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DPX-SM - RIGGTEK GmbH

1. Mustration 32 New Stirrer Speed Adjustment on the MIB and the Stirrer Drive Electronic 4 4 12 3 Stirrer Speed Adjustment on MIB2 S N 2408XXXxX the speed adjustment is performed in the TINI File see Chapter 5 3 1 LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 36 of 68 4 4 13 Maximum and Minimum Level Switch S N lt pooxxxxx There is one type of a Liquid Level Switch which is used both for the Maximum Level Sensor and the Minimum Level Sensor Depending on whether the Liquid Level Switch shall be turned into a Minimum or Maximum Level Sensor the switching polarity of the swimmer must be changed You get a Minimum Level Switch if the open switching marking points to the retaining ring You get a Maximum Level Switch if the closed switching marking points to the retaining ring Further the retaining ring has nipples which must be located towards the swimmer Check the correctness of the switching polarity with an Ohm Meter The contact is closed or zero resistance is measured if the swimmer body of the Minimum Level Switch touches the retaining ring The contact is open if the swimmer body of the Maximum Level Switch touch the retaining ring The Minimum Level Sensor is OFF if the tank is empty The Maximum Level Sensor is ON if the tank is completely full Swimmer Body Retaining Ring Switching P
2. When in Dispense Mode the stirrer is not working If you wait too long the temperature difference between inlet and outlet is too big gt 0 1 C Error ErrSTIRRER or TempGrad will show 7 3 5 Error Message Overheat The heater got too warm mainly after insufficient media supply with ErrFlow interruption a Possible reasons are folded Inlet Tubes an old Filter Cartridge or supplied warm media the FILL Modus will be not interrupted 7 3 6 Error Message MaxLEVEL The maximum liquid level of the tank was exceeded see Chapter 4 4 13 The selected mixing ratio of the Additive is not in the specified range of 1 5 to 1 100 The Transport Lock Screw at units with S N lt 2806XXXxX lt is not released turns see Chapter Transport Lock Screw Balance Fixing Screws Tank Fixing Screw The bottom side tank stabilizing screw Allen hex screw or nut touches the ground on which the DissoPrep stands or under the DissoPrep are lying objects touching the stabilizing screw see Chapter Bottom Side Tank Bearing The media develops too much foam Flush the Tank with the Emptying procedure One of the Inlet Valves MVI MV2 or MV8 has a leakage Watch the Remote Control Software RC Software File DPX_RC exe whose ADC Signal Flow should report zero after the FILL or whose ADC Signal Mass should be stable If old style restrictor fittings are used in the unit see Illustration 5 pa
3. see Chapter 4 4 7 3 If the Balance Check is not satisfying you should adapt the rational position of the tank until a minimal side load is caused through the tubing and wire connections 4 4 10 Manifolds on SIN 2408XXXX In former DissoPrep S N lt 2408XXXxX the internal tubing s were only connected with fittings and the solenoid valves MY 1 MV3 and MV8 had a small gray restrictor inside In newer versions of DissoPrep S N 2408XXXX the single tubing are connected to manifolds The manifolds have different fittings and also a restrictor fitting for MV I MV3 and MV8 If the customer has inacceptable heating results or inaccurate mixing values you should check the restrictors in the solenoid valves MVI and MV8 If they are loose you should change the inlet hose system to manifold 3 If the customer has inacceptable dispensing values you should check the restrictors in the solenoid valves MV3 If they are loose you should change the inlet hose system to manifold 5 Mustration 22 Manifold l Illustration 23 Manifold 2 Mustration 24 Manifold 3 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 32 of 68 Mustration 26 Manifold 6 4 4 11 Manifolds S N gt 4xxxxxxx In DissoPrep with S N gt 4xxxxxxx only three manifolds are needed Moreover there are no restrictor fittings in the internal tu
4. VA Lock Hexnut DIN 439 K Frame i Quter Bearing Shell Inner Bearing Shell Play max 1mm VA Washer DIN 125 Mustration 21 Schematic Diagram of the lower side of the Tank On the bottom side of the tank is a second tank fixing This tank fixing has a floating bearing with plastic bearing shells In case you have to remove the tank completely you must open not only the upper but also the lower Tank Fixing Screw the older models have a Hex Nut This screw is locked with LOCTITE 248 thread locker which must be renewed while reassembling For correct reassembling mark the Rotation Position of the Tank to the Bottom Frame of the DissoPrep e For perfect function of the DissoPrep any physical friction around the tank body must be reduced Never lubricate the Bearings as this would result in very bad dispensing precision e Minimize the side load of the tank by a correct assembly of the tank e When assembling the tank pay attention to the Rotation Position Mark Pay attention also to the Distance between Bottom Frame of the DissoPrep and Tank Fixing Screw with Washer The Distance should be approx 2 mm at upright position of the DissoPrep 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 31 of 68 At the end of reassembling the tank check the performance with the Balance Check
5. turns Mustration 14 Pondering Cell S N lt 2806XXXX 4 4 7 2 Pondering Cell Design 3 WZ3 Units with S N 2808XXXX 2810XXXX work with a nearly similar type of pondering cell as WZI but do not have a Transport Lock Screw as they are more robust against shocks and do not need them anymore A Do not overload the Pondering Cell e g by too heavy shock load Mustration 8 Pondering Cell S N 2808XXXX 2810XXXX 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 26 of 68 4 4 7 3 Balance Check There is an effective test to check the performance of the Pondering Cell in conjunction with any friction around the tank In the FILL Modus during the DEGASS the vacuum pump should operate but no delivery should be in progress a Balance Check should be performed Ignore any drift Put one of the screws of the plastic housing on the tank cover and remove it again meanwhile fa watching the Remote Control Software RC Software File DissoPrep_RC exe whose ADC Signal Mass reports the gram weight of the screw The weight change should move in the range of the weight of this screw You normally receive a value of 3 g Mustration 16 ADC Signals of the Menu Monitor of the Remote Control Software On the Preamplifier Board of the Pondering Cell Design at units with S N lt 2806XXXX you may additionally c
6. CPU ADC I O boards and the Driver Electronic Board DEB for the Magnetic Stirrer Furthermore the MIB contains the amplifiers for the Leak Detector the Temperature Probe and the Heater the power supply cascade for the Pondering Cell and the power driver for the Solenoid Valves The LED reports the activity of the Voltage Supply of the Vacuum Pump of the Heater and of the Solenoid Valves Connection Socket Leak Detector Temperature Probe Tank and Temperature Probe Heater Cable to the S Connection Socket Load Cell ee UA S A DEB of the Magnetic Stirrer N De g Connection Sockets CPU Voltage 5 ue _ MV6 MV10 z 12V 5V Connection Socket P3 12V i LED Heater Clock Battery LED MV1 MV10 LED Vacuum Pump Illustration 10 Old Main Interface Board MIB1 S N lt 2406XXXX LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 22 of 68 The MIB2 of S N 2408XXXX contains all essential components like CPU and ADC and the Connection Sockets The Magnetic Stirrer is connected on the DIB Connection Socket Leak Detector Temperature Probe Heater Temperature Probe Tank Connection Socket Printer Connection Socket DIB Connection Socket X Connection Socket CPU RS 232 Com1 Pressure Transducer Connection Socket Connection Socket iim Load Cell Floppy Disk T12 emp es eee t i ly oe FD
7. Power Socket 5 E EN 12V A z ee eee Connection Sockets A lt a E Am e 5 Solenoid Valves 5V N 3 K i Clock Battery Connection Socket Connection Socket CRT and Keyboard Auxiliary Remote Control Connection Socket Vacuum Pump and the Heater Mustration 11 Main Interface Board MIB2 also MIB3 starting with S N 2408XXXX The MIB4 of S N gt 4xxxxxxx Connection Sockets Leak Detector Temperature Probe Heater RS232 COM 2 RS232 COM DIB Temperature Probe Tank Pressure Transducer Load Cell Printer P Solenoid Valves Clock Battery ij Power supply USB UPS Remote Control Vacuum Pump Network Heater Mustration 12 Main Interface Board MIB4 starting with S N 4XXXXXXX 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 23 of 68 4 4 6 Clock Battery The Clock Battery is a 3 Volts lithium battery of the type CR 2430 It is on the Main Interface Board MIB The battery voltage nominal 3 2 Volts can be checked on the MIB I see Illustration 8 To get access to the battery you must remove the 3 computer module boards Newer boards of MIB will have the battery on the rear side free accessible MIB2 boards have it freely accessible on top side The Clock can be set with the RC Software RC Software File DPX_RC exe 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8
8. 57600 baud 8 data bits NO parity stop bit NO control Use the transfer protocol Zmodem The emulation is ANSI 5 4 I Firmware Update for MIB2 Please contact service riggtek com if you want to update from firmware version 6 XXX to 7 XXKX Force the DissoPrep into the REBOOT Mode by pressing the STOP Key as long as REBOOT appears Send the Firmware File series 6 nnn exclusively with the File Name XX EXE For this rename the original format e g XX6104 exe into XX EXE Send the Firmware File series 7 nnn exclusively with the File Name DPX EXE For this rename the original format e g DPX7102 exe into DPX EXE 5 4 2 Update of the Identification File SETUP DSP If the DissoPrep does not react one of the choices to repair the failure is sending the individual SETUP DSP with HyperTerminal The SETUP DSP contains the S N and calibration data RIGGTEK GmbH has to prepare the specific SETUP DSP of your instrument Please send us an Email service riggtek com and the S N of your instrument A The following procedure is feasible only after individual personal advice Use a DIMM VGA Card and a conventional PC Keyboard and CRT screen Implement the DIMM VGA Card on the MIB of the DissoPrep A Do not forget to remove the DIMM VGA Card after the use 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Electronic Remote Connections Connect the PC Keyboard and the CRT
9. Adjustment on the MIB I New Stirrer Speed Adjustment on the MIB and the Stirrer Drive Electronic Liquid Level Switch of the Tank LED of the Liquid Level Switches the Vacuum and Pressure Switch on the DIB 1 Leak Detector Placing of the Vacuum and Pressure Switch S N lt 2406XXXX look from top side Location of T Piece and Tubing to the Pressure Switch at S N 2406XXXX Pressure Gauge Sensor at S N gt 2408XXXX Heater with Temperature Safety Switch and Safety Sensor Power Supply Pump TRIAC and Heater TRIAC System of the Remote Control Software Monitor of the Remote Control Software for Diagnostic ADC Window SETUP DSP File Screen Step SETUP DSP File Screen Step 2 SETUP DSP File Screen Step 3 SETUP DSP File Screen Step 4 Allen Hex Wrench 5mm Hex Wrench Nut 19mm Digital Barometer 0 to 1300mbar absolute Digital Thermometer 2007 2010 RIGGTEK GmbH Page VI of 68 13 14 15 17 18 18 20 21 22 24 25 25 26 26 27 28 29 30 3l 31 3l 31 32 33 34 35 36 36 38 40 41 44 44 48 48 52 53 53 53 66 66 67 67 DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Welcome Page 7 of 68 Welcome 1 1 Use of the Service Manual Use this Reference Guide at hand to locate basic information about the maintenance and the repair of DissoPrep DissoPrep is known as DPX8 DPX15 DissoMate DosaPrep X8 DisPrep 100 or DissoFill X8 To obtain a complete overview over the DissoPrep also look into the Op
10. at the Exhaust Line Start emptying the tank with OutTb2 The barometric Pressure should be better than 20mbar Disconnect the Barometer If the barometric Pressure or the Vacuum shown on the Protocol is inadequate there are several possible reasons a There is a leakage e g at the Tank Cover Seal at a Valve or a Manifold b The Vacuum Pump s Diaphragm is broken Connect the Barometer directly to the pump vacuum should round about 30mbar If not the exchange of the pump will be needed see chapter 4 4 15 2 c Solenoid MV4 has collapsed under vacuum such that the final vacuum suffers see Chapter 4 4 3 or Chapter 7 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 43 of 68 4 4 18 2 Replacement of the Vacuum Pump You can replace a cylinder pump against a 2 cylinder AC pump or a defective 2 cylinder AC pump against a new one The DC pump needs the MIB2 V45 board and does not operate with MIBI or lt MIB2 V45 In case of a conversion of a cylinder pump into one 2 cylinder pump the fixing points must be slightly modified which is easy to do on the PP plastic mounting bracket If changing the Vacuum Pump the inlet connection tube and the outlet connection tube must A correlate with the arrow labels on the pump head 4 4 19 Temperature Safety Switch and Temperature Safety Sensor The Temperature Safety Switch a
11. be audible for a short while If not tilt the DissoPrep in an acute angle of approx 45 degrees towards the front and to the front left Under unusual conditions it can happen that the Magnetic Stirrer locks the Minimum Level Sensor In this case the corresponding LED of the Minimum Level Sensor see Chapter4 4 13 is ON If so tilt the DissoPrep not only in an acute angle to the front but also to the left and to the right The proper function of the stirrer is finally controlled by the firmware by means of a logical conclusion In case of a malfunction the error message TempGrad or ErrSTIRRER is reported in the Display and it is documented in the AUDIT TRAIL File 4 4 12 1 Old Stirrer Speed Adjustment on MIB I The potentiometer on the Main Interface Board MIB 1 may be in a 10h Position Please change the Stirrer Speed Adjustment in accordance with the explanations in Chapter 4 4 12 2 10h Position Mustration 31 Old Stirrer Speed Adjustment on the MIB 4 4 12 2 New Stirrer Speed Adjustment on MIB I The procedure of the Stirrer Speed Adjustment has changed in 2001 The potentiometer on the MIBI should be in the 2h position Additionally you must adjust the lower side potentiometer on the Stirrer Drive Electronic from the 2h Position to the 7h Position 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 35 of 68
12. correct software key cannot run or cannot itself identify the correct serial number This new firmware has exciting calibration and validation features The vacuum pump is a DC motor driven one needs the MIB2 V45 The heater can be adapted by wiring for 230 and 115 100 volts In 2013 a new generation of the DissoPrep started From serialnumber gt 4woxxxx it is equipped with new MIB3 V46 now running with 24V DC internally lt supports USB and LAN connection Also there are new manifolds new valves a new power supply and a new combined minimum maximum temperature sensor in the tank The pump is now with ventilation to get a better vacuum and is mounted vertically Moreover we now have a LINUX based firmware series starting with version 8 01 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 13 of 68 4 2 Functional Principle of the DissoPrep p _ Ti Load or Pondering Cell Balance It H Heater Vacuum Pump 3 Water Inlet suspended Storage Tank Acid Inlet Dispense Outlet Mustration Pictorial Schematic of the DissoPrep Magnetic Stirrer LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 14 of 68 4 3 Physical Principle of the DissoPrep Filter Catridge Pressure Sensor
13. on the corresponding sockets on the MIB Switch on the DissoPrep DOS PC knowledge is needed Go to subdirectory DPX and copy the SETUP ORI to SETUP DSP Example of the SETUP DSP file content when using the SETUP command is as follows Type SETUP lt ENTER gt and type in the shown lt variable figure gt and lt ENTER gt repeatedly until you see the screen below Set the S N individually Default values for different load cells For Load cell Type Tara ScaleV OffsetV ScaleT OffsetT ScalePressure For Load cell Type 2 Tara ScaleV OffsetV ScaleT OffsetT ScalePressure For Load cell Type 3 Tara ScaleV OffsetV ScaleT OffsetT ScalePressure Protocol Numbers and Calibration Values are different of the below examples 1480 3 79073 3 0000 0 950 8 000 1 000 Only FW gt 6 204 5540 4 95190 5 19000 0 950 13 000 1 000 Only FW gt 6 204 5420 6 41000 4 78000 0 950 11 600 1 000 Only FW gt 6 204 El C WINDOWS system32 conmLexe zS SerNumber Mustration 45 SETUP DSP File Screen Step 2007 2010 RIGGTEK GmbH 28688320 238 i 1 9600 DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Electronic Remote Connections Page 53 of 68 cy C WINDOWS system32 cnmLexe s Act iveMet hod Jesse Volume Additive 5 Vesse lNumber cs c c cs cs Tenperature es DegassTime Mustration 46 SETUP DSP File
14. or a broken piston of the Diaphragm of the pump see also chapter 7 2 12 Connect the Barometer directly to the pump vacuum should round about 30mbar If not the exchange of the pump will be needed see chapter 4 4 15 2 There is a leakage in the DissoPrep e g at the Tank Cover Seal at a Valve or a Manifold If the Error Message ErrVac comes up after the MxPt Mixing Point then check the Solenoid Valve MV4 Replace the Support O Ring see Chapter 4 4 3 7 3 11 Error Message ErrPRESS There is an excess pressure during the DISPENSE a Check the Outlet Hose Coupling and the Outlet Frit Make sure that the Outlet Hose is not folded see Chapter 4 4 2 7 3 12 Error Message ErrLEAK A leak was detected in the DissoPrep The DissoPrep will force an EMPTYING until the leakage is removed The Leak Detectors should be carefully cleaned on both sides For this you take them from the Base Pan and clean them with water and alcohol Better you replace the Leak Detectors see Chapter 4 4 15 7 3 13 Error Message ErrADD The Filling Amount of the Additive is out of range 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Appendix A Installation and Maintenance Tools and Instruments Page 66 of 68 Usually this Error is caused by any disturbances while sucking Check the media supply Check whether the tubes are folded whether the Filter Cartridge or the Inlet Hose Cou
15. shouldn t press the DISPENSE Key too strong since movements of the DissoPrep influence the measurements of the Pondering Cell negatively The Outlet Frit is dry It drips after the stop of the DISPENSE Keep the Outlet Frit wet Don t shake the last drop off the Outlet Frit Move the Outlet Frit carefully to the next vessel The DissoPrep is bad positioned A table which is stable and not vibrating as well as a 2 D horizontal adjustment of the DissoPrep is preferable There is a friction around the Tank or the Pondering Cell Make the Balance Check see Chapter 4 4 7 3 Check the centring of the Transport Lock Screw at units with S N lt 2806XXXX and the Side Load of the tank Check whether disturbing cables tubes or other objects are under the tank Possible reasons for larger deviations The instrument must be protected from direct sunshine other thermal sources or draught The Transport Lock Screw at units with S N lt 2806XXXX is not opened correctly Open the Transport Lock Screw 4 turns see Chapter Transport Lock Screw Balance Fixing Screws Tank Fixing Screw The bottom side tank stabilizing screw Allen hex screw or nut touches the ground on which the DissoPrep stands or under the DissoPrep are lying objects touching the stabilizing screw see Chapter Bottom Side Tank Bearing The Outlet Hose is not the original one and too long The Outlet Frit has an increased fluidic resistance o
16. that the final vacuum suffers see Chapter 4 4 3 or Chapter 7 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Troubleshooting Page 62 of 68 7 3 Error Messages 7 3 1 Error Message REBOOT If you press the STOP Key too long you get EMPTYING first and then REBOOT Switch the main power OFF Switch ON after 5 seconds again 7 3 2Error Message TIMEOUT The Error Message is reporting that an operation sequence is disturbed The Error Message can be a consequence of an inaccurate Flow Rate e g if one of the Inlet Valves MVI for raw medium with a smaller seat diameter or MV8 for acid or buffer one of the Outlet Valves MV3 MV9 or MV 10 or even if the Outlet Frit is clogged Perform a complete EMPTYING with the step EmptALL This procedure will back flush the Valves The Error Message occurs as a consequence if the Vacuum Pump cannot reach the predefined vacuum in less than 4 minutes Reasons can be a weakly working pump or insufficient supply of medium The Error Message may be caused through the printer connecting disconnecting or the switching on off during the DissoPrep is ON The Error Message may indicate that the CPU hangs up because of electrostatic discharge or that the mains power voltage spikes Check the CPU voltage Check whether the TRIAC S solid state relays have the transient voltage suppressor RC Filter If the EMPTYING Procedure cannot be complet
17. 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 24 of 68 4 4 6 2 Inset of the Grounding Lead to MIB I Originally all DissoPrep units with the S N lt 2106XXXX are not equipped with a ground connection If a new Pondering Cell is however installed an electric grounding must be attached on the power socket of the MIB I Use a yellow green coloured Grounding Lead Solder the Grounding Lead between pin 3 and A pin 4 see Illustration 9 of the power socket Below MIBI there is a screwed ground point at the frame At this ground point you screw on the Grounding Lead Mustration 13 Grounding Lead on the MIB A The MIB2 does not need the wired grounding 4 4 7Load or Pondering Cell Balance The Pondering Cell does not need any maintenance LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 25 of 68 4 4 7 Pondering Cell Design Zi The Balance Fixing Screws at units with S N lt 2806XXXX are very tight fastened The Pondering Cell is so adjusted that the bore of the Transport Lock Screw is centred Do not overload the Pondering Cell e g by too strong fastening of the Transport Lock Screw at units with S N lt 2806XXXX or by too heavy shock load Never tighten the Transport Lock Screw at units with S N lt 2806XXXX fastened The Transport Lock Screw must be opened
18. 8 Solenoid Plain Washer 9 Solenoid Nut 10 Valve Housing Nut 19mm 1 Tube Restrictor Fitting 2 Spring 3 Six Shape Popper 4 Diaphragm or Membrane 5 in MV4 only Support O Ring 4 4 3 2Remove the Solenoid 1 Open the valve housing with a 19mm hex wrench nut The installation and maintenance tools are being shown in Appendix A 2 Disassemble the components of the Valve 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 19 of 68 4 4 3 3 Reassembling of a Solenoid Valve 1 Sort the components of the valve carefully 2 The load or also length of the Spring 2 without the Brass Spring Sleeve 1 is correct if it has the same length as its bore in the Six Shape Popper 3 3 The threads are of plastic and therefore should not get tightened to strong 4 Reassemble the components of the Valve 5 When assembling the Solenoid do not tighten the Solenoid Screw 7 The Solenoid must stay moveable to prevent an over heating of the Diaphragm 4 4 4 4 Solenoid Valve SN gt 4xxxxxxx All solenoids of the DissoPrep are of the same type The valve bodies are interchangeable The solenoid s wires have different lengths but need not to be changed The valves are equipped with a diaphragm to isolate media and to prevent a damaging of the internal armature If the Remote Control Software RC Software Fil
19. Application Tips Page 10 of 68 4 Example for 0 1 N HCL diluted from 5 N HCL 5 N HCL has a density of 1 08 Density of water USP related 25 C is 0 9971 Ratio 1 50 980 mL water plus 20 mL 5NHCL 977 plus 21 6 g total 999 g Enter the Volume Vessel 999 Enter the Volume Additive 21 6 3 3 Dilution Factor Limitations Have a look into the Specification List 1 5 to 1 100 Here are the following two examples 1 1 5 Enter the Volume Vessel 1000 and the Volume Additive 200 2 1 100 Enter the Volume Vessel 1000 and the Volume Additive 10 3 4 Removal of Bacteria Flush the system with a normal media preparation program of 8L Add 0 2 Sodium Hypo Chloride most effective or 5 Hydrogen Peroxide more compatible Also other sterilization means of your choice are feasible For cleaning run an 8L program with pure water Finalize with the EMPTYING Modus 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page of 68 4 Understanding of the Functions and Components of the DissoPrep 4 1 Introduction DissoPrep prepares the dissolution media according the demanded rules of the USP and recommendations of the FDA for specification see Operation Manual Any delivery of the media sucking or dispensing is actuated by vacuum or pressurized air The control of the quantity of the delivered medi
20. Media Input Temperature Safety Probe Load or Pondering Cell Balance Exhaust Inline Output Heater Temperature Safety Switch Restri O Pana Maximum Level L Sensor Storage Tank Minimum Level Acid Input Sensor D L Dispense MV8 Restrictor n Output vie 3 a w TI Fitting Magnetic Stirrer Temperature Probe Magnetic Stirrer Drive D Restrictor MV3 Fitting Mustration 2 Physical Diagram of the DissoPrep 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page I5 of 68 4 4 Disassembly and Assembly of Components 4 4 I Inlet Filter The Filter Cartridge must be attached correctly and corresponding to the Illustration 3 Inlet Filter Cartridge of the Inlet Hose below This guarantees the maximum filter capacity The volume throughput is counted The end of life time of the Filter Cartridge is noticed on the Display of the DissoPrep The nominal filter capacity is approximately 5000 litres If the DissoPrep is used only occasionally then the life time of the Filter Cartridge is shorter There where pure water is used the filter capacity can reach lt 10000 litres To reset the counter of the volume throughput see the Operation Manual The vent screw situated at the Filter Cartridge shouldnt be used Hold the screw closed Vent Scre
21. RIGGTEK Dissolution Test Systems Copyright Schutzrecht beachten The copyright of this document drawings images and all supplements even in part to the recipient personally entrusted remains anytime at RIGGTEK GmbH Without our written authorization no part of this document may be photocopied nor communicated to third persons passed on or be made accessible to pray Intended only for use of RIGGTEK distributors By no means do pass on the Service Manual to the customer DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 CONTENTS l Welcome 1 1 Use of the Service Manual 1 2 Contact 1 3 Warning 2 Installation Work 3 Application Tips 3 1 Mixing of Acid Buffer or SLS 3 2 Setting of Weight Equivalents 3 3 Dilution Factor Limitations 3 4 Removal of Bacteria 4 Understanding of the Functions and Components of the DissoPrep 4 1 Introduction 4 2 Functional Principle of the DissoPrep 4 3 Physical Principle of the DissoPrep 4 4 Disassembly and Assembly of Components 44 1 Inlet Filter 4 4 2 Outlet Frit 4 4 3 Solenoid Valves SN lt 4xxxxxxx 4 4 3 1 Disassembling of a Solenoid Valve 4 4 3 2 Remove the Solenoid 4 4 3 3 Reassembling of a Solenoid Valve 4 4 4 Solenoid Valve SN gt 4xxxxxxx 4 4 5 CPU with Chip Disk MIB based 4 4 6 Main Interface Board MIB 4 4 6 1 Clock Battery 4 4 6 2 Inset of the Grounding Lead to MIB I 4 4 7 Load or Pondering Cell Balance 4 4 7 1 Pondering Cell De
22. Screen Step 2 ev CA WINDOWS system32 cma exe cs PilterCap ecs PilterLife cs Total ProtNumber ertificate Lef thHargin cs Tara 1450 Scale 3 79873 Offset 3 80088 aleT 6 956 setT 8 0900 ScalePressure 1 000 Mustration 48 SETUP DSP File Screen Step 4 After the Upload of your specific SETUP DSP with HyperTerminal first switch the power OFF and then START the instrument again A complete Calibration is necessary In case of the Error Message ErrSMIN perform an EMPTYING with the Step OutTb2 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Maintenance Work Page 54 of 68 be oe Firmware gt 7 000 will run exclusively only with a proprietary software key This key includes the serial number Update from firmware series 4 nnn or 6 nnn to series 7 nnn are not allowed and will not operate MIB2 series with firmware 6 nnn needs a hardware update of the LCD display and new operating files besides the firmware file itself 6 Maintenance Work 6 1 Overview over annual preventive Maintenance Use the RC Software for diagnosis Check the CPU Voltage Read out the Volume Throughput up to now and pull logical conclusions to change the Stirrer the Vacuum Pump or Solenoid Valves Read out the Remaining Filter Capacity and pull logical conclusions to change the Filter Cartridge or the Outlet Frit of the Outlet Hose Read out the Error Messa
23. Software over the folder IniData If the period of the Fine Dispense is too short long e g sec make VorstopPunkt 80 5 higher 5 lower The Main Interface Board MIBI or MIB2 could be defective and have to be exchanged 7 2 9 Insufficient Temperature Precision Make an individual calibration only for the temperature Use a fast responding thermometer There are 3 methods to get reasonable results a Fill the vessels of a preheated Dissolution Bath stir the media and measure the temperature b Fill a plastic vessel of 5 litres set Number of Vessels and Volume of Vessel 5000 stir the media and measure the temperature c Use the method with 5 litres While dispensing measure the temperature and enter this as measured value 7 2 10 Spill of Medium through the Exhaust Condensed water in the tubes of the pump will be spilled occasionally After use of SLS or other surfactants residual foam will leave which is normal Attach a tube with a length of max Meter The tube should lead into a waste vessel and must not dive into the liquid Check whether the Transport Lock Screw at units with S N lt 2806XXXX is correctly opened 2 turns see Chapter Transport Lock Screw Balance Fixing Screws Tank Fixing Screw Check whether cables tubes or other objects are lying under the DissoPrep Nothing may be under the unit so that the tank remains freely hanging After an overfl
24. Take into account that the temperature in the heater and in the tank is partially and temporarily higher than the nominal set point Surfactants like SLS cause a foam waste at the exhaust Therefore connect a hose to a waste drain or bottle The end of the hose may under no circumstances be dived into liquid or into foam 3 2 Setting of Weight Equivalents Here are the following two theoretical and two realistic examples 1 In each vessel are 1000mL media including 40mL buffer The weight of the media is measured by an experiment with 003g Enter the Volume Vessel 1003 The weight of 40mL buffer is measured with 44g Enter the Volume Additive 44 2 Water 0 997 kg L volume at related USP condition at 25 C Additive 1 2 kg L volume at 20 to 25 C Volume Ratio 10 1 dilution ratio 1 10 Make your manual volumetric mixture 900 mL plus 100 mL 1000 mL and define the density 0 897 kg 0 12 kg 1 017 If there is no volume contraction the density of the mixture is 017g Enter the Volume Vessel 1017 Enter the Volume Additive 120 3 Example for 0 1 N HCL diluted from N HCL N HCL has a density of 02 Density of water USP related 25 C is 0 9971 Ratio 1 10 900 mL water plus 100 mL INHCL 897 3 plus 102 g total 999 g Enter the Volume Vessel 999 Enter the Volume Additive 102 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28
25. XX with Firmware Versions 6 203 can perform not only a Vacuum Test but also a Calibration of the Pressure Gauge Sensor at ambient pressure 3 Press the SETUP Key and select the CALPRESS Mode with the Key Accept with the START Key Press START again to release the vacuum Wait for the displayed value Disconnect the Barometer Place the disconnected Barometer next to the DissoPrep If the Display of the DissoPrep does not change its value anymore press the START Key Read off the value of the disconnected Barometer and enter the ambient pressure value of the Barometer with the Keys if necessary S N R2908XXXX with Firmware Versions 7 000 can perform not only a Vacuum Test but also a 2 point Calibration of the Pressure Gauge Sensor Follow the calibration and validation menus on the LCD display 4 4 18 Vacuum Pump There are 3 versions of the Vacuum Pump The earlier version is a cylinder pump with AC motor The cylinder pump reaches a higher pressure Thereby it can dispense faster The 2 cylinder pump has a better end vacuum and consequently a better degassing effect The electric coil of the AC motor has a Thermal Protection Switch which independently recovers The current version since S N R2908XXXX with Firmware Versions 7 000 is a 2 cylinder pump with DC motor This pump turns the same RPM on 50 or 60 Hz mains power 4 4 18 Vacuum Pump Check Activate OutTb2 of the EMPTYING Menu Connect the Barometer
26. a is performed by a Pondering Cell or Pondering Cell or simply said Ba ance Normally we avoid saying balance in front of the client because of the confusion this term is causing in a GLP aboratory environment as balances have to be calibrated itself The electronics of the DissoPrep is based on a powerful 86 compatible PC with RAM and a Hard Disk Chip Disk On the Hard Disk all operating protocols are filed according the FiFo Principle in a stack memory and all error messages are filed in an AUDIT TRAIL File The software of the DissoPrep better described as firmware runs under a Real Time Kernel Software The knowledge of conventional DOS is helpful but not necessary All the experience of maintaining and servicing the DissoPrep is based on an over 10 year s period We can generally guarantee that the electronics of the DissoPrep doesn t have any weak points All firmware releases in this field work without any remarkable bug Nevertheless we recommend during a routine service to update the latest firmware version Updates will be best executed with HYPERTERMINAL accessory of MS Windows In addition the internal watch of the DissoPrep can be adjusted with the Remote Control Software Date and time are stamped on all internal protocols incl error listing in the AUDIT TRAIL Furthermore the Remote Control Software helps the user to administrate protocols and predefined operation methods complying with the 21 CFR part II rul
27. and check if the magnetic stirrer is audible 8 Check the display and buttons 9 If everything is ok go ahead with point 18 10 If anything is NOT ok go ahead with the following points therefore open the Side Panels II Check the tubings clean not collapsed 12 Check if there is anywhere a leakage check if the leakage sensors are corroded 13 Check if all electrical connections are visibly ok 14 Check the CPU Voltage adjust it carefully to 5 15 0 02V for MIBI or 5 05 0 02V for MIB2 3 cp chapter Rear Panel with Power Supply I5 Check the pump vacuum MIBI only Connect the Barometer at the Maximum Pressure Switch MIB2 3 use the RC Software for monitoring the vacuum 16 If the error is not clear use the Remote Control Software DP_RC exe a Delete the old data in the subdirectory data of DP_RC exe b Open Protocol Folder read the last Protocols Note the Volume throughput up to now Every 50kL change the Stirrer Every 50kL change the Pump or check it carefully Every 50kL change the Heater or check it carefully Note the Remaining filter capacity If no Remaining filter capacity is left change the Filter Cartridge Check the colour and the tightness of the Outlet Frit of the Outlet Hose f necessary change the Outlet Frit of the Outlet Hose c Open Audit Trail Folder Make a diagnosis o
28. bings anymore Illustration 27 Manifold Illustration 28 Manifold 2 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 33 of 68 Mustration 29 Manifold 3 If there are too high flow rates the temperature in the tank and the dispensing volume are A incorrect 4 4 12 Magnetic Stirrer There are 3 magnetic stirrer types which are used in the DissoPrep If there is an inspection of the internal tank change the stirrer assembly to the latest version see Illustration 19 New Stirrer The actual Magnetic Stirrer has a conical shape is PTFE coated and has an approximate dimension of L38mm x D8mm Retatrrer P 4 Qe Old Stirrer Pe LV yy lt New Stirrer N Pi ail Device in the Shape of a Disk Mustration 30 Magnetic Stirrer Assembly of the Tank 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 34 of 68 From time to time the Magnetic Stirrer must be replaced anyway because the PTFE coating gets porous and the inside of the magnet corrodes After transportation and installation of the DissoPrep or after replacing the Magnetic Stirrer Fa ensure that the Magnetic Stirrer is in its position in the pit After power ON and during the electronic boot sequence the Magnetic Stirrer should
29. ce the CPU Voltage and counter clockwise to increase the CPU Voltage A The potentiometer reacts very sensitive therefore adjust it unplugged S N lt 2406XXXX for Adjust on the unplugged Power Supply Get on the MIBI Test Point MIBI to 5 17 Volts 5 15 0 02 Volts 5 13 5 17V S N 2408XXXX for Adjust on the unplugged Power Supply Get on the MIB2 FD Socket MIB2 to 5 17 Volts 5 15 0 02 Volts 5 13 5 17V Plug on the 8 pole cable again and check the CPU Voltage on the MIB 4 4 21 Rear Panel with Power Supply and TRIAC s S N gt o0000xx Mustration 42 Power Supply and Heater TRIAC 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 46 of 68 4 5 Performance of a Tank Emergency EMPTYING It may happen by accident the tank is filled and there is no way emptying it through normal operation In this case you may disconnect internal tubes to empty the tank Disconnect the tubing of MV7 top side plug on the rear side valve array Disconnect also the tubing of MV10 bottom side plug on the front side valve array Before final removing squeeze the tubing to avoid dropping of liquid Feed the tubing in an appropriate vessel A Take attention if acid is in the tank DEPT DI AKI LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of
30. ck load Never tighten the Transport Lock Screw at units with S N lt 2806XXXX fastened The Transport Lock Screw must be opened 2 turns In former DissoPrep the Transport Lock Screw at units with S N lt 2806XXXX was coated with a glue tape or glue to lock the adjustment Remove the glue not only from the bore of the Transport Lock Screw but also from the Space Washer of the Transport Lock Screw Alternatively to save the screw from turning itself you carefully hurt the screw thread with pliers The Tank Fixing Screw is fastening the Tank over a Silent Rubber Block Mustration 19 Transport Lock Screw Tank and Balance Fixing Screws at units with S N lt 2806XXXX LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 29 of 68 4 4 8 2 Opening of the Tank Ra Transport Lock Screw Tank Firing Scriw Balance Fixing Screws Aff f l f i i a TOP FRAME l peat ae i Space Washer bol bx Stent Block A Rubah 7 4 lt ROTATION POSITION MARK Fann Cover TANK COVER ROTATION POSITION MARK ariii TANK FRAME CEET vere j TANK Mustration 20 Schematic Diagram upper side of the Tank at WZI WZ3 without Transport Lock 1 Before opening the tank the Pondering Cell Design must be fixed with the Transport Lock Screw at units with S N lt 2806XXXX Units with S N 2806XXXX do no
31. e DPX_RC exe is used in the main menu Monitor the actuated valve numbers and the corresponding ADC Signals of the Flow in g sec can be red Illustration 7 Solenoid Valve of the DissoPrep SN gt 4xxxxxxx 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 20 of 68 Mustration 8 Opened Solenoid Valve of the DissoPrep To remove the valve from the manifold you have to 4 4 5 CPU with Chip Disk MIBI based The computer module consists of an output device the analogue digital converter and the CPU with Chip Disk The Chip Disk stores the firmware all relevant auxiliary files and the individual settings of the DissoPrep like S N and calibration parameters If replacing the Chip Disk you change the identity of the DissoPrep Take care to plug on the Chip Disk carefully and correctly and don t shift the pins horizontally or vertically ChipDisk i penea emer emer memsl CPU CE gg CED a ete x Lex es00ceoR Coes eecocooacocoonen o Mustration 9 CPU with Chip Disk on MIBI S N lt 2406XXXX LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 21 of 68 4 4 6 Main Interface Board MIB The MIBI S N lt 2406XXXX contains mainly the Connection Sockets and holds the PC104 modules
32. ed Oxygen Meter e g WTW Oxi 330 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Appendix A Installation and Maintenance Tools and Instruments Page 68 of 68 Appendix B Spare Part List Please find the latest version of the Spare Part List under http www riggtek com laboratoryinstruments login htm and login with Username and Password Prices indicated are purchase prices for the representatives Changes will be made without advanced notice 2007 2010 RIGGTEK GmbH
33. ed after location of the Magnetic Stirrer and the TIMEOUT Error Message arises the Magnetic Stirrer is not yet located in its position correctly Follow repeatedly the instructions to locate the Magnetic Stirrer see Chapter Magnetic Stirrer 7 3 3 Error Message NoBalance The Pondering Cell balance does not work Release the Transport Lock Screw at units with S N lt 2806XXXX 4 turns see Chapter Transport Lock Screw Balance Fixing Screws Tank Fixing Screw The Error Message changes to the readout of the actual Pondering Cell Signal e g Weight 14778 In that case the Pondering Cell works generally Any other reason is causing the Error Message Check the voltages on the circuit board of the Pondering Cell see Chapter Load or Pondering Cell 7 3 4Error Message TempGrad or ErrSTIRRER A temperature gradient of the media was detected in the tank The Magnetic Stirrer does not work sufficiently The Magnetic Stirrer is not in its position in the pit of the tank Tilt the DissoPrep in an acute angle to the front and to the front left After reposition of the 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Troubleshooting Page 63 of 68 Magnetic Stirrer the Error Message ErrSmin may arise Follow the EMTYING and use the last step with OutTb2 to set a new tare internally The inside magnet of the stirrer is corroded see Chapter 0
34. emperature Safety Sensor see Chapter Temperature Safety Switch and Temperature Safety 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Troubleshooting Page 58 of 68 Sensor fixed on the heater Both safety devices recover after cooling down There is a LED near the plug of the heater on the MIB This LED flashes ON during heating power is commanded from the firmware The LED also indicates a proper connection of the solid state relay TRIAC The TRIAC with 25 amps switches the mains power of the heater If the temperature setting is 20 C the Heater is disabled If the LED of the heater flashes but does not heat check the heater coil and the Temperature Safety Switch Measure the internal resistance of the heater which should be approx 7 to 25 Ohm according mains power voltage If the heater and the Temperature Safety Switch are checked as all right then replace the TRIAC If the monitor from the RC Software File DP_RC exe indicates heater activity but LED do not flash the TRIAC is defective on the driver side input or the polarity of the input wiring is wrong 7 2 6 Disagreement between Dispensed Amount and Protocol Printout Result It is unavoidable that the actual external dispensed amount diverges with that one of the internal protocol Too many influences can disturb a proper result e g dripping of the Outlet Hose after ending of the DISPENSE or a deviation from weighin
35. emperature Safety Switch Na Mustration 40 Heater with Temperature Safety Switch and Safety Sensor 4 4 20 Rear Panel with Power Supply and TRIAC s S N lt 4xxxxxxx On the Rear Panel are assembled the Power Supply and the TRIACs The TRIACs are Solid State Relays for switching the AC Vacuum Pump and the Heater The TRIAC for the AC Vacuum Pump has 0A and the TIAC for the Heater has 25A rating TRIACs with 10A are connected with a transient voltage suppressor RC filter circuit The DC Vacuum Pump does not need the TRIAC it is wired directly with the pump socket on the MIB2 V45 unplugged 8 pole cable 5 17V Mustration 41 Power Supply Pump TRIAC and Heater TRIAC To get access not only to the Power Supply and the TRIACs but also to the rear Solenoid Valves and the MIB you open the screws of the Rear Panel remove the plugs and turn the Rear Panel over to you 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 45 of 68 4 4 20 CPU Voltage Adjustment On the switching Power Supply is a small potentiometer to adjust the CPU Voltage For adjusting the CPU Voltage you have to remove unplug the 8 pole cable of the switching Power Supply Measure the CPU Voltage at the unplugged 8 pole cable If necessary you adjust the CPU Voltage carefully For this you turn the potentiometer with a small screwdriver clockwise to redu
36. ent EMPTYING 60 7 2 12 Not enough vacuum vacuum test failed 6l 7 3 Error Messages eee 7 3 1 Error Message REBOOT 62 7 3 2 Error Message TIMEOUT 62 7 3 3 Error Message NoBalance 62 7 3 4 Error Message TempGrad or ErrSTIRRER 62 7 3 5 Error Message Overheat 63 7 3 6 Error Message MaxLEVEL 63 7 3 7 Error Message ErrSMIN 63 7 3 8 Error Message ErrFLOW 64 7 3 9 Error Message ErrFlowADD 65 e Check the Additive supply Check whether the tubes are folded whether the Filter Cartridge or the Inlet Hose Coupling causes the problem of insufficient Additive supply 65 7 3 10 Error Message ErrVAC 65 7 3 11 Error Message ErrPRESS 65 7 3 12 Error Message ErrLEAK 65 7 3 13 Error Message ErrADD 65 7 3 14 Error Message ErrUnknown 66 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Page V of 68 Appendix A Installation and Maintenance Tools and Instruments 66 Appendix B Spare Part List 68 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Welcome TABLE OF ILLUSTRATIONS Illustration Pictorial Schematic of the DissoPrep Illustration 2 Physical Diagram of the DissoPrep Illustration 3 Inlet Filter Cartridge type of the Inlet Hose Illustration 4 Solenoid Valve of the DissoPrep Illustration 5 Opened Solenoid Valve of the DissoPrep Illustration 6 Tube Restrictor Fitting as Flow R
37. eration Manual for the DissoPrep and the Operation Manual for the Remote Control Software RC Software File DP_RC exe The Chapters of this Reference Guide are self contained The stringing together of the Chapters does not follow any definite order The Reference Guide at hand is not meant for the end user You may tell the end user about or show him the Service Manual but never hand it over 1 2 Contact Please inform me about your experiences and let me know should you need any advice or support Send an email to service riggtek com and indicate the S N and the failure of the DissoPrep 1 3 Warning All maintenance or repair work should be carried out only by trained service personnel to A avoid dangers particularly by AC power or acidic medium 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Installation Work Page 8 of 68 2 Installation Work Follow the instructions of the Operational Manual 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Application Tips Page 9 of 68 3 Application Tips 3 1 Mixing of Acid Buffer or SLS When mixing additives the specified dilution ratio and the viscosity of the concentrate are limiting factors High concentrate viscosity reduces the flow rate during filling the tank The salt of the buffer or of the SLS must be completely dissolved Any crystallization must be avoided even during the desired temperature increase
38. es In 2004 a new electronic design renewal of all PCB Hardware has been launched All FA DissoPrep with S N 2408XXXX are equipped with new Electronic Hardware and an electronic Pressure Gauge Sensor The complete hardware package is plug compatible to the old hardware but not the individual components MIB2 are not compatible Do not mix up the old electronic with new Firmware Versions All DissoPrep with S N lt 2406XXXX or Main Interface Board MIBI are equipped with the Firmware Version 4 nnn all DissoPrep with S N 2408XXXX or Main Interface Board MIB2 are equipped with the new Firmware Version 6 nnn A Firmware Versions of the old electronic design MIBI and that of the new electronic design In 2008 a new Pondering Cell has been launched All DissoPrep with S N 2806XXXX are equipped with a new type of Pondering Cell No Transport Lock Screw is used anymore quipp typ IS P yI 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 12 of 68 Fa In 2009 a new electronic design and Firmware generation has been launched All DissoPrep with S N 2908XXXX are equipped with new MIB2 V45 and a 2 lines LCD display The serial number starts with R for better distinguishing The firmware is from series 7 nnn and this one is combined with a software key which includes the Serial Number exclusively DPX which do not have a
39. estrictor for MV I MV3 and MV8 Illustration 7 CPU with Chip Disk on MIBI S N lt 2406XXXX Illustration 8 Old Main Interface Board MIB 1 S N lt 2406XXXX Illustration 9 Main Interface Board MIB2 also MIB3 starting with S N 2408XXXX Illustration l0 Illustration Illustration 2 Illustration 13 Illustration 4 Illustration I5 Illustration 16 Illustration 7 Illustration l8 Illustration 19 Illustration 20 Illustration 21 Illustration 22 Illustration 23 Illustration 24 Illustration 25 Illustration 26 Illustration 27 Illustration 28 Illustration 29 Illustration 30 Illustration 31 Illustration 32 Illustration 33 Illustration 34 Illustration 35 Illustration 36 Illustration 37 Illustration 38 Illustration 39 Illustration 40 Illustration 41 Illustration 42 Illustration 43 Illustration 44 Grounding Lead on the MIBI Pondering Cell S N lt 2806XXXX Pondering Cell S N 2808XXXX 2810XXXX ADC Signals of the Menu Monitor of the Remote Control Software Preamplifier Board of the Pondering Cell Design Pondering Cell Design 3 Fixing Arrangement Transport Lock Screw Tank and Balance Fixing Screws at units with S N lt 2806XXXX Schematic Diagram upper side of the Tank at WZI WZ3 without Transport Lock Schematic Diagram of the lower side of the Tank Manifold Manifold 2 Manifold 3 Manifold 4 and 5 Manifold 6 Magnetic Stirrer Assembly of the Tank Old Stirrer Speed
40. f the Error Messages d Open System Folder get and set the Date and the Time get and note the Firmware Version f necessary make a Software download for an update note the new Firmware Version e Open Monitor Folder Note the ADC of Leak and check leakage traces inside housing 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Troubleshooting Page 56 of 68 If the amount of Leak is lt 4000 clean the Leak Sensors and check the Leakage Lanes Note the ADC of Mass at empty tank Ifthe amount of Mass is gt 4500 on WZI or gt 6800 on WZ2 WZ3 change the Pondering Cell 17 Run the Methods sequence of the VALIDATION LOGBOOK and make checks additionally as follows a PREFILL Check time from START until PREFILL or FILL starts max 4 min Perform a Balance Check during DEGASS period end of FILL note the result 3 Ig at the end of DEGASS period check stability of the vacuum max loss 3 mbar in 5 min f specified vacuum is not reached in time check the Air Leakage If timing and vacuum do not correlate perform the Vacuum Pump Check according 4 4 14 1 If the vacuum pump check is not ok change the Pump b FILL Note the ADC of Flow of MVI 7 2g sec Note t
41. g A difference of 2 grams is a normal result Other results can be based on mechanical friction a wrong calibration or a wrong setting of the parameter VorstopPunkt 80 see Chapter INI DATA Folder accessing the TINI FILE If the values lie over the usual difference of 2 grams you should check the period of the Fine Dispense The period of the Fine Dispense should last 6 2 seconds If necessary adjust the period of the Fine Dispense by varying VorstopPunkt 80 in the TINI 230 File or in the TINI 115 File The TINI File is accessible with the RC Software over the Folder IniData If the period of the Fine Dispense is too short long e g sec make VorstopPunkt 80 5 higher 5 lower 7 2 7No Dispense Function This Error occurs mainly after longer Stand By Bacteria have clogged the outlet valves MV3 MV9 and MV1O Open the valves and clean the diaphragms Clean the tank by filling with 0 2 Sodium Hypo Chloride most effective or 5 Hydrogen Peroxide more compatible Set the Temperature to 20 0 C Do not use the heating Check whether the Vacuum Pump can suck in and expel air through the Exhaust tubing The tubing should not be in a closed vessel or beaker 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Troubleshooting Page 59 of 68 7 2 8 Insufficient Dispense Precision Possible reasons for smaller deviations The operator
42. ges of the AUDIT TRAIL File After technical diagnosis of the Error Message s in the AUDIT TRAIL File make logical conclusions for the repair of the DissoPrep Check the Leak Sensors and Leakage Lanes Check the timing and the amount of the pressure and the vacuum Check the Pondering Cell balance test Check the Flow Rates 10 Should be part of the user and not of the Maintenance Clean by filling the tank with 0 2 Sodium Hypo Chloride most effective or 5 Hydrogen Peroxide more compatible 1 Execute a Validation according Validation Logbook Calibration and Performance Test 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Maintenance Work Page 55 of 68 6 2 Maintenance Checklist for DissoPrep Pos Description Figures Done Check the position of the DPX stable and horizontal underground no direct sunshine 2 Check the power connection the printer connection if existing and the RC Software connection if existing 3 Check the inlet tubings sloped ends dense without sharp bend without algae growth filter visibly ok 4 Check the media supply sufficient ventilation clean media supply in all filling situations 5 Check the outlet tubing dense without sharp bend without algae growth outlet frit visibly ok 6 Check the Transport Lock Screw adjustment at S N lt 2806XXXX or WZI open I 4 turns 7 Switch the unit on
43. he ADC of Flow of MV2 18 5g sec if lower Flowrate check the inlet Filter Cartdrige Note the ADC of Flow of MV 8 8 3g sec Check noise of the pump c DISPENSE With begin of the Dispense note the final reached vacuum according 4 4 13 Vacuum Test lt 250mbar Note the ADC of Flow of MV3 7 2g sec Note the ADC of Flow of MV9 plus MV10 50 I 0g sec During the Dispense check flow rate approx 30 sec 1000 mL f the flow rate is too low or the pressure is to high valves are switching for suspending pumping change the Dispense Hose Outlet Frit At the end of a dosage note the Fine Dispense timing 4 8sec f necessary adjust the period of the Fine Dispense by varying VorstopPunkt 80 in the IniData TINI File if the period is too short long e g Isec make VorstopPunkt 80 5 higher 5 lower 18 Perform the complete Validation while the housing is closed routine conditions 19 Check the lifetime of the filter in the media inlet tube change when remaining life time lt 500I ask customer 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Troubleshooting Page 57 of 68 7 Troubleshooting 7 1 General Troubleshooting Tips Follow the troubleshooting recommendations and do not guess the failure without making logical conclusions Use also the content of the error message s in the AUDIT TRAIL File and
44. heck the supply voltage of 5V and the signal voltage of 0 1 to 2 5V The typical signal voltage at empty tank is 0 5V Signal 5 Volis AG Ground Mustration 17 Preamplifier Board of the Pondering Cell Design LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 27 of 68 4 4 7 4Replacement of the Pondering Cell Design WZ1 or Design 3 WZ3 Have also a look to the assembly drawing in chapter Opening of the Tank 1 At units with S N lt 2806XXXX and or Pondering Cell Design 1 fix the Transport Lock Screw 4 turns Units with S N 2806XXXX amp Pondering Cell Design 3 do not have a Transport Lock Screw 2 Mark the Rotation Position of the Tank Cover against the Tank Body Mark the Rotation Position of the Bottom Tank Body against the aluminium chassis of the Bottom Frame 3 Unplug the Pondering Cell Wire and remove it from clips 4 Open the Top Tank Fixing Screw at Pondering Cell Let the tank body move down carefully Gluing tape may still fix the tank A screw driver helps to lever the gluing Silent Rubber Block 5 Open the Transport Lock Screw at units with S N lt 2806XXXX and or Pondering Cell Design I remove it and take away the Space Washer Units with S N 2806XXXX amp Pondering Cell Design 2 do not have a Transport Lock Screw 6 Open the Balance Fixing Screws and take a
45. lectronic Remote Connections Page 49 of 68 5 3 1 INI DATA Folder accessing the TINI File The TINI File allows configuring adjustable parameters for the Initialisation Normally no adjustments are necessary But there are different values for the individual mains supply voltage e g 230 115 and 100 Volts Nevertheless the actual data are shown here Remark The following TINI parameters are for firmware lt 6 nnn or the older heater with single coil Remark not all the parameters shown here are necessarily on your DissoPrep 2009 03 26 DissoPrep Initialisation File for 230 VAC Power Supply rr Optimized for 230 Volt MV 1 Takt 12 MV2Takt 6 Kontrollmasse 400 Heizleistung 0 6 maxHZG 4 MixPunktPause 30 KeineMixPunktPause 9000 Min FlussRate 2 0 Fluss TestAnzahl 6 DiffEmptySMin 1500 Kernwaage GrenzTempGrad 0 2 SpuelVolumen 1500 DspSpuelVolumen 500 VorstopPunkt 80 AddVorStopPunkt 7 AdditiveSupplement 500 PressureGauge PressureGaugeCal_ 1 235 PressureGaugeOffset_ 0 PressureGaugeVac_ 300 PressureGaugePress_ 1600 PressureGaugeFill_ 90 PressureGaugeFHyst_ 10 MixerRPM 255 FlussFaktor 1 8 WaagenPause 4000 MaxLevelWZ 7000 guilty for WZ3 For WZI and WZ2 4 0 MIB 1 400 individual setting following lines for MIB2 only ErrADD then set 5 to 8 usually superior value ErrADD then set 400 to 800 usually 100 higher than the former set value Note only for instrumen
46. nd the Safety Sensor are fastened at the Heater In the case of a higher temperature as 75 C the Temperature Safety Switch interrupts the AC power to the Heater The Temperature Safety Switch recovers when temperature cools down to normal The Safety Sensor is a NTC resistor and has a trigger temperature of approximately 65 C If the temperature rises above 65 C the heater control circuit will switch off the heater and the error message OverHeat appears on the display of the DissoPrep The Temperature Safety Sensor recovers when temperature cools down to normal OverHeat events are documented in the AUDIT TRAIL File which can be read with the Remote Control Software RC Software File DP_RC exe The RC software folder Monitor indicates under normal conditions in window ADC T_Heat approx 4000 digits This figure falls as soon as dangerous heat occurs The trigger level lies between 3000 and 1000 digits S N 2408XXXX the indication of the triggered Safety Sensor is also monitored in the syspos window under Heat_X With the reaching of the trigger level the heater control is suspended However the FILL mode will not be interrupted The Temperature Safety Switch and the Safety Sensor don t have to be adjusted 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 44 of 68 Temperature Safety Sensor T
47. never disabled Leak events are documented in the AUDIT TRAIL File which can be read with the Remote Control Software RC Software File DPX_RC exe is lt 4000 digits This value decreases as soon as liquid is discovered The trigger level is MIBI Under normal conditions the default value which can be read in the ADC Signal Leak between 1000 and 3000 digits MIB2 A leak is indicated in the syspos Frame at position Leak X 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 38 of 68 The Leak Detectors should be carefully cleaned on both sides For this you take them from the Base Pan and clean them with water and alcohol Corroded Leak Detectors must be replaced Mustration 36 Leak Detector LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 39 of 68 4 4 16 Vacuum and Pressure Switch S N lt 2406XXXX The Vacuum Switch and the Pressure Switch are located in the front right upper corner of the DissoPrep at units with S N lt 2406XXXX A The factory settings of the Vacuum Switch and the Pressure Switch shouldn t be changed The Vacuum Switch controls the vacuum and determines the vacuum trigger limit With reaching of the vacuum the filling of the tank starts A Central Adjus
48. nstead During the PREFILL with begin of sucking you check the barometric pressure The barometric pressure should be 330mbar absolute in less than 4 minutes Mustration 38 Location of T Piece and Tubing to the Pressure Switch at Y N 2406XXXX LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 41 of 68 4 4 17 Pressure Gauge Sensor S N 2408XXXX With the launch of a new electronic design in 2004 all DissoPrep with S N 2408XXXX were equipped with a Pressure Gauge Sensor instead of the Vacuum and Pressure Switch The pressure gauge is flanged on the manifold over the solenoid valve MV4 Mustration 39 Pressure Gauge Sensor at S N gt 2408XXXX 4 4 17 1 Vacuum Test Please find the detailed Vacuum Test in the Validation Logbook 1 S N 2408XXXX with Firmware Version lt 6 202 see Validation Logbook or Chapter4 4 18 1 A maximum of vacuum is reached when setting the degassing time to 360 instead of 120 seconds 2 S N 2408XXXX with Firmware Version 6 203 see Validation Logbook or Chapter4 4 18 1 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 42 of 68 4 4 17 2 Calibration of the Pressure Gauge Sensor Please find the detailed Calibration of the Pressure Gauge Sensor in the Validation Logbook S N 2408XX
49. of the Flow in g sec can be red The side of the valve marked with a red dot in the Illustration 4 Solenoid Valve below represents the seat position of the valve 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 17 of 68 Pee Seat Position of the Valve Mustration 4 Solenoid Valve of the DissoPrep The tubing connection nipples are not too rigid and can break if the tube is not put on or off A in a straight axial direction Warm the PE tube with a hair dryer to prevent breaking off the nipple 4 4 3 1 Disassembling of a Solenoid Valve The valve can be disassembled according to the following Mlustration 5 Opened Solenoid t Valve of the DissoPrep LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 18 of 68 Solenoid N N 2 amp i ta S _ 107 ji O Disassembled Valve 1 2 3 4 5 6 7 Mustration 5 Opened Solenoid Valve of the DissoPrep RR ay Mustration 6 Tube Restrictor Fitting as Flow Restrictor for MVI MV3 and MV8 Above labelled components in Opened Solenoid Valve and Tube Fitting as Flow Restrictor Brass Spring Sleeve 6 in MV1 MV3 MV8 only Restrictor Insert replaced by 1 7 Valve Body Fixing Screw
50. olarity Marking Mustration 33 Liquid Level Switch of the Tank The LEDs of the Liquid Level Switches are on the Display Interface Board DIB The LEDs are OFF at empty tank The illustration may vary but the LED s are indicated Y LED Vacuum Switeh LED Pressure Switch LED Maximum Level Sensor LED Minimum Level Sensor Mustration 34 LED of the Liquid Level Switches the Vacuum and Pressure Switch on the DIB 1 If the LED of the Minimum Level Sensor doesn t turn OFF or ON any more at all or become weaker just glowing very low then the level switch must be replaced 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 37 of 68 4 4 14 Maximum and Minimum Level Switch with temperature sensor S N gt 00000x In DissoPrep S N gt 4xxxxxxx a combined minimum maximum temperature sensor is used It is installed in the top of the tank and can be changed without opening the tank and without loosening the balance Mustration 35 Combined minimum maximum temperature sensor 4 4 15 Leak Detector There are two Leak Detectors on the Base Pan of the DissoPrep which are connected in series The purpose of the Leak Detectors is the search for media leaks in the DissoPrep As soon as the Leak Detectors discover liquid or strong acid vapour the filling of the tank is stopped However the dispensing or emptying procedure will be
51. olenoids of the DissoPrep are of the same type The valve bodies are interchangeable The solenoid s wires have different lengths but need not to be changed The valves are equipped with a diaphragm or membrane 4 to isolate media and to prevent a damaging of the internal armature Old DPX lt 2004 There are two versions of valve bodies one version for a lower flow rate and a second version for a higher flow rate The valve version with the smaller seat diameter has a Restrictor Insert 6 The smaller valves are MV1 MV3 and MV8 They have typical flow rates of 8 3g sec Instead of the Restrictor Insert there is a Tube Fitting as flow restrictor 11 available The Restrictor Fitting is placed on the valve manifolds The larger valves are MV2 MV9 and MV 10 These valves have a typical flow rate of 25 0g sec The valves MV4 MV5 MV6 and MV7 are used to switch the air stream around the pump The Valve MV4 is equipped with a Support O Ring 5 d 2mm OD 3mm R7 made of EPDM to avoid a collapse of the Diaphragm 4 under high vacuum The Support O Ring 5 is positioned as a floating insert in the internal valve seat chamber All DissoPrep with S N lower 22040105 have not been equipped originally with this Support O Ring They should be upgraded If the Remote Control Software RC Software File DPX_RC exe is used in the main menu Monitor the actuated valve numbers and the corresponding ADC Signals
52. ow and the Error Message MaxLev media will leave See also Error Message MaxLev in Chapter 7 3 6 After a system break down media will leave See also Error Message TIMEOUT 7 2 11 Permanent EMPTYING Be sure that the Magnetic Stirrer is in its position in the pit Tilt the DissoPrep in an acute angle to the front and to the front left After reposition of the Magnetic Stirrer the Error Message ErrSmin in Chapter 7 3 7 may arise Follow the EMTYING and use the last step with OutTb2 to set a new tare internally 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Troubleshooting Page 61 of 68 7 2 12 Not enough vacuum vacuum test failed If the barometric Pressure or the Vacuum shown on the Protocol is inadequate not enough see vacuum check Chapter 4 1 15 or in Validation Logbook there are several possible reasons There is a leakage e g at the Tank Cover Seal at a Valve or a Manifold Make a visual check if you can see any leakage while the Dissoprep is performing PREFILL FILL DISPENSE Then check with the RC software the flow rate at the valves according the Maintenance Checklist of DissoPrep chapter 6 2 The Vacuum Pump s Diaphragm is broken Connect the Barometer directly to the pump vacuum should round about 30mbar If not the exchange of the pump will be needed see chapter 4 4 15 2 Solenoid MV4 has collapsed under vacuum such
53. pling causes the problem of insufficient media supply Select a lower ratio at a concentrate with high viscosity f ErrADD appears after a new Flow Restrictor was implemented check the setting in the INI DATA Folder of the RC Software content of the TINI File AddVorStopPunkt 5 to 8 see Chapter 5 3 1 Usually the superior value of the former set value is entered If the Error ErrADD appears repeatedly check Solenoid Valve MV8 7 3 14 Error Message ErrUnknown This error may occur if the pressure sensor is not working properly This error also may occur if you have an defective load cell type WZ2 Appendix A Installation and Maintenance Tools and Instruments Allen Hex Wrench 5mm for the Transport Lock Screw at units with S N lt 2806XXXX Mustration 49 Allen Hex Wrench 5mm Allen Hex Wrench 8mm for the Tank Fixing Screw Hex Wrench 3mm for the Tank Cover Hex Wrench Nut 19mm for the Valves Illustration 50 Hex Wrench Nut 19mm 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Appendix A Installation and Maintenance Tools and Instruments Page 67 of 68 Digital Barometer 0 to 300mbar absolute for Auto Calibration of Pressure Mustration 51 Digital Barometer 0 to 1300mbar absolute Digital Thermometer for Auto Calibration of Temperature Mustration 52 Digital Thermometer Remote Control Software RC Software File DPX_RC exe Dissolv
54. r is clogged by bacteria That may cause an increased not a decreased dispense result One of the Valves MV3 MV9 or MV 10 which are responsible for the outlet switches not correctly or has a leakage Also possible one of the inlet valves MV1 MV2 or MV8 has a leakage Watch the Remote Control Software RC Software File DPX_RC exe whose ADC Signal Flow should report zero after the DISPENSE or whose ADC Signal Mass should be stable If old style restrictor fittings are used in the unit see Illustration 5 part no 6 and Illustration 6 Valve MV3 has loosen the old style restrictor fitting The flow rate is too high Check with the RC Software see chapter 6 2 Maintenance Checklist Tendentious deviation of the set point Perform a repeated calibration in accordance to the ordinary use of the volume weight Keep the unit housing closed during this calibration to get temperature conditions as in a routine usage 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Troubleshooting Page 60 of 68 If the calibration values are higher the usual 4 gram 2 you check the period of the Fine Dispense see Chapter Maintenance Checklist for DissoPrep The period of the Fine Dispense should last 6 2 seconds If necessary adjust the period of the Fine Dispense by varying VorstopPunkt 80 in the TINI 230 File or in the TINI 115 File The TINI File is accessible with the RC
55. raw medium with a smaller seat diameter or MV8 for acid or buffer one of the Outlet Valves MV3 MV9 or MV 10 or even if the Outlet Frit is clogged Perform a complete EMPTYING with the step EmptALL This procedure will back flush the valves Check the Flow Rates with the Remote Control Software RC Software File DPX_RC exe in the Monitor Menu Watch the values and compare them with the specified values in Chapter Solenoid Valves or have a look into the DissoPrep Maintenance Checklist see Chapter Maintenance Checklist for DissoPrep The balance is not working correctly Make a Balance Check see Chapter 4 4 7 3 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Troubleshooting Page 65 of 68 7 3 9Error Message ErrFlowADD e Check the Additive supply Check whether the tubes are folded whether the Filter Cartridge or the Inlet Hose Coupling causes the problem of insufficient Additive supply 7 3 10 Error Message ErrVAC The Error Message occurs as a consequence if the Vacuum Pump cannot reach the predefined vacuum in less than 5 minutes or if air is sucked in while raw media is running low The vacuum should be at least 300mbar absolute Check the Vacuum Pump see Chapter 4 4 18 1 Have also a look into the DissoPrep Maintenance Checklist see Chapter Maintenance Checklist for DissoPrep Reasons for the Error Message can be a weakly working pump
56. rrer even when the Minimum Level Sensor works correctly Follow the EMTYING and use the last step with OutTb2 to set a new tare internally The Minimum Level Sensor also can be irritated if the Magnetic Stirrer springs out of its pit because of too high speed Adjust the Stirrer Speed see Chapter 4 4 12 2 But adjust the potentiometer from 12h to the Ih or 10h Position The Error Message may indicate that the Minimum Level Sensor does not switch properly see Chapter 4 4 13 If the LED of the Minimum Level Sensor does not turn off any more at all also does not flicker or if it just glows then the Switch must be replaced 7 3 8Error Message ErrFLOW The Error Message can be caused through an insufficient flow during the PREFILL the FILL or the DISPENSE ErrFlow simply can be caused during the first time of PREFILL Press START again The Inlet Hose is too long The Filter Cartridge is too large Check the media supply Check whether the tubes are folded whether the Filter Cartridge or the Inlet Hose Coupling causes the problem of insufficient media supply Check whether any cables or tubes lie under the DissoPrep Remove them The Transport Lock Screw at units with S N lt 2806XXXX must be released 4 turns see Chapter Transport Lock Screw Balance Fixing Screws Tank Fixing Screw The Error Message can be a consequence of an inaccurate Flow Rate e g if one of the Inlet Valves MVI for
57. rt no 6 and Illustration 6 Valves MV I or MV8 has loosen the old style restrictor fitting The flow rate is too high Check with the RC Software see chapter 6 2 Maintenance Checklist Reason for the Error Message also can be a wrong calibration Execute a calibration with a single vessel first followed by a multiple vessel calibration The balance is not working correctly Make a Balance Check see Chapter Balance Check 7 3 7Error Message ErrSMIN The Error Message may arise if the Minimum Level Sensor is irritated from the Magnetic Stirrer see Chapter Maximum and Minimum Level Switch That may happen after transport or moving of the DissoPrep Be sure that the Magnetic Stirrer is in its position in the pit After switching the DissoPrep 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Troubleshooting Page 64 of 68 on during the time of the boot the Magnetic Stirrer should be audible for a short moment If not then tilt the DissoPrep in an acute angle to the front and to the front left see Chapter 0 Under unusual conditions it can happen that the Magnetic Stirrer locks the Minimum Level Sensor In this case the corresponding LED of the Minimum Level Sensor see Chapter 4 4 13 is on If so tilt the DissoPrep not only in an acute angle to the front but also to the left and to the right see Chapter 0 The Error Message may arise after reposition of the Magnetic Sti
58. sign WZI 4 4 7 2 Pondering Cell Design 3 W23 4 4 7 3 Balance Check 4 4 7 4 Replacement of the Pondering Cell Design WZ1 or Design 3 WZ3 2007 2010 RIGGTEK GmbH Page Il of 68 10 10 II 13 14 15 15 15 16 17 18 19 19 20 21 23 24 24 25 25 26 27 DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Page Ill of 68 4 4 8 Storage Tank and Pondering Cell Assembly 28 4 4 8 1 Transport Lock Screw Balance Fixing Screws and Tank Fixing Screw at S N lt 2806XXXX 28 4 4 8 2 Opening of the Tank 29 4 4 9 Bottom Side Tank Bearing 30 4 4 10 Manifolds on S N 2408XXXX 3I 4 4 11 Manifolds S N gt 4xxxxxxx 32 4 4 12 Magnetic Stirrer 33 4 4 12 1 Old Stirrer Speed Adjustment on MIB I 34 4 4 12 2 New Stirrer Speed Adjustment on MIB I 34 4 4 12 3 Stirrer Speed Adjustment on MIB2 35 4 4 13 Maximum and Minimum Level Switch S N lt 4xxxxxxx 36 4 4 14 Maximum and Minimum Level Switch with temperature sensor S N gt 4xxxxxxx 37 4 4 15 Leak Detector 37 4 4 16 Vacuum and Pressure Switch S N lt 2406XXXX 39 4 4 16 1 Vacuum Test S N lt 2406XXXX at closed DissoPrep 40 4 4 16 2 Vacuum Test S N lt 2406XXXX at opened DissoPrep 40 4 4 17 Pressure Gauge Sensor S N 2408XXXX 41 4 4 17 1 Vacuum Test 4l 4 4 17 2 Calibration of the Pressure Gauge Sensor 42 4 4 18 Vacuum Pump 42 4 4 18 1 Vacuum Pump Check 42 4 4 18 2 Replacement of the Vacuum Pump 43 4 4 19 Temperature Safety Swi
59. t have a Transport Lock Screw 2 Mark the Rotation Position of the Tank Cover against the Tank Frame Mark the Rotation Position of the Bottom Tank Frame against the aluminium chassis of the Bottom Frame 3 Unplug the Pondering Cell Wire and remove it from clips 4 Unplug the Maximum Level Sensor Wire 5 Unplug the Ribbon Cable of the Main Interface Board MIB which is directed to the Display Interface Board DIB 6 Circularly loose the 8 hex screws of the Tank Cover 7 Open the Top Tank Fixing Screw Do not remove the Tank Fixing of the bottom side 8 Remove the 8 screws of the Tank Cover Swing the Tank Cover carefully to the left side and put it down on top of the aluminium frame of the DissoPrep 9 Now you have access to the Magnetic Stirrer the Liquid Level Sensors and the Temperature Probe For full access to the Minimum Level Sensor and the Temperature Probe put the DissoPrep on the left side and remove the Base Panel For avoiding stress on the wire connection feed the wire twist by hand 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 30 of 68 10 For screwing in or out of the Minimum Level Sensor there is a special tool key available 4 4 9Bottom Side Tank Bearing Tank Plastic Washer a A Stirrer Drive Silent Block Rubber Frame
60. tch and Temperature Safety Sensor 43 4 4 20 Rear Panel with Power Supply and TRIAC s S N lt 4xxxxxxx 44 4 4 20 1 CPU Voltage Adjustment 45 4 4 21 Rear Panel with Power Supply and TRIAC s S N gt 4xxxxxxx 45 4 5 Performance of a Tank Emergency EMPTYING 46 5 Understanding of the Electronic Remote Connections 47 5 1 DOS Connection S N lt 2406XXXX 47 5 2 Floppy Disk Connection for S N 2408XXXX MIB2 47 5 3 WINDOWS Connection with RC Software 48 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Page IV of 68 5 3 1 INI DATA Folder accessing the TINI File 49 5 4 WINDOWS Connection with HYPERTERMINAL S N 2408XXXX MIB2 5I 5 4 1 Firmware Update for MIB2 5I 5 4 2 Update of the Identification File SETUP DSP 5I 6 Maintenance Work 54 6 1 Overview over annual preventive Maintenance 54 6 2 Maintenance Checklist for DissoPrep 55 7 Troubleshooting 57 7 1 General Troubleshooting Tips eee 7 2 List of Errors 2 ee ee ee 7 2 1 No lighting LED at the Mains Switch 57 7 2 2 No lighting Display 57 7 2 3 No Operation no Display only lighting SETUP MINUS and PLUS LED 57 7 2 4 Inoperable Vacuum Pump 57 7 2 5 Inoperable Heater 57 7 2 6 Disagreement between Dispensed Amount and Protocol Printout Result 58 7 2 7 No Dispense Function 58 7 2 8 Insufficient Dispense Precision 59 7 2 9 Insufficient Temperature Precision 60 7 2 10 Spill of Medium through the Exhaust 60 7 2 11 Perman
61. the Electronic Remote Connections Page 47 of 68 5 Understanding of the Electronic Remote Connections 5 1 DOS Connection S N lt 2406XXXX The DOS Connection is not important anymore for your update work since the Remote Control Software RC Software is available Nevertheless this Chapter is for documentation of the very old instruments To connect the DissoPrep with the PC you need a so called Zero Modem Cable which is either a 9 pole RS 232 Cable or a 25 pole parallel Date Transmission Cable with female plugs at the two ends Please contact service riggtek com if you want to update from firmware version 4 XXX to 7 XXX 5 2 Floppy Disk Connection for S N 2408XXXX MIB2 This procedure is especially helpful for S N 2408XXXX as firmware releases cannot up dated with the RC Software Please contact service riggtek com if you want to update from firmware version 6 XXX to 7 XXX S N 2408XXXX have a new MIB2 with connection possibilities of a CRT Card Graphic Card special DIMM Version a CRT Monitor a Keyboard and a 1 44 MB Floppy Disk Even if no CRT Card is available it is possible to input the commands blindly but with some care when copying the new Firmware File on the DissoPrep 1 Connect a Floppy Disk Drive 1 44 MB and a Keyboard on the MIB2 see Picture of Chapter4 4 6 2 Switch the DissoPrep ON Force the DissoPrep into the REBOOT mode by pressing the STOP Key for a long time or pressing the ESC Key 3 T
62. the error message s of the user Please inform us about your experiences and do not hesitate to ask us in case you need any advice or support Send an email to service riggtek com with information about the S N the used method and the failure occurred The newest Version of the Service Manual is available under http www riggtek com laboratoryinstruments login htm login with Username RIGGTEK Customer number and Password 7 2 List of Errors 7 2 1 No lighting LED at the Mains Switch Check the mains supply 7 2 2 No lighting Display Check on the back panel on the right the 2 fuse for the electronics The fuse is specified 2 amps slow blow 7 2 3INo Operation no Display only lighting SETUP MINUS and PLUS LED Upload the individual SETUP DSP File by means of the HyperTerminal see Chapter Firmware Update with Hyper Terminal Update of the identification File SETUP DSP The CPU Board might be defective 7 2 4Inoperable Vacuum Pump The Vacuum Pump has a thermal safety switch in its solenoid which recovers after cooling down Check on the back panel on the left the fuse for the Vacuum Pump The fuse is specified 2 amps slow blow Check the plug of the Vacuum Pump on the MIB The LED near the plug indicates a proper connection during the operation 7 2 5 Inoperable Heater There are no power fuses inside or outside of the instrument for the Heater but there is a Temperature Safety Switch and a T
63. tment Screw permits to adjust the trigger level to approximately 700mbar vacuum 300mbar absolute pressure or 230Torr Turn the Central Adjustment Screw of the Vacuum Switch counter clockwise to get higher vacuum or lower absolute pressure and clockwise to get lower vacuum or higher absolute pressure towards atmospheric pressure Use an isolated Screw Driver Move the Central Adjustment Screw carefully in 1 2 turns and A check the result Never touch the smaller screws for hysteresis The Pressure Switch indicates excess pressure Excess pressure arises if the outlet hose is e g folded or not connected A Central Adjustment Screw permits to adjust the trigger level to approximately 700mbar pressure 1300Torr Turn the Central Adjustment Screw of the Pressure Switch counter clockwise to get lower A pressure and clockwise to get higher pressure LEFT BLANK 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 40 of 68 _ Central Adjustment Screws r7 Mustration 37 Placing of the Vacuum and Pressure Switch S N lt 2406XXXX look from top side 4 4 16 1 Vacuum Test S N lt 2406XXXX at closed DissoPre Please find the detailed Vacuum Test in the Validation Logbook 4 4 16 2 Vacuum Test S N lt 2406XXXX at opened DissoPre Disconnect the Tubing at the T Piece to the Pressure Switch and connect the Barometer i
64. ts with Vacuum Pressure Sensor individual setting or automatic entry through pressure calibration no entry 0 for Firmware Versions 26 110 max speed Pondering Cell WZI S N lt 2806XXXxX 0 85 WZ2 1 2 guilty for WZ2 and WZ3 WZI 14000 rr Optimized for 15 Volt MVITakt 15 MV2Takt 6 Kontrollmasse 400 Heizleistung 0 8 maxHZG 50 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Electronic Remote Connections Page 50 of 68 r Optimized for 100 Volt MV 1Takt 25 MV2Takt 6 Kontrollmasse 400 Heizleistung 0 9 maxHZG 55 Remark The following TINI parameters are for firmware gt 7 nnn or the newer universal heater with twin coil DissoPrep Initialization File universal for 100 to 230 VAC Power Supply KKK KKK KKK KR RK KK KK KK KK KEK KKK RK KR KK KKK RR KK RK KEK KK KKK ER KK RK KEK RK KR EK KK KER 3 for Firmware 7 000 and higher or with universal heater MV1Takt 35 Range lt 5 100 gt 100V 55 MV2Takt 7 Range lt 5 100 gt Heizleistung 0 8 Range lt 0 000 10 000 gt 100V 1 0 MaxHZG 44 Range lt 35 90 gt 100V 55 15V 44 Kontrollmasse 400 MinTHeat 500 MixPunktPause 30 KeineMixPunktPause 9000 FlussTestAnzahl 6 Min FlussRate 3 00 SpuelVolumen 1500 DspSpuelVolumen 500 GrenzTempGrad 0 20 VorStopPunkt 80 AddVorStopPunkt 7 DiffEmptySMin 2000 DspOWait 3500 FlussFaktor 1 000 WaagenPa
65. use 3000 AdditiveSupplement 500 MixerRPM 255 Kernwaage PressureGauge PressureGaugeVac_ 400 PressureGaugePress_ 1350 PressureGaugeCal_ 1 235 PressureGaugeOffset_ 0 PressureGaugeVent_ 850 PressureGaugeFill_ 90 PressureGaugeFHyst_ 5 MaxLevelWZ 7000 Range lt 100 1000 gt Range lt 50 1500 4000 gt Range lt 10 600 gt Range lt 1000 10000 gt Range lt 2 32 gt Range lt 10 00 100 00 gt Range lt 100 8000 gt Range lt 100 8000 gt Range lt 10 00 10 00 gt Range lt 50 150 gt Range lt 0 150 gt Range lt 250 2500 gt Range lt 100 100000 gt Range lt 0 000 100 000 gt Range lt 0 30000 gt Range lt I 1500 gt Range lt 0 255 gt Range lt 0 gt Range lt 0 gt Range lt 10 700 gt Range lt 1000 1450 gt Range lt 0 500 3 000 gt Range lt 50 50 gt Range lt 750 950 gt Range lt 10 700 gt Range lt 5 75 gt Range lt 14000 17000 25500 gt PrintTempGradErr l Range lt 0 no error printing on protocols gt 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Electronic Remote Connections Page 51 of 68 5 4 WINDOWS Connection with HYPERTERMINAL S N 2408XXXX MIB2 To communicate with the DissoPrep you need to use a Null Modem Link and HyperTerminal HyperTerminal must be set to the following protocol COM port
66. w Flaw Direction Mustration 3 Inlet Filter Cartridge type of the Inlet Hose Such a Filter Cartridge can be used also at the Acid Inlet Hose If the pollution possibilities are however restricted e g if medium is taken from inferred bottles a filter cannot be recommended There is also a Filter Cartridge type 2 in use which has CPC couplings instead of hose barbs 4 4 2 Outlet Frit There is an Outlet Frit at the end of the dispense hose Its purpose is not to filter the media but to brake the liquid jet and to prevent dropping of the hose after the dispense stop making the dosage possibly imprecise A dropping can be prevented for certain only if the Outlet Frit is soaked sufficiently with medium Use the Tube Holder to avoid a drying of the Outlet Frit If the Outlet Frit is clogged an Error could appear ErrPress and the first vessel could be overfilled Please check the internal pressure with the RC Software see Chapter 5 3 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 16 of 68 Do not touch the surface of the Outlet Frit with your fingers This destroys the material as it is of porous PP If the Outlet Frit is affected with bacteria it then changes the colour to yellow or grey to black This also may cause a back pressure which deteriorates the dosage precision 4 4 3 Solenoid Valves SN lt 4xxxxxxx All s
67. way the double hole distance washer of the Balance Fixing Screws 7 Replace the Pondering Cell Mustration 98 Pondering Cell Design 3 Fixing Arrangement Go step by step reverse direction Notice particularly to the following points 1 At units with S N lt 2806XXXX and or Pondering Cell Design place the Space Washers and then fix the Transport Lock Screw Units with S N 2806XXXX do not have a Transport Lock Screw See 5 above also 2 When fixing the tank take care for the original rotational position marks 3 When replacing the Pondering Cell WZI on instruments with MIB and firmware 4 xxx you have also to perform a firmware update to version 4 443 by means of the RC software 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Functions and Components of the DissoPrep Page 28 of 68 4 4 8 Storage Tank and Pondering Cell Assembly 4 4 8 1 Transport Lock Screw Balance Fixing Screws and Tank Fixing Screw at S N lt 2806XXXKX The Pondering Cell Design is fixed with Balance Fixing Screws and one Transport Lock Screw Units with S N 2806XXXX do not have a Transport Lock Screw The Balance Fixing Screws are very tight fastened The Pondering Cell is so adjusted that the bore of the Transport Lock Screw is centred Do not overload the Pondering Cell e g by too strong fastening of the Transport Lock Screw at units with S N lt 2806XXXX or by too heavy sho
68. ype key lt F10 gt 4 Type key lt CR gt carriage return or ENTER 5 Push your Floppy Disk into the drive containing the Firmware File e g XX6107 EXE in the Root Directory 6 Type lt a gt and lt CR gt 7 Type lt copy_xx6 07 exe_c xx exe gt and lt CR gt for Firmware lt 7 000 for firmware gt 7 000 type lt copy_yy7 exe_c dpx exe gt and lt CR gt Remark use the actual firmware File Name the underscore character is showing the blank only 8 Reboot the DissoPrep by turning the main switch OFF and seconds later ON again 9 Run a calibration and check the new Firmware Release on the protocol 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the Electronic Remote Connections Page 48 of 68 5 3 WINDOWS Connection with RC Software For a MS WINDOWS Connection use the Remote Control Software File DPX_RC exe For further information about the software use the Operation Manual for the Remote Control Software See http www riggtek com laboratoryinstruments login htm and login with Username and Password The Remote Control Software provides a convenient Firmware Update for version 4 442 xx4 442 exe on DissoPrep with S N lt 2406XXXX or Firmware gt 7 000 Mustration 44 Monitor of the Remote Control Software for Diagnostic ADC Window 2007 2010 RIGGTEK GmbH DissoPrep Service Manual ID 20100430 Rev 8 2013 10 28 Understanding of the E

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