Operatng Manual Bedenungsanletung UVvatec Lab GMP Lab Verson 3.4 Software verson 4.11 or hgher Montorng software verson 2.0 or hgher Verson 3.4 Ab Software-Verson 4.11 Ab Montorng-Software-Verson 2.0 85034-537-89 Vers. 05 2015
Table of Contents Englsh Page 2 Deutsch Sete 40 Notce of protected rghts The duplfcaton, dstrbuton and utlsaton of ths document as well as the communcaton of ts contents to others wthout expressed authorsaton s prohbted. Non-complance shall be subject to lablty for damages. All rghts reserved n the event of the grant of patent, utlty model or ornamental desgn regstraton. Trademark Mcrosoft Wndows and Mcrosoft Wndows Installer are trademarks of the Mcrosoft Corporaton. Other trademarks mentoned and dsplayed n the text are trademarks of the respectve owner and are protected as such. 1. Notes for the Operatng Manual 3 1.1 Ths operatng manual 3 2. For Your Safety 3 2.1 Product safety 3 2.1.1 Basc nformaton 3 2.1.2 Proper use 3 2.2 Structure of the safety notes 3 2.2.1 Level 1 safety notes (WARNING) 3 2.2.2 Level 2 safety notes (CAUTION) 4 2.3 General nformaton 4 3. Descrpton of the Unt 5 4. Gettng Started 8 4.1 Transport and nstallaton 8 4.2 Lamp Module nstallaton 8 4.3 Temperature control crcut 8 4.3.1 Connectng and fllng 8 4.3.2 Dranng the temperature control crcut 9 4.3.3 Cleanng the temperature control crcut 9 4.4 Mans connecton 9 4.5 Connectng an optonal GMP wrter 9 5. Operaton 10 5.1 Operaton and montorng 10 5.2 Sgnals and error messages 10 5.3 Start screen 10 5.4 Password 11 5.5 Man menu 13 5.5.1 Settng the date and system tme 13 5.6 Self-Test 14 5.7 Pump calbraton 15 5.7.1 Automatc flow control 16 5.8 Inactvaton 17 5.9 Cleanng 20 5.10 System data 22 5.10.1 Prnt out 22 5.10.2 Contrast 23 5.10.3 Touch calbraton 23 5.10.4 Change n nactvaton 23 5.10.5 To PC average value 23 5.10.6 Dagnoss 23 5.10.7 Password Management 24 5.10.8 UV Lamp 24 6. Mantenance 25 7. Correctng Operatng Errors 26 8. Message Texts 29 9. Techncal Data 29 10. Spare Part Lst 30 10.1 Electrcal parts as per the equpment dentfcaton code (EID) of the wrng dagram 30 10.2 Mechancal components 31 11. Montorng Software (Opton) 32 11.1 Applcaton area 32 11.2 Installaton 33 11.3 Startng the program 34 11.4 Overvew of functons 35 11.4.1 Menu commands symbols 35 11.4.2 Navgaton bar 37 11.5 Operatonal procedures 38 11.5.1 Recordng values from a procedure and savng the resultng data 38 11.5.2 Evaluatng a procedure at a later tme 39 12. Appendx 12.1 Wrng Dagram 74 12.2 Ppe and Instrument Dagram 77 2
1 Notes for the Operatng Manual 2 For Your Safety 1.1 Ths operatng manual supports the user when usng UVvatec Lab and UVvatec GMP Lab (called UVvatec Lab GMP Lab n the followng). Ths manual prncpally contans: rmaton about proper use rmaton about use Safety nformaton The operatng manual must be readly avalable n the vcnty of the unt for ts entre servce lfe. The operatng manual s part of the unt and must be passed on to every subsequent user or operator. Ths operatng manual s an orgnal operatng manual. 2.1 Product safety 2.1.1 Basc nformaton Frst read and understand then act Ths manual contans all nformaton requred to operate UVvatec Lab GMP Lab safely. Although UVvatec Lab GMP Lab s state-of-the-art and fulfls all safety regulatons, falure to follow ths manual could be hazardous. Ths means that every person nvolved wth the nstallaton, operaton or mantenance of the UVvatec Lab GMP Lab or the assocated components should have read and understood ths manual, partcularly the safety chapter. The operator must be nstructed n the proper work manner accordng to the applcable accdent preventon regulatons. Observe all safety notes n ths manual and the safety notes on the machne. The UVvatec Lab GMP Lab may only be operated when t s n perfect condton. Do not perform any structural changes to the unt snce they may lead to addtonal hazards, and safety measures may become noperable. 2.1.2 Proper use The UVvatec Lab GMP Lab treats lqud meda wth UV-C radaton. The unt may only be used n a laboratory envronment wthout purty level requrements. All other uses are consdered mproper. The manufacturer s not lable for damages whch may result from such use. The user or operator bears all rsk. 2.2 Structure of the safety notes Ths manual contans two types of safety notes that dffer accordng to warnng level. In order to clarfy the safety notes, each level s assgned specfc symbols and sgnal words. Some of these are attached to the machne as labels. 2.2.1 Level 1 safety notes (WARNING) Structure and meanng of safety note level 1 Ths safety note ndcates hazards that could lead to personal njury. Falure to follow the nstructon, ether fully or partally, could lead to njury. In extreme cases, ths could lead to loss of lfe. Sgnfcant property damage can also result. Structure of level 1 safety notes: Warnng! Source Type of danger Consequences of non-complance. Measures for preventon Symbols used: Warnng! General danger Warnng! Dangerous electrcal voltage! Warnng! Hot surface! Warnng! UV radaton! Warnng! Rotatng rollers! 3
Example of a level 1 safety note: Warnng! Hot surface! The ppes heat up to the temperature of the cleanng agent durng cleanng (max. 90 C). Do not touch the ppes as there s a rsk of burnng. Avod touchng the ppes. 2.2.2 Level 2 safety notes (Cauton) Structure and meanng of safety note level 2 Ths safety note ndcates the danger of possble property or envronmental damage. Falure to observe the note, ether fully or partally, could lead to damage to the product or neghbourng objects. Also, envronmental damage may result.!! Structure of the level 2 safety note: Cauton Source Type of danger. Consequences of non-complance. Measures for preventon. Example of a level 2 safety note: Cauton The UV lamp s senstve to pressure and drt. The UV lamp can be destroyed by the mpact of slght pressure. Drt and grease resdue on the lamp can destroy t. Carry out all work on the UV lamp wth extreme care. Wear protectve gloves. Do not touch the lamp wthout gloves to prevent fnger prnts and drt that could nfluence the performance. 2.3. rmaton and Instructons on Dsposal and Repars Packagng that s no longer requred must be dsposed of at the local waste dsposal faclty. The packagng s made of envronmentally frendly materals that can be used as secondary raw materals. The equpment, ncludng accessores and batteres, does not belong n your regular household waste. The EU legslaton requres ts Member States to collect electrcal and electronc equpment and dspose of t separately from other unsorted muncpal waste wth the am of recyclng t. In Germany and many other countres, Sartorus AG takes care of the return and legally complant dsposal of ts electrcal and electronc equpment on ts own. These products may not be placed together wth household waste or brought to collecton centers run by local publc dsposal operatons not even by small commercal operators. For dsposal n Germany and n the other Member States of the European Economc Area (EEA), please contact our servce techncans on locaton or our Servce Center n Goettngen, Germany: Sartorus AG Servce Center Weender Landstrasse 94 108 37075 Goettngen, Germany Sartorus Stedm Botech GmbH August-Spndler-Strasse 11 37079 Goettngen, Germany Phone +49.551.308.0 Fax +49.551.308.3289 www.sartorus-stedm.com In countres that are not members of the European Economc Area (EEA) or where no Sartorus afflates, subsdares, dealers or dstrbutors are located, please contact your local authortes or a commercal dsposal operator. Pror to dsposal and or scrappng of the equpment, any batteres should be removed and dsposed of n local collecton boxes. Sartorus AG, ts afflates, subsdares, dealers and dstrbutors wll not take back equpment contamnated wth hazardous materals (ABC contamnaton) ether for repar or dsposal. Please refer to the accompanyng leaflet manual or vst our Internet webste (www. sartorus.com) for comprehensve nformaton that ncludes our servce addresses to contact f you plan to send your equpment n for repars or proper dsposal. 2.4. General rmaton All work must be carred out wth approprate protectve equpment (safety glasses, gloves, etc.). Never carry out cleanng, mantenance, adjustment work and fault repars when the unt s runnng. The unt must be swtched off and the mans plug dsconnected before carryng out such work. The unt must not be operated f the nspecton wndow s damaged as harmful UV radaton can escape. Never operate the pump wthout the cover as the rotatng rollers pose an ncreased rsk of njury. 4
3 Devce Descrpton 1 Levelng feet 2 Vewng wndow 3 Log prnter 4 Prnter cover 5 Touch panel 2 3 4 5 6 Door 7 Grp 6 7 1 Fg. 1 Front vew 1 Product nlet 2 Ar nlet 3 Ar outlet 4 4 Product outlet 3 2 1 Fg. 2 Sde vew 5
1 Power supply 2 Sgnal generator 3 Connecton to GMP wrter (UVvatec GMP Lab only) 4 Seral nterface 5 Power swtch 5 6 Levelng feet 4 3 2 1 6 Fg. 3 Rear vew Electrcal control unts, the temperature sensor, the UV sensor, the flow meter and the unt s ppng are located behnd the rear wall. 1 Module holder 2 UV sensor 3 Door poston swtch 4 Pressure sensor 1 5 Perstaltc pump 6 Collectng tray 11 12 13 2 7 Pump outlet 8 Pump nlet 9 Collectng tray lock 10 Level swtch 3 4 11 Lamp connecton 12 Ignton lamp 5 13 Cover 10 9 8 7 6 Fg. 4 Interor vew 6
Temperature control crcut: 1 Membrane pump 2 Temperature control cap 3 Temperature control devce 4 Flow montor Flow meter swtch 5 Water reservor 6 Temperature sensor 7 Ar outlet 7 6 5 4 3 1 2 Fg. 5 Interor vew, temperature control crcut wthout cover 7
4 Startup 4.1 Transport and nstallaton Warnng! Heavy unt! Rsk of njury and damage to the unt durng transportaton. Always transport wth two persons. The unt must be nstalled on a level surface whch has a mnmum sze of 600 + 400 mm. The unt s levelled usng turnable levellng feet located under the unt. The locknuts must then be tghtened to mmoblse the unt. The unt must be nstalled so that the mans swtch on the sde of the unt s easly accessble. 4.2 Lamp nstallaton Module nstallaton! Cauton The UV lamp s senstve to pressure and drt. The UV lamp can be destroyed by the mpact of slght pressure. Drt and grease resdue on the lamp can destroy t. Carry out all work on the UV lamp wth extreme care. Wear protectve gloves. Do not touch the lamp wthout gloves to prevent fnger prnts and drt that could nfluence the performance. The UV lamp s equpped wth two plugs whch make contact n the unt. A heat-resstant shrnk tube, whch prevents the lamp from slppng through the reactor quartz tube, s ftted onto the upper end of the lamp. For dentfcaton, a pece of red hose s shrnk-ftted onto the connecton cable on the lower end of the lamp. To nstall the lamp, nsert the plug at the red end nto the quartz ppe at the head of the reactor (reactor outlet wthout UV wndow). Push the lamp nto the ppe up to the shrnkable tubng stop. Va the free lamp end, push the temperature control hood from underneath and snap t nto the reactor module. Make sure that the glass wndow of the reactor module faces n the same drecton as the temperature control cap. To fasten the temperature control cap n place, clp the clamp (ncluded n the equpment suppled) beneath the temperature control module onto the lamp ppe. The lamp cap unt created ths way can now be nserted, n the drecton of the devce rear wall, wth the glass wndows nto the reactor ntake, and snapped n. Before nsertng the lamp module unt, the collectng tray must be pushed nto the devce to prevent pullng t out unntentonally, because the UV lamp protrudes after assembly n the collectng tank. Use the arrester lever, whch s attached to the center wall, to frmly fx the collectng tank. Conversely, the lamp module unt must be unnstalled before removng the collectng tray, to prevent damagng the UV lamp. Both lamp plugs are plugged nto the sockets attached next to the reactor holder. The plugs have a push-pull lock. By slghtly pullng on the cable or the clampng nuts, the plugs are locked n the sockets. Thus t s very dffcult to separate the plug connecton. However, f you pull on the outsde connector bushng anyway, then the plug connecton can be separated easly. After connectng the lamp, the connecton of the module to the ppe can be realzed usng the enclosed elbow jont. The correspondng seals must be nserted n the flange before applyng the tr-clamp screw. UV lamps contan mercury and are therefore hazardous waste. Dspose of UV lamps accordng to the local regulatons. The servce lfe of the UV lamp s 1000 h at 100% power-on tme. Frequent gntons wll reduce the servce lfe. It s recommended to replace the UV lamp at least once a year. 4.3 Temperature control crcut The temperature control crcut s used to cool or heat the bottom UV lamp segment to the product temperature. To avod deposts n the temperature control crcut, a daly replacement of the water and regular cleanng of the temperature control unt s recommended (for detals see Chapter 4.3.3 and 4.3.4). The temperature control crcut must be prepared n accordance wth Chapter 4.3.3, f not usng the devce for an extended perod and t must be stored n a dry place. 4.3.1 Connectng and fllng! Cauton Malfunctons due to unsutable temperature control lqud. Turbd lquds nfluence the ntensty measurement and regulaton. The leak sensor does not recognze leaks, f usng non-conductng lquds. Only use fully desalnated water wth a 0.1 0.3 mm NaCl content. Do not use tap water. To fll the temperature control crcut, frst remove the cover by unscrewng the lateral knurled nuts, then lft the cover slghtly, and remove t from the front of the devce. The water reservor s then removed from the frame, and the rubber plug along wth the hoses and the temperature sensor are pulled off the tank flange. The tank should only be flled up to the startng lne of the upper curvature. 100 ml are usually suffcent. Installaton s carred out n reverse order. Fnally, the tube connectons are attached as labeled. Make sure that flow passes through the temperature control hood from below to the top. 8
4.3.2 Dranng the temperature control crcut 1. Remove the water reservor as descrbed n Chapter 4.3.1 2. Open the quck couplng between temperature control devce and tank. 3. Place an empty contaner n the collectng tray. 4. Attach a sutable tube to the tube-end of the temperature control devce, and gude t nto the collectng tank. 5. Start the temperature control pump va PUMP TEMP n the menu CALIBRATION PUMP (see Chapter 5.7). 6. Leave the pump on, for about one mnute, untl entrely draned. 4.3.3 Cleanng the temperature control crcut It s recommended to clean the temperature control crcut weekly when operatng the system weekly. For ths purpose, frst dran the temperature control crcut and fll t wth 70% ethanol afterwards. After a fve-mnute recrculaton perod, dran the temperature control crcut. Then rnse the temperature control crcut twce wth water, and at the end fll wth water. Please note that: Only fully desalnated water wth 0.1 0.3 mm NaCl content should be used. Tap water can lead to the buld-up of lmescale n front of the measurement wndow. The temperature control crcut must be cleaned usng 70% ethanol and draned as descrbed above before longer pauses n operaton. Store the system n a dry place. Before the next use, rnse the temperature control crcut twce, usng fully desalnated water wth 0.1 0.3 mm NaCl. 4.4 Mans connecton Power s suppled to the unt through the suppled IEC cord va the mans connecton on the rear sde. The permtted voltages are lsted n the specfcatons n chapter 8. 4.5 Connectng an optonal GMP wrter A 12-pole sgnal plug s provded on the rear of the UVvatec GMP Lab for connecton. Warnng! Electrcal connecton work! Rsk of njury and damage to the unt caused by unprofessonal or ncorrect connecton work. Electrcal connecton work must only be carred out by authorsed electrcans. The followng analoge sgnals are output as standard sgnals: Measurement Parameter Valence Output Sgnal Plug Assgnment -XS + Pressure 0.0 4.0 bar 4.0 20.0 ma C D UV ntensty lamp 0 9 W/m 2 4.0 20.0 ma G H Flow rate 0.0 27.0 l/h 4.0 20.0 ma J K A potental-free contact s also provded at the -X5:L/M connecton. Ths s used to dentfy the real nactvaton tme on the wrter. The contact s only closed after acknowledgng the Contaner Changed? or Start Inactvaton? prompt. The contact must be suppled wth an external voltage source (see wrng dagram). The unt s connected to a GMP wrter usng the accompanyng 12-pole cable. Connect the free wre ends to the requred channels of the GMP wrter accordng to the wrng dagram for ths. Afterwards, connect the cable to the sgnal plug at the rear wall of the UVvatec GMP and tghten the unon nut. 9
5 Operaton 5.1 Operaton and montorng The unt s operated usng the bult-n touch panel. Entres can be made n the ndvdual menus usng a fnger or a stylus. To enter or change values, press on the approprate entry feld or number feld followng the process value and then enter the value usng the dsplayed number feld. The value s accepted after you confrm t wth The ntermttent tone may be shut off after the error s corrected by acknowledgng t wth Reset. Errors nterrupt the actve process and are dsplayed n the message lne of the menu. If an error has occurred, the message text starts wth Error. The followng symbol s also dsplayed: 5.3 Start screen After the unt s turned on usng the mans swtch, the followng menu, ncluded n the panel s frmware, appears followng the start phase. 5.2 Sgnals and error messages The bult-n sgnal generator on the rear sde of the unt provdes audble sgnals. Steady tone (2 s) Procedure complete Intermttent tone Error Fg. 6 Error symbol The number n the symbol ndcates the number of the error that has occurred. By pressng the symbol, you are taken to an overvew screen whch shows all errors that have occurred. Pressng the cross located n the upper rght n the menu takes you out of the overvew. Errors that lead to cancellng nactvaton are documented separately n the prntout. A lst of error messages s located n chapter 7. Fg. 7 Menu after turnng unt on By pressng the button, ether the followng sub-menus are called or functons are carred out: Transfer Calls the transfer sub-menu (only for servce) Start Starts the UVvatec program Control Panel Calls the control panel sub-menu (only for servce) If you do not enter anythng n the menu, the UVvatec program starts automatcally after about 5 s. 10
By pressng Start, the UVvatec program s called mmedately wth the followng startup screen: 1 Software verson of the touch panel 2 Software verson of the control program Fg. 8 Start Screen To enter a password, press the START button at the lower rght. 5.4 Password General nformaton The operaton of UVvatec Lab GMP Lab s dvded nto four authorsaton categores usng passwords: Category 0 No password Category 1 (vewer) VIEWE (factory settng) Category 2 (operator) OPERA (factory settng) Category 3 (master) MASTE (factory settng) The varous optons for the data vewng, data entry and process startup n the menus are lsted n the followng table. 11
Format: Data vew Data entry or process startup Explanaton of characters: 0 Not possble Possble (restrcted) + Possble (unrestrcted) Category Man Menu Self Test Calbraton Cleanng Inactvaton Prnt out Last System Data 0 + 1 + 0 + 0 + 0 + 0 + 0 + 2 1 + 1 + 0 + 3 + 0 + 0 + + + 4 2 + + + + + + + + + + + + + 5 3 + + + + + + + + + + + + + + 1 Date and tme 2 Contrast; touch screen calbraton 3 Fllng 4 Contrast; touch screen calbraton; prnt out 5 Everythng except password management To enter the password, press on the 00000 entry feld and enter the password (max. 5 characters) usng the dsplayed alphanumerc key pad. The password entry s hdden and represented by astersks (*****). Confrm the entry wth. The Logn button takes you to the man menu. Entry elements are hdden or dsplayed n the menus dependng on the authorsaton category (see above table). It s recommended to change the passwords set at the factory mmedately after startup. Changes can only be made wth authorsaton category 3 (master) (see chapter 5.10.7). Fg. 9 Password entry 12
5.5 Man menu Dsplays On the left 2/3 of the screen, the followng sensors and actuators of the system are dsplayed as symbols: Pump Pressure sensor Flow meter Reactor module UV lamp External PC (n connecton wth the UVvatec Montorng software only) The dsplays above or below the symbols show the followng process values: Fg. 10 Man menu l/h: Actuell value dsplay of the flow rate bar: Actual value dsplay of the system pressure ma: Actual value dsplay of the UV ntensty (lamp) C: Set value dsplay of the temperature The operatng mode automatc or manual (see Chapter 5.7.1) s dsplayed as follows: A: Automatc Mode M: Manual Mode The PC symbol only appears f an external PC s connected va the seral nterface to the back of the system, and the UVvatec Montorng software (opton) was started (see Chapter 11). The followng submenus are accessed, or functons are performed, by operatng the buttons on the rght sde of the screen: SELF-TEST Open submenu Self-Test CALIBRATION Open submenu Pump calbraton INACTIVATION Open submenu Inactvaton CLEANING Open submenu Cleanng SYSTEM DATA Open submenu System Data Montor settng, prntout, etc. ERROR RESET Acknowledges errors The LOGOUT button exts the current authorsaton category and returns you to the password entry. 5.5.1 Settng the date and system tme To change the date and the system tme, press on the correspondng nput feld, enter the number usng the dsplayed number block, and confrm wth. 00/ 00/ 0000 00: 00: 00 AM The data s entered usng the followng formats: DATE MM/ DD/ YYYY TIME HH: MM: SS AM/PM The settngs for date and tme wll be saved wthn the software for one week. 13
5.6 Self test The SELF TEST functon tests the basc functons of the followng parts of the system: 1. Door poston swtch 2. Pump 3. Flow meter 4. Pressure sensor 5. Motor potentometer (UV power control) 6. UV lamp 7. UV sensor In dong so, the ndvdual unts are ether turned on by the system or ther values are checked by the controller one after another n the order lsted above. The test lasts approx. 30 seconds. A message approprate for each unt appears n the message lne as the test s carred out (see chapter 8). Because the temperature swtch s cyclcally montored durng operaton, t s not separately tested. The system must be flled wth a conductve lqud for the self test ( FILLING n the CALIBRATION sub-menu) as otherwse pressure sensors and flow meter can not be checked. It s recommended to carry out a self test each tme a lamp or module s replaced. Fg. 11 SELF TEST menu The process can be cancelled at any tme usng the RESET, STOP and EXIT buttons. Operatng elements START Starts the self test Button swtches to STOP durng operaton STOP Stops the self test RESET Acknowledges errors and resets the process to the ntal state EXIT Returns to the man menu START begns the self test. The button changes to STOP and the OPEN DOOR or CLOSE DOOR prompt appears n the message lne. After openng or closng the door, the remanng functons are tested as descrbed above. Completon wthout errors After the self test s completed, the message SELF TEST OK appears n the message lne. You can return to the man menu usng the EXIT button. 14
If an error has occurred, an approprate error message appears n the message lne: ERROR: PUMP Pump or pump controller defectve ERROR: FLOW CONTROL Flow meter defectve or system not flled The level sensor s desgned to montor conductve lquds. Saltfree solutons, such as demneralsed water, do not trgger the swtch and, thus, may not be used for the test. To nsure that the level swtch functons correctly, the unt must always be operated wth the collectng trough n place. 5.7 Calbraton pump The CALIBRATION PUMP menu can be used to calbrate the pump and to select between the automatc and manual controlled modes. For calbraton, the system must be flled ahead of tme usng the FILLING button. ERROR: PRESSURE Pressure sensor defectve or system not flled ERROR: UV-POTI Motor potentometer or controller defectve ERROR: UV UV lamp, UV sensor or UV ballast defectve Every error nterrupts the self test and must be acknowledged after t has been corrected wth RESET (also see chapter 9). After that, the self test can be restarted. Dsplays The dsplays above or below the symbols dsplay the actual values and change n value durng the test. The dsplay x.x ma (lamp) shows the actual value of the UV sensor on the lamp. The dsplay 4.0 ma corresponds to 0 W/m 2 ; the dsplay 20.0 ma corresponds to the maxmum ntensty. Because the level sensor n the nteror of the unt cannot be automatcally tested, we recommend that you test t manually. To do ths, take the collectng trough out of the unt and hold a damp cloth under the swtch. After closng the door, the error message ERROR: LEAKAGE s dsplayed, whch s acknowledged usng RESET. After testng, the swtch must be dred agan. Fg. 12 CALIBRATION PUMP menu The STOP, RESET ; CANCEL & EXIT and SAVE & EXIT buttons can be used to stop the process at any tme. Operatng elements START Starts calbraton Button swtches to STOP durng operaton STOP Interrupts calbraton FILLING Turns on the pump for fllng Pressng the button agan turns off the pump PUMP TEMP. Inchng operaton of the temperature crcut pump when door s opened for emptyng the crcut RESET Acknowledges errors and resets the process to the ntal state CANCEL & EXIT Returns to the man menu wthout acceptng the new entered values SAVE & EXIT Returns to the man menu and accepts the new entered values 15
After the system s flled wth WFI buffer usng FILLING, an approprate measurng vessel (at least 500 ml) and or a balance must be placed under the product output. Calbraton of the pump s begun wth START. The button changes to STOP and the pump feeds for two mnutes at 2/3 power (approx. 500 ml water). Once the pump automatcally swtches off, the measured volume can be entered wth the nput V [ml] xxx.x usng the dsplayed keyboard n the mddle of screen. After acceptng wth, the value appears n the nput. When you have exted the menu usng SAVE & EXIT ; the value s accepted nto the system. The nput has a volumetrc upper lmt of 999.9 ml. The mnmum controlled volume of the pump s 20.0 ml. If these values are too hgh or too low, the nput s not accepted. Every error nterrupts the calbraton and must be acknowledged after t has been corrected wth RESET (also see chapter 9). After that, calbraton can be restarted. ON The pump s operated n automatc mode. The speed of the pump s regulated by the software n ths operatng mode based on the output of the flow meter. The control loop software operates wth the nomnal flow rate whch has been specfed n the INACTIVATION menu and wth the actual value whch s measured by the flow meter. An A for Automatc appears n the left lower corner of the screen. OFF The pump s operated n manual controlled mode. In ths operatng mode, the software calculates the speed of the pump based on the nomnal flow rate specfed n the INACTIVATION menu and the volumes calbrated durng manual performed pump calbraton and outputs t constantly to the pump. The actual value s reported by the flow meter, but has no nfluence on the pump output. An M for Manual appears n the left lower corner of the screen. The flow s the decsve factor for both modes. For ths reason, the tme calculated and output by the system may be exceeded or not met (e.g. due to ar bubbles n the system). When you have exted the menu usng SAVE & EXIT ; the value s accepted nto the system. Flow rate measurement only functons correctly wth lquds havng conductvtes 5 µs/cm. 5.7.1 Automatc flow control The Automatc flow control swtch can be used to swtch between the automatc and manual controlled pump modes for the nactvaton. For CLEANING, the pump s operated n manual controlled mode ndependent of the swtch poston. Fg. 13 Automatc flow control swtch Pressng the swtch changes ths settng from ON to OFF and vce versa. 16
5.8 Inactvaton Operaton! General nformaton The nactvaton process s operated usng the INACTIVATION menu. The process s dvded nto two segments: 1. UV lamp warm-up phase 2. Inactvaton The followng should be observed for nactvaton: Cauton Malfunctons due to unsutable product temperature control. For precse product rradaton, the product lnes must be flled permanently wth a temperature-controlled sample lqud durng nactvaton. Otherwse ths may lead to a rse n temperature n the module and ultmately to an uncontrolled dose nto the product. The module should not run empty for longer than two mnutes. Before startng, set the flow rate. The flow should be the same for the warm-up phase and nactvaton. The dsplayed lamp performance x.x ma (lamp) corresponds to the actual value of the lamp durng the test. When usng cold meda, the clmate n the room must be regulated to avod the formaton of condensaton water. Durng the nactvaton, the product temperature must be kept constant n accordance wth the entered set pont. A devaton of the product temperature (temperature cycle) from the set pont by more than ± 2 C can lead to a dose devaton of > 15%. Inactvaton should not be completed wth a flow rate of < 6 l/h, because ths could lead to an nhomogeneous mx of the product n the module due to nsuffcent turbulences. Fg. 14 INACTIVATION menu Operatng elements The STOP, RESET ; CANCEL & EXIT and SAVE & EXIT buttons can be used to stop the process at any tme. START Starts the nactvaton process Button swtches to STOP durng operaton STOP Cancels the nactvaton process YES NO Postve negatve message confrmaton RESET Acknowledges errors and resets the process to the ntal state CANCEL & EXIT Returns to the man menu wthout acceptng the new entered values SAVE & EXIT Returns to the man menu and accepts the new entered values Inputs T [mn] Inactvaton duraton: 999.99 T 0.1 V [l] Volume: 999.99 V 0.01 V [l/h] Volume flow: 20.0. V 2.0 UV [ma] Nomnal UV ntensty: 20.0 UV 7.0 Product [ C] Nomnal temperature (temperature control crcut): 30 > Product > 15 17
Before actvatng the nactvaton process, the correspondng nputs for duraton, volume, and flow rate must be entered. But only two values must be entered. The thrd value s calculated usng the formula. X V = V + T X s a correcton factor resultng from the pump calbraton (manual mode). If the values calculated by the system after nput le above or below the stated nput lmts, the values are automatcally changed to allowed values. Example: Input: 20.0 l/h; 335 l; 999,99 mn The volume s automatcally changed to the value 333.33 l, because otherwse the permtted nput lmt of tme s exceeded. When enterng the tme, the transmtted volume may devate +5 ml from the dsplayed value, snce the touch panel can only dsplay 10 ml ncrements. Wth the pump overshoot, there may be an addtonal devaton of max. 6 ml. The requested UV ntensty must be adjusted accordngly. Here the 7 ma corresponds to an ntensty of 20% and 20 ma to an ntensty of 100%. The system does not accept smaller or larger values. Fnally, the temperature for the product to be nactvated must be entered. Ths value s a set pont for the nstalled temperature control crcut, whch wll warm up or cool down the bottom end of the lamp to the product temperature. As a result the ntensty remans constant throughout the entre lamp length. When operatng START, the UV lamp and pump are turned on. The pump runs at the preselected flow rate. If a self-test was completed and faled before the nactvaton, then the followng message prompt appears: SELF-TEST NOT OK, CONTINUE? Answer wth YES or NO. If YES s selected, nactvaton s started and the message s deleted. Even when restartng the nactvaton, the message wll no longer appear. If NO s selected, the nactvaton s not started and the self-test can be repeated. A passed self-test deletes the message, and no further messages appear. It s not recommanded to perform an nactvaton run f the self test was not passed successfully. Durng the warm up phase of the lamp, the UV lamp s necessary, the UV ntensty s set to a fxed value and montored by the system untl a stable value has been reached. Ths warm-up phase can take a few mnutes. Durng ths perod, the temperature control crcut s also heated or cooled to the product temperature. If the adjusted ntensty cannot be reached because the product s too cold, due to the operatng perod of the lamp or because of a defect (devaton by +0.5 ma for a perod of > 15 mn), the process s nterrupted wth the message UV CONTROL VALUE NOT REACHED. In ths case the mmedate replacement of the lamp or temperature adjustment s recommended. The process may be repeated wth less ntensty, less flow rate, and a hgher product temperature. If the specfed nomnal temperature of the temperature control crcut s not reached wthn 30 mnutes, the followng message appears: TEMP. CONTROL VALUE NOT REACHED. Reasons may nclude: Ambent temperature (see Chapter 9) may be too hgh or too low, or there s a defect. The process s not canceled by ths message and may be termnated by adjustng the parameter or ambent condtons. After warm-up, the lamp s set at the pre-selected value; the CHANGE CONTAINER? prompt appears n the message lne. You can answer ths queston wth YES or NO. If the set ntensty can not be met due to the operatonal duraton of the lamp or a defect (devaton of ±0.5 ma for a perod > 30 s), the process s cancelled wth the message UV CONTROL VALUE NOT REACHED. In ths case, mmedate replacement of the lamp s recommended. If necessary, the process can also be repeated wth a lower ntensty and lower flow. Answer wth YES After you answer wth YES, the pump s stopped, and you may change the product contaner for the nactvaton. The lamp stays lt, and the CONTAINER CHANGED? prompt appears. In order to avod module overheatng, the prompt must be confrmed wthn 15 mnutes; otherwse, the lamp s swtched off and the procedure s nterrupted wth the message ERROR: NO INPUT. After confrmng once more wth YES, the pump delvers the preselected flow rate over the set tme. The product temperature s montored at so that t does not exceed a maxmum of 70 C durng nactvaton (Safety swtch). If ths s exceeded, the procedure s nterrupted wth the error message ERROR: HIGH TEMP. The current nactvaton tme and the volume delvered (calculated value) are dsplayed next to the nomnal values T [mn] and V [l] for checkng. Upon completon, the pump and lamp are swtched off. 18
Answer wth NO After answerng NO, the pump s stopped and the START INACTI- VATION? prompt appears. In order to avod module over-heatng, the prompt must be confrmed wthn 15 mnutes; otherwse, the lamp s swtched off and the procedure s nterrupted wth the message ERROR: NO INPUT. Prnt out last After confrmng wth YES, the pump delvers the pre-selected flow rate over the set tme. The current nactvaton tme and the volume delvered (calculated value) are dsplayed next to the nomnal values T [mn] and V [l] for checkng. The product temperature s watched so that t does not exceed a maxmum of 70 C durng nactvaton (Safety swtch). If ths s exceeded, the procedure s nterrupted wth the error message ERROR: HIGH TEMP. Upon completon, the pump and lamp are swtched off. Fg. 15 PRINT OUT LAST menu To save the set values, leave the menu usng SAVE & EXIT ; to dscard the set values, use CANCEL & EXIT. Operatng elements YES Starts prntng the log and returns to the man menu NO Returns to the man menu wthout prntng a log Every error nterrupts the nactvaton process and must be acknowledged after t has been corrected wth RESET (also see chapter 8). After that, nactvaton can be restarted. Openng the door durng the process causes the pump and UV lamp to swtch off mmedately thus leadng to nterrupton. After leavng the nactvaton menu, you may prnt out a log usng the bult-n prnter. Pressng YES starts the log prntout. If you want to prnt out the log at a later tme usng SYSTEM DATA or do not wsh to prnt t out, ext the menu usng NO. Even when you prnt out a log, the nactvaton data s saved n the system up to 10 data sets (see also chapter 5.10.1). In order to protect the UV lamp, t s blocked from beng swtched on agan for 30 seconds after t s swtched off. UV COOLING appears n the message lne. 19
5.9 Cleanng General nformaton The system can be cleaned n the CLEANING menu usng lquds havng a maxmum temperature of 90 C. Warnng Hot surfaces! The ppes heat up to the temperature of the cleanng agent durng cleanng (max. 90 C). Do not touch the ppes as there s a rsk of burnng. Avod touchng the ppes. Operaton Inputs T [mn] Duraton of cleanng (0.1 T 999.99) V [l] Volumes (0.01 V 999.99) V [l/h] Flow rate (2.0 V 20.0) After enterng the duraton, the volume and the flow rate (see chapter 5.8), the START button begns the cleanng step. The pump delvers the selected volume over the set tme. The current cleanng tme and the volume delvered (calculated value) are dsplayed next to the nomnal values T [mn] and V [l] for checkng. Snce the devce s also cleaned usng lquds wth a conductvty of < 5 µs/cm, and these cannot be recorded by the flow meter, there s no dsplay of the actual flow rate n ths fgure. The product temperature s watched so that t does not exceed a maxmum of 90 C durng cleanng. If ths s exceeded, the procedure (Safety swtch) s nterrupted wth the error message ERROR: HIGH TEMP. After the tme has elapsed, the pump s swtched off and you may swtch to the man menu. Fg. 16 CLEANING menu The STOP, RESET ; CANCEL & EXIT and SAVE & EXIT buttons can be used to stop the process at any tme. Operatng elements START Starts the cleanng process Button swtches to STOP durng operaton STOP Interrupts the cleanng process Upon extng the menu, the nputs can only be saved usng SAVE & EXIT. Every error nterrupts the cleanng procedure and must be acknowledged wth RESET after t has been corrected (also see chapter 9). After that, cleanng can be restarted. RESET Acknowledges errors and resets the process to the ntal state CANCEL & EXIT Returns to the man menu wthout acceptng the new entered values SAVE & EXIT Returns to the man menu and accepts the new entered values 20
Prnt out last Fg. 17 PRINT OUT LAST menu Operatng elements YES Starts prntng the log and returns to the man menu NO Returns to the man menu wthout log prntng After leavng the cleanng menu, you may prnt out a log usng the bult-n prnter. Pressng YES starts the log prntout. If you want to prnt out the log at a later tme usng SYSTEM DATA or do not wsh to prnt t out, ext the menu usng NO. Even when you prnt out a log, the cleanng data s saved n the system up to 10 data sets (see chapter 5.10). 21
5.10 System data The followng functons are operated n the System data menu: Prntng out of the last ten log records: Prnt out Settng the touch panel contrast: Contrast Calbratng the touch panel: panel calb. Outputtng average values to an external PC: To PC average value Changng the UV setpont durng nactvaton: Change n Inactvaton Message and error management: Dagnoss Password management: Password management Operaton When you press the PRINT button next to the data set s contnuous number, the followng log s prnted out: UV MIN: = 14.0 ma Mnmum UV ntensty UV MAX: = 15.2 ma Maxmum UV ntensty UV AVER: = 14.6 ma Average UV ntensty T: = 21 C Target temperature for control crcut TIME: = 2.0 H Process perod FLOW: = 10.0 l/h Flow rate VOLUME: = 20.0 l Volume DATE: 5/31/10 Process date 10:36:22 AM Process start tme Fg. 18 SYSTEM DATA menu 5.10.1 Prnt out General nformaton After each cleanng and nactvaton procedure, the system creates a set of data wth a contnuous number, even f the procedure was nterrupted. A maxmum of 10 sets of data are saved. If 10 sets are already saved, the set of data wth the lowest contnuous number s overwrtten wth the new data set. PRINT OUT Calls the prntng menu for the last ten logs RETURN Returns to the man menu wthout prntng a log NUMBER: 16 Consecutve number USER: Lne for user name If the flow rate was changed durng nactvaton, the flow rate lne s marked wth an astersk ( * ), and a supplemental message, * VALUE WAS CHANGED, s prnted out. (Also see chapter 5.10.4). If the UV ntensty was changed durng nactvaton, the UV lnes are marked wth an astersk ( * ), and a supplemental message, * VALUE WAS CHANGED, s prnted out. (Also see 5.10.4). Fg. 19 PRINT OUT menu 22
UV AVER s an average value calculated by the system. The average value s calculated usng the max. and mn values recorded from start to end or cancelaton of a process. T s the product temperature entered n the touch panel, and s therefore the set pont of the temperature control crcut. If the nactvaton procedure was nterrupted, the supplemental message INACTIV. INTERRUPTED appears on the prntout. 5.10.5 To PC average value If an external PC usng the UVvatec Lab Montorng Software (optonal) s connected to the extra seral port on the rear sde of the unt, the output of ndvdual or average values can be pre-selected usng the swtch. When the swtch s n the OFF poston, all values recorded by the system are transferred to the PC. When the swtch s n the ON poston, an average value s determned over the perod of tme set n the montorng software. Ths means that the average value s output to the PC; for example, f 2 s s set, the average value of all values wthn 2 s s calculated and output (also see chapter 11.2). The determnaton of the average value starts when the nactvaton or cleanng s begun. If an error occurs durng the warmup phase of the nactvaton, data are not saved and prntable. 5.10.6 Dagnoss The DIAGNOSIS button takes you to the followng screen: By pressng the Return button, you return to the man menu. 5.10.2 Contrast You can set the touch panel contrast usng the Increase and Decrease buttons. 5.10.3 Touch calbraton The nput of the touch panel can be calbrated usng Touch Calbraton. Ths s requred f the nputs cannot be made n the proper poston on the screen, but rather from somewhere else on the screen. Fve consecutve calbraton crosses are shown on the screen. Touch each calbraton cross as t s dsplayed. After that, you have 30 seconds n whch to touch the screen at any poston. It s only then that the new calbraton s accepted. If the calbraton was not carred out properly, the new values are not accepted. 5.10.4 Change n nactvaton It s always possble to change the flow rate durng the nactvaton procedure. Also the UV ntensty can be changed durng the procedure f the change n nactvaton s swtched to on. Fg. 20 Dagnoss menu All messages and errors that occur after the unt s swtched on are logged here wth tme and date. The K n the message lne ndcates the tme of occurrence, and KG marks the tme of settlement. The scroll bar can be used to scroll through multple pages. Pressng Return takes you out of ths overvew agan. When the swtch s n the OFF poston, the functon s swtched off so that t s only possble to enter a value before nactvaton starts. Ths functon s made avalable agan by swtchng to ON. Ths s helpful f several tests wth dfferng retenton tmes and ntenstes need to be made consecutvely. 23
5.10.7 Password Management The PASSWORD MANAGEMENT button takes you to the password management: Message lne Fg. 21 Password management Press the correspondng nput feld to change the passwords of the ndvdual authorsaton categores (see chapter 5.4). Enter the password (max. 5 characters) usng the dsplayed alphanumerc key pad. Lower case letters, upper case letters and numbers can be entered. Confrm the entry wth wth the enter button. To save the passwords entered, ext the menu usng SAVE & EXIT ; to dscard them, use CANCEL & EXIT. 5.10.8 UV LAMP The UV LAMP button takes you to the followng screen: Change the count of gntons and operatng hours In the button part of the UV LAMP screen the total gnton counter as well as the total operatng hours of all lamps operated wthn the system are counted. The data n the upper part of the screen can be reset or adjusted manually durng every lamp exchange. To change the numbers of gnton and the operatng hours of a new lamp press the concerned felds. An alphanumerc keypad wll appear, allowng to enter a new value. Confrm wth the Enter button. The menu can be exted va the Return button. Fg. 22 UV LAMP menu 24
6 Mantenance WARNING Conductve parts! Danger to lfe f conductve parts are touched durng mantenance work. Before any mantenance work, shut off the devce by the power swtch and unplug the power plug from the mans. Ensure that the devce cannot be nadvertently swtched on agan. Regular mantenance and checks (mantenance tasks) must be completed to guarantee operatng safety. Ths work s specfed n the followng table along wth the tme ntervals. Make sure to follow the safety nstructons lsted n Chapter 2. Always keep the devce clean. Mantenance Actvtes Mantenance Actvty Spare Part Requred Interval Note Check man components (devce self-test) Daly and after each Chapter 5.6 lamp module change Check seals and tubes of the product crcut Daly Vsual nspecton (seal, correct ft, wear, damage) Replace water n the temperature control crcut Daly Chapter 4.3 Check seals and tubes of the temperature control crcut Weekly Vsual nspecton (seal, correct ft, wear, damage) Clean temperature control crcut Weekly Chapter 4.3 Replace UV lamp + Annually or when lamp Chapter 4.2 operatng perod exceeds 1000 h Calbrate UV sensor Annually or no later than when operatng perod exceeds 1000 h Contact servce techncans Replace temperature control crcut tubes + Annually Mantenance by the manufacturer + Annually Contact servce techncans Replace seals and tubes of the product crcut + Annually Contact servce techncans 25
7 Correctng Operatng Errors The followng table shows the ndvdual errors suggestons regardng ther causes and possble ways to correct them. Every error nterrupts the nactvaton and must be acknowledged after t has been corrected wth RESET. Alarm Cause descrpton Threshold values and descrpton Alarm delay Correctve acton by operator mantenance ERROR: PUMP ERROR: PRESSURE ERROR: UV ERROR: LEAKAGE No rotaton sgnal from the pump Unt not flled Pressure sensor defectve Lamp defectve or ncorrectly nserted UV sensor or ballast defectve Lqud n the collectng trough Lower frequency lmt = 0 (For each rotaton, the pump gves a feedback sgnal (frequency).) The alarm occurs, f the system s n automatc operatng mode, but the pump s not gvng a feedback (frequency = 0). p < 0.5 bar (at 100 % pump speed) or current output of the pressure sensor < 4.0 ma durng self-test: open loop. Seconds Mllseconds (after out of range) Notfy servce Reset error and clean the system. Check the flud pathway and fll the unt appropate. Start a new nactvaton run. Notfy servce f neccessary. < 5.0 ma read on the UV-sensor. Seconds Reset error, clean the system, check the lamp connecton or replace the lamp. Check UV sensor and ballast. If the lamp was runnng, start a new nactvaton. If lamp s runnng and the error stll occurs, notfy servce. Conductvty > 20 µs/cm Possble mpacts on nactvaton knetcs: If the leakage s before the flow sensor, the feedback control of the pump wll ncrease the pump speed (n automatc mode) => but only the entered flow wll be proceeded => correct dose (but contamnated lqud n the drp pan) Mllseconds (after gettng a readng) Reset error and clean the system. Check ppe, hoses and connectons for leakage, correct f possble. Remove lqud from the trough n the approprate manner. Dry leakage sensor. Start a new nactvaton. Notfy servce f neccessary. ERROR: DOOR IS OPEN Door s not properly shut If the leakage s behnd the flow sensor or the system runs n manual mode, a part of the meda s splt off (to the drp pan) and the rest wll go through the module wth decreased flow. Consequently the process meda gets a hgher dose. If the pressure drops < 0.5 bar, the system wll stop because of ERROR: PRESSURE. 0/1: Open/closed Mllseconds Shut the door properly, check the door poston swtch, reset error, clean the system and start a new nactvaton. Notfy servce, f neccessary. 26
Alarm Cause descrpton Threshold values and descrpton Alarm delay Correctve acton by operator mantenance ERROR: HIGH TEMP Product temperature durng nactvaton > 70 C Temperature durng cleanng > 90 C The temperature s guarded by temperature swtches whch are mounted on the outsde of the ppng. If the temperature exceeds the nomnal value, the system wll shut down. Both swtches are descrbed n the P&ID and the component lst as postons 107 and 108. Mllseconds (after out of range) Dsconnect the meda, reset the error and clean the system. Lower the product or the cleanng soluton temperature, as approprate and start a new run. For 70 C t s Mcrotherm T11A07005DGL100U174 and for 90 C T11A07005DGL100U174. Max Tme for nteracton > 15 mn ERROR: NO INPUT ERROR: HIGH PRESSURE ERROR: TEMP. SENSOR ERROR: UV SENSOR ERROR: FLOW CONTROL Tme exceeded durng nput > 15mn Pressure n the ppes s too hgh Temperature sensor or transducer defectve (Coolng cycle) UV sensor defect Plug not plugged n Unt not flled Plug s not attached properly p max = 2 bar The sensor: Endress+Hauser - cerebar PMP135-A4G0DA1Q, lsted n component lst and P&ID as number 48, s used. T sgnal < 4.0 ma For ths measurement the sensor: Jumo 902150/10-360-1011-1-6-50- 11-1000/000, lsted n component lst and P&ID as number 10, s used. UV-sgnal < 4.0 ma (UV sensor doesn t work) Dfference to ERROR UV: UV sensor s workng (I 4.0 ma) but no UV ntensty readngs avalable. Unt not flled. Connecton plug to the SPS/power s not attached (sgnal < 4.0 ma) Delay of 15 mnutes Mllseconds (after out of range) Seconds Mllseconds Mllseconds Reset the error and start a new nactvaton. Provde the nput wthn the tme allowed. Reset error, clean the system. Check the ppes, hoses and module for stoppages and deposts. Start a new nactvaton wth a lower flow rate. Notfy servce, f necessary. Notfy servce Reset the error, clean the system, shut down and dsconnect the power, check the UV sensor plug or replace the sensor and restart the system. Notfy servce, f necessary. Fll unt. Attach plug properly. Flow meter defectve Ths error concerns the flow meter n the product cycle. Flow < 3 l/h durng self test (100 % pump speed) Flow < 1 l/h durng nactvaton (out of specs). Notfy servce, f necessary. Flow meter defectve: Open loop (sgnal < 4.0 ma). The motor potentometer s an electrcal component and located n the electrcal compartment of the system. ERROR: UV-POTI Motor potentometer defectve Seconds Notfy servce It s used for regulaton of the current to the UV-lamp due to varaton of resstance and so for regulaton of the UV ntensty. If t s defectve, the ntensty cannot be regulated. Therefore the system checks the functon of the potentometer. The treshold values are predetermned at (max current) 1x0 Ω and (mn current) 1x ca. 320 (turnng off the motor gear). 27