug strip) and allow 3 hours for it to stabilize. After 3
hours, it will correctly display the oxygen and hydrogen content inside the Chamber.
The Analyzer has two separate alarms; one for the oxygen channel and one for the hydrogen channel. The oxygen alarm
is user adjustable (preset at the factory to 300 ppm) by simultaneously depressing the "ALARM CONTROL" switch and
rotating the "ALARM SET" pot with a small screwdriver. If the oxygen content inside the Chamber exceeds the preset
value, an audible and visual alarm will indicate“high” oxygen content.
The hydrogen alarm is not user adjustable; it is preset at the factory to 1% for low hydrogen condition and 10% for high
hydrogen condition. As with the oxygen channel, the hydrogen channel also has an audible and visual alarm. If the
hydrogen content goes below 1% or above 10%, the alarms will indicate a problem.
NOTE: The Model 10 Gas Analyzer does not function without Hydrogen Gas so to prevent problems do not allow the H2
readings to drop below 1%.
CAUTION. Gas mixes containing more than 4% hydrogen may be flammable.
2. MODEL 2000 INCUBATOR
The Coy Model 2000 Incubator consists of 3 heating cones, temperature controlling printed circuit board, temperature
sensor, and a fan to circulate air inside the Incubator. To operate the Incubator, plug it into a suitable outlet and turn the
"POWER" switch on. The digital readout will display the temperature inside the Incubator in degrees Celsius. To adjust
the temperature, simultaneously depress and hold the "DISPLAY CONTROL" switch to the "SETPOINT
TEMPERATURE" position and rotate the "SETPOINT CONTROL" knob until the desired temperature is shown on the
display. After the desired temperature is reached, release the "DISPLAY CONTROL" switch. After the Incubator has
stabilized, it will automatically control the temperature. The device that senses the Incubators internal temperature
(temperature sensor) is located inside the Incubator on the rear wall. The temperature sensor should not be blocked by
miscellaneous items, as a clear air path should exist from the fan to the temperature sensor.
3. INCANDESCENT FLAMING DEVICE (IFD)
If ordered with a vinyl anaerobic chamber a separate Utility Nipple will be provided for the IFD’s Footswitch. If adding
the IFD to an existing Chamber you will have to use one of the utility nipples equipped standard with the chamber. The
rubber stopper for sealing the Utility Nipple is installed on the footswitch cord. The power cord is plugged into any
available outlet on the chamber interior.
Every time the foot switch is depressed the IFD turns on, and in a few seconds the "Nichrome" wire loop will turn bright
red. To flame a bacteria loop, simply insert the loop into the hot wire coil and withdraw it slowly. When the foot switch
is released, the IFD will turn off. The IFD is designed to operate on an intermittent basis only, IT SHOULD NEVER BE
LEFT UNATTENDED WHILE IN OPERATION.
Periodically, you will have to replace the "Nichrome" wire loop (COY Part #. To do this, unscrew two terminals holding
- 26 -

the old "Nichrome” wire loop. Then, insert the new "Nichrome" wire loop and tighten the terminals. You may have to
spread the leads on the new loop to achieve a satisfactory fit.
5. STAK PAK
Stak-Paks are constructed of a clear anodized aluminum frame and stainless steel screen. Their purpose is to provide
users flexibility when adding chemicals to the chamber in order to produce a controlled environment. Typically, if the
Stak-Pak contains palladium catalyst, it will be seated horizontally on the Catalyst Box. If more than 3 Stak-Paks are
required, they should rest vertically on the Catalyst Box. Up to 6 Stak-Paks can be vertically installed in a Catalyst Box.
NOTE: Both heated and unheated Catalyst Boxes can accept Stak-Paks mounted vertically. Examples of chemicals the
user can place in a Stak-Pak are:
1. ADDITIONAL PALLADIUM CATALYST
2. DESICCANT
3. ACTIVATED CHARCOAL
Aluminum and stainless steel construction allows the user to elevate rejuvenation temperature and decrease rejuvenation
time.
6. RECIRCULATING ATMOSPHERE FILTER
The Atmosphere Filter consists of a filter housing, small vacuum pump and tubing. The atmosphere is circulated through
the pump then through the filter and back into the
chamber. This removes 99.9% of airborne contamination with a size of 0.3 micron or larger. The pump cycles 30 cu. ft.
per hour. Depending on the contamination present you may have to run the filter 2-3 times a week or just a few times a
month.
7. GAS INJECTION SYSTEM
Consisting of small, internal vacuum pump, solenoid valve and 3 timers, the Gas Injection System is designed to maintain
a constant level of hydrogen gas mix in your anaerobic system. The timers allow the user to fully adjust how often the
gas mix (H2 5%) is purged into the system and for how long. As each anaerobic chamber has different usage levels this
item allows for those adjustments.
HINT: If used with a Model 10 Gas Analyzer you can quickly judge to most economical settings for your chamber by
manually timing your weekly purge operations and choosing settings according to those times, the unit may require slight
adjustment if work load increases or decreases significantly.
8. INTERIOR SHELVES
Aluminum anodized Shelves with three adjustable shelves must be assembled outside of the chamber and are designed to
fit through the standard Large Equipment Opening. Capacity is 500 lbs evenly distributed.
8.0 THEORY OF DESIGN
1 PALLADIUM CATALYST/GAS REACTION
- 27 -

2. The following is an explanation of how the catalyst and gases react to remove oxygen so an anaerobic condition
may be retained.
3. The catalyst is constructed of alumina and coated with a thin layer of palladium chloride. The main purpose of
the catalyst is to provide a meeting ground for oxygen and hydrogen. Water is formed when oxygen and hydrogen meet
in the presence of palladium chloride. The alumina in the catalyst absorbs the water which is driven off during catalyst
rejuvenation.
4. During normal operation, oxygen continuously enters the Chamber by diffusion and other means. Without the
presence of hydrogen, the catalyst will not remove oxygen. Hydrogen, unfortunately, cannot enter the chamber by itself;
you must introduce it into the chamber. You can introduce hydrogen into the chamber in 3 ways:
A. Manually vacuum the chamber about half way and fill it with gas mix. This will allow hydrogen to enter the
chambers atmosphere. Coy recommends performing this procedure once a week if you do not use the chamber on a
routine basis.
B. Using the airlock to enter the chamber on a day to day basis allows hydrogen from the gas mix to enter the
chamber when you open the airlocks inside door.
C. Using the COY Gas Injection System (ordered separately). See Section 1.7 (Optional Equipment).
Depending on how often you use the Chamber, both methods help to ensure the chamber has hydrogen. However,
hydrogen concentration in your chamber will be diluted depending upon the volume of your Chamber. (See Section
2.2.2 following)
Heat is generated by the catalyst when an abundance of oxygen and hydrogen combine. This is apparent when the chamber
is initially purged. If a rich amount of oxygen and hydrogen are present, the catalyst, if spilled, will generate heat and
possibly melt the Chamber PVC. If the correct guidelines are followed when you purge the chamber, the catalyst will
only feel warm to the touch.
8.1 OXYGEN ENTERING THROUGH AIRLOCK
Regardless of how many times the airlock is cycled, there will always be a small amount of oxygen entering the
chamber. Removing oxygen is the catalyst's job. This amount differs, depending on the volumetric size of your chamber.
When the airlock's inside door is opened, the gases from the airlock will start to mix with gases in the chamber. Coy has
found that gases from the airlock flow out of the airlock and across the chamber floor. If oxygen is present in the gases, it
will flow across the chamber floor until it reaches the catalyst, at which time it will be removed (providing you have fresh
catalyst and hydrogen present). Because the oxygen concentration is higher in the airlock than in the Chamber, an oxygen
gradient is created. Oxygen levels are greatest at the airlock door and become progressively less as the distance from the
door increases.
This is an important concept to remember when placing your Gas Analyzer and Catalyst Fan Box (see section 1.4
Component Placement)
- 28 -

8.2 AUTOMATIC AIRLOCK
One complete cycle consist of vacuuming the airlock 3 times to 21" of mercury and backfilling it twice with nitrogen and
once with gas mix. At the end of one complete cycle, ambient oxygen (209,000 ppm) will be diluted to 7,639 ppm. To
determine the amount of oxygen that will enter your chamber, a dilution factor must be established between the airlock
and your chamber. To do this, divide the airlock's volume (2,868 cu. in.) by the chamber's volume. The dilution factor
for Coy's standard type "A", "B", or "C" chamber are as follows:
TYPE DILUTION FACTOR
"A" .034
"B" .026
"C" .056
To calculate the amount of oxygen that will enter your chamber, multiply the amount of oxygen remaining in the airlock
after one complete cycle (7,639) by the dilution factor of the chamber. The calculated values are as follows:
TYPE AMOUNT OF OXYGEN
"A" 260 ppm
"B" 199 ppm
"C" 427 ppm
- 29 -

8.3 MANUAL AIRLOCK
Gas
Mix
Off
Grass Lake, MI www.coyl ab.com
BG
(N2)
CLOSED
MANUAL VACUUM
BALL VALVE
OPEN
TOP VIEW
Before operating the Manual Airlock, you must determine to what level your vacuum pump will go. The COY vacuum
pump will go to a maximum of approximately 24 inch of mercury, and will require 3 cycles NOTE: Automatic cycles
only go to 20 inches of mercury and all test data below is based off of this figure. You may have your own pump with a
capability of 29 inch of mercury, and this will need only 2 cycles. At the end of this cycle, ambient oxygen (209,000 ppm)
will be diluted to 6,270 ppm. To determine the amount of oxygen that will enter your chamber, a dilution factor must be
established. Since the manual airlock shares the same physical size as the automatic airlock, the dilution factors will
remain constant. To calculate the amount of oxygen that will enter the chamber, you multiply the amount of oxygen
remaining in the airlock by the dilution factor. The amount of oxygen entering a standard Coy Chamber is as follows:
TYPE AMOUNT OF OXYGEN
"A" 213 ppm
"B" 163 ppm
"C" 351 ppm
The oxygen levels derived for the chamber using both types of airlock is a net oxygen level based on the assumption that
all the gas from the airlock is homogeneously mixed with the gases in the chamber. These calculations used the volumes
of the sleeves and expanded chamber as if it were normally inflated. If the airlock has been cycled correctly, the chamber
is at 0 oxygen level, and the catalyst has been removed, the chamber will attain an oxygen level of that calculated above.
When the airlock's inside door is opened, the gases from the airlock will start to mix with gases in the chamber. Coy has
found that gases from the airlock flow out of the airlock and across the chamber floor. If oxygen is present in the gases, it
will flow across the chamber floor until it reaches a catalyst box, at which time it will be removed (providing you have
fresh catalyst and a small amount of hydrogen). Because the oxygen concentration is higher in the airlock than that in the
chamber, an oxygen gradient will be created. Oxygen levels will be greatest at the airlock door and become progressively
less as the distance from the door increases.
8.4 MOISTURE
This section will discusses how moisture can enter the chamber, and how it can be controlled.
1. ENTERING MOISTURE
Moisture can enter the chamber in several ways:
1. GAS SUPPLY TANKS (NITROGEN/GAS MIX)
2. AMBIENT MOISTURE IN THE AIRLOCK
3. MOISTURE PRODUCING MATERIAL IN THE CHAMBER
4. MIGRATION THROUGH THE CHAMBER WALLS
5. HUMIDITY CAUSED BY BEING LOCATED IMMEDIATELY
BELOW AN AIR CONDITIONING UNIT
- 30 -

8.5 CONTROLLING MOISTURE
Moisture may be controlled in the chamber using alumina desiccant. For the best control, provide as much desiccant
surface area as possible to the chambers atmosphere. Placing desiccant horizontally on a catalyst box does not meet this
requirement since airflow is restricted. The Stak-Pak may be placed on their edge, vertically in the catalyst box. The
Stak-Pak is designed to allow up to 3 units to be stacked horizontally see figure # 6 units to be stacked in the vertical
position. Mounting the Stak-Pak vertically allows the catalyst box to expose the maximum amount of chamber
atmosphere to the desiccant, while minimizing airflow restriction. The use of Stak-Paks can be extended to palladium
catalyst or a combination of each (catalyst and desiccant). Coy has found that moisture can be controlled to less than 20%
for 2 days in a type "B" chamber, with 2 catalyst boxes, using 6 Stak-Paks (3 in each catalyst box) containing alumina
desiccant. With 2 sets of Stak-paks, moisture can be continuously controlled. As the desiccant absorbs moisture, its
pores become saturated with water vapor and must be rejuvenated. Alumina desiccant contained in Stak-Paks can be
rejuvenated at 125-200 ° Celsius for 2 hours.
Below is an illustration of how desiccant stak-paks should be mounted on catalyst stak-paks for the efficient
removal of moisture.
Screw
Nut
Screw
Hole
9.0 CARE AND MAINTENANCE
PRECAUTIONS
Stak-paks
Here are several precautions you can take to prolong the life of your chamber. Precautions you should carefully follow
are:
1. DO NOT SET EQUIPMENT WITH SHARP EDGES ON THE CHAMBER
FLOOR. ONLY SHELVING UNITS AND INCUBATORS SUPPLIED BY COY SHOULD BE PLACED ON
CHAMBER FLOOR.
2. ALWAYS KEEP SMALL INSTRUMENTS AND SHARP OBJECTS ON THE WORK MATS. IF YOU
DON'T, THEY MAY GET LOST UNDER THE WORK MATS AND PUNCTURE THE PVC.
3. KEEP EQUIPMENT AND SHELVING UNITS WITHIN EASY REACH SO YOU DO NOT STRETCH THE
CHAMBER SLEEVES.
4. RINGS AND JEWELRY SHOULD BE REMOVED PRIOR TO USING.
Spacer
- 31 -

9.1 CLEANING THE PVC
Any commercially available cleaner recommended for polyvinyl chloride (PVC) will be sufficient for cleaning dust, dirt
and grease off the chamber and restoring its optical clarity. Coy Lab. Products uses "PLASTIC CLEANER MAGIC" (pt.
no. 1600-480). It is also available at hardware stores or super markets. You should avoid cleaning the chamber with
products containing ketones or other compounds that will damage PVC. If you need to sanitize the chamber, see question
#9 (Sec 3.3).
9.2 DETECTING LEAKS
1. Using the Gas Leak Detector supplied soak a rag in alcohol. Place the rag on the inside of the glove box. The
alcohol is necessary as the gas leak detector only picks up hydrocarbons present in the alcohol.
2. With the inside door open inflate the chamber until the arms become extended. This stretches the vinyl and
makes it easier to find small leaks.
3. Turn the Gas Leak Detector on and turn the sensitivity to the highest level and allow it to “warm” for 5-10
minutes. After the “warm-up” period turn the sensitivity down to the lowest point. If the “beeping” slows down then the
Leak Detector is ready.
4. Turn the sensitivity up slightly so that you can audibly hear an increase in the beeping.
5. Now begin to go slowly over the entire glove box. Pay special attention to all the seals and seams, especially
around the sleeves and gloves.
NOTE: The interior of the sleeves and gloves will indicate a slight increase in the beeping. This may or may not
be a leak as the gloves are more a the most porous material on the glove bag, thus the slight increase in the beeping
noise. A true leak in this area will have a large increase in the beeping noise. Call your local COY representative or the
factory if you are unsure.
6. The gloves can easily be checked for leaks by simply pouring water into them. If water drips into the interior of
the glove box then the glove should be replaced.
9.3 HOW TO PATCH PUNCTURE AND TEARS
Punctures and tears can be easily patched using the vinyl repair kit found in your chamber care kit. Before attempting to
repair chamber leaks, release the pressure on the chamber by manually vacuuming it until gloves sag. If the leak is small,
directly apply the liquid vinyl repair to the hole and surrounding area. Let it cure for about an hour and reapply. If the
leak is large , cut a patch out of the extra vinyl supplied with the vinyl repair kit. Generously spread the liquid vinyl
repair around the hole and apply the patch. You may have to temporarily hold the patch in place while the liquid vinyl
repair is curing. In about an hour, apply the liquid vinyl repair to the edges of the patch, sealing the patch and PVC
together.
After leaks are repaired, check them with your gas leak detector to verify correct repair. NOTE: SINCE LIQUID
VINYL REPAIR CONTAINS HYDROCARBONS, WHICH ACTIVATE THE DETECTOR, IT MUST BE FULLY
CURED BEFORE VERIFYING CORRECT REPAIR. The liquid vinyl repair works on the principle of softening the
vinyl. When the vinyl is soft, it adheres to itself thus eliminating the leak.
9.4 CARE OF GLOVES
PRECAUTIONS
The gloves are made of neoprene rubber and are susceptible to punctures and tears. Wear cotton gloves when working
with sharp objects. Remove jewelry. If a hole is punctured in the glove, it must be replaced.
- 32 -

9.5 DETECTING LEAKS
Most of the leaks found in the chamber will occur in the gloves. Leaks can be detected in the gloves by using the gas leak
detector or by hanging it with the fingers outstretched and pouring water into it.
9.6 REPLACING A DAMAGED GLOVE
Damaged gloves may be replaced without losing the anaerobic atmosphere using the following instructions.
1. Obtain the extra glove and cuff, supplied with your chamber care kit. COY suggests the use of double sided tape
to hold the new glove onto the white cuff. A strip of the tape around the wide end of the cuff, and the glove stretched
over it will hold the glove in place. Insert new glove with cuff into the sleeve.
2. After the new glove is inserted, plug the sleeve with a large jar or flask.
3. Working in the chamber through another glove, remove the yellow tape holding the damaged glove in place.
Now, pull the damaged glove and cuff into the chamber.
4. Reach in the sleeve and pull the new glove with cuff into place. Once the glove is pulled into place and
orientated, seal it with yellow tape. When you tape the new glove, make sure the tape is flat and wrinkle free, stretching
the tape when you seal the new glove in place will help you eliminate wrinkles.
10.0 ANSWERS TO QUESTIONS FREQUENTLY ASKED ABOUT THE CHAMBER
This section is intended to answer questions you may have about the Chamber. If you have questions about the Chamber
that are not discussed, please consult the factory.
Q1. HOW MUCH GAS CAN I ANTICIPATE USING WHEN I OPERATE THE CHAMBER ON A
ROUTINE BASIS?
A. This is a difficult question that does not have an exact answer. The exact answer will depend on how many times you
enter the Chamber through the airlock. On an average, suppose you entered the Chamber 5 times a day and were using
"K" size supply tanks (304 cubic feet) for nitrogen gas and "A" size supply tanks (230 cubic feet) for the gas mix. If you
have an automatic Airlock, your nitrogen gas will last approximately 47 days and your gas mix will last approximately 72
days. These figures assume you are vacuuming the Airlock to 20 inches (0.69 Kg/sq. cm) of mercury. If you have a
manual Airlock, your gas mix will last approximately 25 days, assuming you vacuum the Airlock to 29 inches (1 Kg/sq.
cm) of mercury. These figures are calculated for Airlock use only. They do not include gas usage during Chamber
purges.
Test show in a static environment (no airlock operation/transfer) the chambers will consume .2-.4% hydrogen per day.
Q2. HOW OFTEN, AT WHAT TEMPERATURE AND FOR HOW LONG DO I REJUVENATE MY
CATALYST?
A. Rejuvenating the Catalyst is very important in keeping the Chamber in an anaerobic condition. Rejuvenating the
Catalyst a minimum of once a week at 125-200 ° Celsius for two hours is recommended. Included in the Chamber
package are 2 sets of Catalyst Stak-Pak. Replace the Catalyst you rejuvenate with the extra set. Then your Chamber will
always have fresh Catalyst. If you have an extremely busy Chamber, you may need to rejuvenate the Catalyst more
frequently.
Q3. WHY DOES MY CHAMBER LOSE ITS ANAEROBIC CONDITION OVER A PERIOD OF
TIME?
A. There are a couple of variables that must be considered to answer this question. First, does your Chamber have a
leak (noted by the Chamber top collapsing over night)? Second, are the catalyst fresh, have they been rejuvenated? Once
these variables have been considered and eliminated from the probable cause, concentrate on the hydrogen content in
the Chamber. Deficient hydrogen content is usually the cause for losing anaerobic conditions in the Chamber. Oxygen is
- 33 -

constantly entering the Chamber by Airlock use and diffusion through the PVC walls. Without the hydrogen the catalyst
cannot react to remove the oxygen. If you do not regularly use the Chamber, once a week manually vacuum the
Chamber about half way and introduce gas mix (containing hydrogen) into the Chamber. You must keep in mind the
dilution factor when the gas mix enters the Chamber. If you are using a 10% hydrogen gas mix your Chamber will not
contain 10% hydrogen. It will be diluted to approximately 6% or 7% Hydrogen. (see section 2.0). Coy Labs
Oxygen/Hydrogen Analyzer can be used to display the amount of hydrogen in percent that is present in your Chamber.
Also, the Analyzer has an alarm that indicates when the hydrogen content goes below 1%. If you have exhausted every
probable cause and your Chamber still loses its anaerobic condition, test your gas mix for hydrogen content. We have
seen and heard of gas companies that do not comply with customer specifications.
Q4. HOW DO I KNOW MY CATALYST IS WORKING AND HOW OFTEN SHOULD I
REPLACE IT?
A. A good test to determine if your catalyst is working is to place a tray containing catalyst inside the Airlock.
Place a thermometer in direct contact with the catalyst. Then manually vacuum the Airlock (manual or automatic) to 25"
(0.53 Kg/sq. cm) of mercury and back fill it with gas mix containing hydrogen. If the catalyst is working correctly, the
temperature will increase due to the reaction of catalyst, oxygen, and hydrogen. Temperature will increase about 10
degrees Celsius over 10 to 15 minutes. Coy recommends catalyst replacement on a yearly basis or if the catalyst does not
respond to the above test.
Q5. WHERE DO MOST LEAKS OCCUR IN THE ANAEROBIC CHAMBER?
A. Leaks can occur anywhere in the Chamber but most will be present around work areas. Before you begin leak
detection, you must first make sure the Chamber contains your normal amount of pre-mixed gas. A towel saturated with
isopropyl alcohol, and allowed to sit in the Chamber for a few minutes, will assist in detecting the very small (slow) leaks.
With your gas leak detector, check the following areas first:
1. GLOVES AND CUFFS
2. ALONG CHAMBER SLEEVES
3. UNDER WORK PAD
4. AROUND AIRLOCK SEALS
5. ALL CORNERS OF THE CHAMBER
6. AROUND CHAMBER SEAMS
Don't be alarmed if the beeping tone increases around your neoprene rubber gloves. Neoprene rubber has larger pores
than PVC so gases diffuse through it faster. Around the gloves, lower the detector sensitivity since the faster diffusion
rate will give the appearance of a leak.
Q6. WHAT WILL THE HYDROGEN SULFIDE PRODUCED BY SULFUR BACTERIA DO TO
THE CHAMBER AND HOW CAN I CONTROL IT?
A. It is important to control hydrogen sulfide in the Chamber because it attacks certain metals and can "poison"
catalyst. It also accelerates the discoloring of the PVC over time. Hydrogen sulfide is especially detrimental to the
oxygen and hydrogen sensors in the Gas Analyzer, and to printed circuit boards in incubators and heated catalyst boxes.
These printed circuit boards are coated with a protective substance, but hydrogen sulfide will attack any exposed metal
and will, with time, creep under the coating, thus attacking the metal on the boards. The time taken to affect the metal
will depend on the concentration of hydrogen sulfide and the humidity level.
To control hydrogen sulfide within the chamber, use one of the following methods:
1. ACTIVATED CHARCOAL
2. LEAD ACETATE
3. SILVER CHLORIDE
4. SILVER SULFATE
For chemicals 2 through 4 the sulfur will bind with the metal forming an insoluble precipitate leaving acetic acid (2 &
3) or sulfuric acid (4) as the byproduct. The activated charcoal will adsorb the hydrogen sulfide molecule. However,
- 34 -

we generally DO NOT recommend its use since the adsorption is not specific to hydrogen sulfide, but is general to most
molecules in the Chamber. A specific procedure for the use of silver sulfate is as follows:
1. Bring 2 liters of distilled water to a boil.
2. Add 10g of silver sulfate (Ag2O4S) to the boiling water and allow it to dissolve. This will take 5-10 minutes.
3. After the solution has cooled to near room temperature, add 20 ml of 1 N-aqueous sulfuric acid (H2 So4). This
will inhibit the formation of carbonates in the solution.
4. Add 2 liters of Glycerol (Glycerin) and mix the solution thoroughly.
NOTE: Greater Success is achieved when the Silver Sulfate mix is bubbled with an aquarium pump. This circulates the
chamber atmosphere through the silver sulfate making the solution an active part of the chamber rather than passive.
The glycerol will inhibit evaporation. The solution can be used in the Chamber by bubbling the atmosphere through it or
by simply letting a beaker of it sit open in the Chamber. Add water to the vessel if necessary to maintain the initial
volume.
The silver sulfide formed is a black precipitate that serves as an indicator that your solution is removing Hydrogen Sulfide
from the atmosphere. Over time you will learn what your vessel looks like when all of the silver sulfate has been
converted to the precipitate. If you need to test the activity of your solution, you may use sodium sulfide. When put into
an active solution the black precipitate, silver sulfide, will form.
7. DOOR ADJUSTMENTS
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.
Q8. HOW DO I REMOVE THE INCUBATOR DRAWER FROM THE CHAMBER?
A. Removing the incubator drawer from the chamber can be accomplished 2 ways. The first, and most successful is
as follows:
1. With both airlock doors closed, cycle the airlock and tape a large plastic bag to the outside door frame. Make sure the
tape is as flat and wrinkle free as possible.
2. With the incubator drawer removed, open both doors of the airlock. Quickly transfer the incubator drawer through
the airlock doors into the plastic bag. After the incubator drawer has cleared the inside door, close it.
3. Reverse the procedure to install the incubator drawer except close the outside door as soon as the incubator drawer
clears.
The second method is to open both airlock doors, quickly slide the incubator drawer through and then close the inside
door as soon as the incubator drawer clears. Reverse procedure to install drawer.
- 35 -

Q9. WHAT KIND OF DISINFECTANT CAN I USE IN MY CHAMBER?
A. 1. Alcide Brand LD disinfectant has been reported to be satisfactory. It may be applied as a wipe or a spray.
Periodic rinsing is suggested with cold water. Available from:
Alcide Corporation
8561 154th Avenue NE
Redmond, WA 98052
Phone: (425) 882-2555
Fax: (425) 861-0173
E-mail: info@alcide.com
2. With proper care, Isopropyl Alcohol (I.P.A.) or a 1%-2% Clorox solution may also be used. Make sure all excess is
wiped off completely.
3. Peracetic acid may be used to sterilize the chamber.
Q10. HOW CAN I CONTROL THE MOISTURE IN MY CHAMBER?
A. Moisture is controlled in the chamber by using a desiccant. Coy sells ALUMINA desiccant in bulk or in the
Stak-Pak. ALUMINA can be rejuvenated in the same manner as catalyst. If you have severe moisture in your chamber,
something is drastically wrong.
Severe moisture can be caused by:
1. LEAK IN CHAMBER, CATALYST BURNING UP ALL AVAILABLE HYDROGEN, AND EMITTING
MOISTURE.
2. SOMETHING IN THE CHAMBER PRODUCING MOISTURE.
(Additional information on moisture control, can be found in section 2.3)
Q11. WHY DOES THE FUSE KEEP FAILING (BLOWING)?
A Usually the fuse will fail when there is a problem with the vacuum pump, which sometimes will also cause a
component (the triac) on the PC Board to fail. Check the pump first by unplugging it from the Airlock and plugging into
a wall outlet. If the pump works, the triac is most likely the problem and the PCB should be returned for repair. If the
pump will not work, use the following procedure. (Refer to the vacuum pump diagram for help).
1) Remove the two filter elements (8 & 9) from the front of the muffler box (6), and then carefully remove the five bolts
holding the muffler box in place. Tap the muffler box gently to loosen it for removal.
DO NOT PRY WITH A SCREWDRIVER AS THE GASKET WILL BE DAMAGED. DAMAGED GASKETS WILL
LEAK AND CAUSE A POOR VACUUM.
2) Remove the six bolts holding the end plate (4) to the body (1). Carefully remove the end plate to expose the carbon
vanes (2). Carefully remove the vanes from the rotor (*). If the vanes are stuck because of a rust deposit, very carefully
remove the rust so the vanes can be moved.
3) Wipe the body wall with an alcohol cloth to remove any accumulation of rust. Leave
the surface clean and dust free so that later the vanes will rotate freely and without damage. Replace damaged vanes.
4) Reverse this procedure to reassemble
5) To prevent future trouble, please consider installing the COY Moisture Trap Assembly (No. 7002-050)
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11.0 REPLACEMENT PARTS AND PART NUMBERS
Vinyl ONLY Anaerobic
Chamber Accessories
6100002 Incubator, Model 2000, High Temperature Range (up to 65 C) 110V
6100000 Incubator, Model 2000, Low Temperature Range (up to 40 C) 110V
6140000 Incubator, Wolfe (Anaerobic Incubator) 110V
7002050 Moisture Trap Assembly
6520007 Plug Strip (without footswitch)
6520000 Plug Strip (with footswitch)
6595000 Shelves, 28" (71 cm)
6596000 Shelves, 36" (91 cm)
7000080 Stainless Steel Pan, Specify Chamber Size A, B, or C
Vinyl ONLY Anaerobic
Chamber Replacement Parts
7001005 Base, Type A (77" x 36"/ 195 cm x 91 cm)
7090005 Base, Type B (96" x 36" / 244 cm x 91 cm)
7101005 Base, Type C (60" x 36"/152 cm x 91 cm)
1601430 Cuff, Plastic for Glove, Sleeve Assembly (pair)
7000010 Equipment Entry Port
7001002 Frame, Aluminum Support for Type A Chamber
7090002 Frame, Aluminum Support for Type B Chamber
7101002 Frame, Aluminum Support for Type C Chamber
7000053 Gas Leak Detector
1601426 Gloves--Large
1601423 Gloves--Medium
1601428 Gloves--x-Large
1600321 Tape, Double Sided (transfer) used to secure the gloves to plastic cuff
1600323 Tape, Filament, 20 mm wide
1600320 Tape, Yellow Vinyl
1600480 Vinyl Cleaner
7005020 Vinyl Repair Kit
7000060 Work Pad, Plastic
_____________________________________________________________
14500 Coy Drive, Grass Lake, Michigan 49240
Phone 734-475-2200, Fax 734-475-1846
E-mail: sales@coylab.com Web Site: www.coylab.com
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