Operators Manual Peristaltic Dispenser PD22 OEM
Contents
1. WATSON Operators Manual MARLOW PD22 OEM Operators Manual Peristaltic Dispenser PD22 OEM WATSON Operators Manual MARLOW P PD22 OEM 1 Table of Contents 1 Table dedo He 2 2 Declaration of InCOFDOFAEI OTI a coax napi EuRxEExRnd qna x bu sx ECCME M A DIAM ME EEEEE DEI E A MEME CEN KUEEE 3 3 PD22 important nollE amp isi eei Eat celi cedo in nani Sod k ecu CU uide Cea Der cU Dd ace cR DUM MU LU DUE 4 EU n0 ecco SS E 5 5 Incorporation of PD22 OEM iiesese pneu Erga paa roe EReyEE Eo Eod nans aa RFERn ER eESDRa a eS E RayRoEEEERER MR SERA paa anus 6 SEE C D rcIEnII gu t 7 6 1 Unpacking and inspection ssssssssssssee mmn nnne nnne 7 6 2 The peristaltic principle esses nennen nennen enne nennen nennen 8 ooo e GRRE E 9 7 1 Addressing of filling E r 1070 or C 9 Meu e 10 8 1 IB FJer ii iM i o 10 8 2 Status LED Seprene rere IRE RERO ERR KERN RE X E ERA A RR NR RR RR ERR E ER E ER KD EN IR RR 10 9 Dispensing with PD22 uiu onim usb a paux EU ua dea aap aap UN IN nr x Aaaa aa 11 10 Tube assembly neniii pr EPIRI EI UHR US DUUM IM UI MEE 14 10 1 Assembly OF W CORMO ror ER 14 10 2 Placing tubes in the pump head ssssssssse Rs 15 11 Programming c n 17 T4 Programming pro2. as described in PD22 OEM Installation Manual OR External safety switch for means of preventing pinching hazards in the dispenser head must be connected to the control unit as described in PD22 OEM Installation Manual Hazards from rotating coupling on dispenser head must be prevented by mounting of drive system in closed cabinet or by a protection cover PD22 OEM OM 1 00 EN doc Version 1 01 Page 6 of 20 Operators Manual Flexicon PD22 OEM 6 General information 6 1 Unpacking and inspection PD22 is a peristaltic filler in the Watson Marlow Flexicon Multi Filling System FMFS The PD22 can not do fillings by itself but must be connected to Watson Marlow Flexicon Master Controller the MC12 or MC100 or to a PC with RS485 multidrop communication Please check that all ordered items have been received and that no items were damaged during transport In case of any defects or omissions please contact Watson Marlow Flexicon or your supplier immediately When ordering spare parts or accessories for the PD22 please state the serial number stamped The serial number is stamped on the label on the control unit of the PD22 OEM Fig 6 1 ALWAYS REMEMBER that this machine must be earthed PD22 OEM OM 1 00 EN doc Version 1 01 Page 7 of 20 WATSON Operators Manual MARLOW P PD22 OEM 6 2 The peristaltic principle PD22 operates with a peristaltic dispenser head tube pump whe
3. Flexicon is under no obligation to update manuals already published PD22 OEM OM 1 00 EN doc Version 1 01 Page 20 of 20
4. Tube assembly 10 1 Assembly of Y connectors Since the dispenser head of PD22 is fitted with a double rotor two suction tubes are used all the way through the dispenser head These two suction tubes are joined by a Y connector just behind the dispenser head Fig 10 1 The chosen tube is joint by a Y connector as shown in Fejl Henvisningskilde ikke fundet Since the Y connectors are made from polypropylene the total tube system can be sterilized in an autoclave Standard Watson Marlow Flexicon Y connectors Size Order No 4mm 84 010 004 6 mm 84 010 006 8 mm 84 010 008 Q 10mm 84 010 010 Q 12mm 84 010 012 Q 14mm 84 010 014 Tab 10 1 PD22 OEM OM 1 00 EN doc Version 1 01 Page 14 of 20 WATSON MARLOW Operators Manual 10 2 Placing tubes in the pump head After selecting a suitable tube diameter and after fitting the tubes with Y connector and filling needle assemble the tubes in the dispenser head Fig 10 2 Open the dispenser head by turning the two locking pins 1 over the tube bridge 2 after which the tube bridge can be lifted up It will now be possible to remove the tube lock 3 from its dowel pin Fig 10 3 PD22 OEM OM 1 00 EN doc Version 1 01 Page 15 of 20 PD22 OEM MARLOW Operators Manual PD22 OEM Mount he correct tube lock 1 on its dowel pin and place the tubes 2 i
5. according to the following guidelines Flexicon part no Tube dimension Min volume recommended 84 401 030 3 0 mm i d 10 ml 84 401 050 5 0 mm i d 20 ml 84 401 065 6 5 mm i d 50 ml 84 401 080 8 0 mm i d 85 ml 84 401 100 10 0 mm i d 150 ml 84 401 125 12 5 mm i d 250 ml Tab 9 1 Above mentioned tubes are silicone tubes and supplied by Watson Marlow Flexicon These can be sterilised by autoclaving Tubes must be cut in the right length in order to achieve optimised dispensing It is recommendable that the tubes are of such length that can allow placing the vessel close to the pump head The tube ends must always be kept below the liquid level of the suction vessel in order to keep the tubes from sucking air Avoid having tubes close to the bottom of product vessel Nature of fill media The peristaltic dispensers are not suitable for viscous products For viscous product can another type of dispenser from Flexicon be used In the case that the PD22 should be used and the product is of viscous nature then heating the product before dispensing with PD22 is recommended Another consideration is the surface tension of liquid Product with high surface tension tends to produce drip Due to this fact it is difficult to have sufficient cut off after every individual dispensing When filling with small volumes and high surface tension present drips are often produced and constitute inaccuracy Filling
6. with large volume and high surface tension might have tendency to suck air back in the filling line PD22 OEM OM 1 00 EN doc Version 1 01 Page 12 of 20 Operators Manual PD22 OEM Priming tubes In order to evacuate air from the tubes and prepare the tubes for filling it is necessary to prime the tubes Priming must be done adequately and continued until the tube material hysteresis disappears as well as any air bubbles Drip When dispensing very small volumes the last drop of the filling constitutes a big part of the total filling Therefor it is necessary to take necessary measures for avoiding the last drop For small volumes a dumping nozzle system can be applied to eliminate the last drop of filling When dispensing with very large volumes the shape of nozzle and the filling speed required may not always be compatible For this reason consideration should be done if using non return valve or forced back suction is necessary Flexicon dispensers offer back suction reversing after every individual dispensing Hard Feed When dispensing with small tubes counter pressure on the pressure side of pump head might constitute inaccuracy and instability in filling hard feed In some cases the problem can be resolved by using a larger tube on the pressure side after Y connector PD22 OEM OM 1 00 EN doc Version 1 01 Page 13 of 20 WATSON Operators Manual MARLOW P PD22 OEM 10
7. C On the approximation of the laws of the Member States relating to electromagnetic compatibility AS THE PD22 OEM IS TO BE INCORPORATED INTO ANOTHER MACHINE THIS MACHINE MUST BE DECLARED IN CONFORMITY WITH THE PROVISIONS IN THE DIRECTIVE 2006 42 EC BEFORE PD22 OEM IS PUT INTO SERVICE Signature pl L opp np Decembler 2009 Ringsted Denmark J rn Jeppesen Development Manager PD22 OEM OM 1 00 EN doc Version 1 01 Page 3 of 20 Operators Manual PD22 OEM 3 PD22 important notice There are 4 versions of the PD22 The PD22 Individual The PD22 P Panelmount The PD22 PS Panelmount with shaft seal The PD22 OEM Separate dispenser head with shaft seal and control unit for incorporation The 4 versions share the same functions and programming routines They also share the same components for the dispenser head regarding parts acting on the peristaltic tube The main difference is that the PD22 has its own separate cabinet for placing the machine on a table the PD22 P and PD22 PS are mounted through a panel and the PD22 OEM is intended for incorporation in another cabinet or filling machine Besides there are differences in the way the versions are connected to power supply and to the external Master Controller MC12 or MC100 In the last sections of the manual we will describe the connections and interfaces For the remainder of this manual the PD22 will be designated as follo
8. SW2 1 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 SW3 1 1 1 1 0 lo O JO 1 1 1 1 0 0 0 0 SWA 1 1 1 1 1 1 1 1 0 0 0 0 0 0 0 0 Fig 7 1 Address 1 is the factory setting of PD22 If the PD22 is one of several filling stations in a system none of the stations may have the same address and it must therefore be changed Change of address is performed via a dip switch placed at the side of the PD22 OEM control unit This change may only be carried out when the machine is turned off at the main isolator Addresses between 1 and 16 may be chosen and Fig 7 1 shows the various combinations PD22 OEM OM 1 00 EN doc Version 1 01 Page 9 of 20 WATSON MARLOW Operators Konun Flexicon 8 Control 8 1 Dispenser head The dispenser head can work with six different tube diameters The dispenser head is mounted with quick change tube bridge The dispenser head works with two parallel tubes which are squeezed by six rollers mounted on ball bearings The rollers in the two sections are offset in order to eliminate pulsing 8 2 Status LED s Fig 8 1 1 power Red LED when 24VDC supply of control system is on 2 online Green LED when communicating with master controller 3 busy 2 Red LED when dispenser is running PD22 OEM OM 1 00 EN doc Version 1 01 Page 10 of 20 WATSON Operators Manual MARLOW P PD22 OEM 9 Dispensing with PD22 For optimal dispensing with the PD22 the following should be o
9. bserved Vessel placement Tubes Nature of fill media Priming tubes Drip Hard feed 00000 0 Vessel Placement In order to build up adequate pressure and reduce friction it is recommendable to place the vessel containing fill media at the same level as pump head or preferably above the pump head level Placing the vessel higher than pump head level provides positive product support and may reduce the calibration interval It is also recommended to place the vessel as close as possible to the pump on suction side Suction side Pressure side Preferred Placement of container T Pump Head ES s Flexicon ze Normal Placement of container Fig 9 1 PD22 OEM OM 1 00 EN doc Version 1 01 Page 11 of 20 WATSON Operators Manual MARLOW PD22 OEM Tubes Tube size Tubes must be selected according to the application and volume to be filled Use the table shown below for choice of tubes according to minimum volume to be filled PD22 can operate with six different tube dimensions chosen according to the volume to be dispensed The tubes are designated by their internal diameters i d in millimetres This value is always used as designation for the individual tube and this is also the value to be entered in function 2 at the MC12 master controller PD22 can operate with the tubes listed in the table below In order to obtain stable and good results the choice of tube may be made
10. celeration deceleration Value An integral number Range 1 100 The acceleration and the deceleration will always be the same The lowest value 1 will give the slowest acceleration and the highest value 100 will give the fastest acceleration If the acceleration is changed a recalibration should be made 5 Reversing back suction Value An integral number Range 0 10 If the rotor is moved a little backwards reversing after the completion of fillings a minor back suction will be created This can prevent dripping from the filling needle PD22 OEM OM 1 00 EN doc Version 1 01 Page 17 of 20 WATSON MARLOW Operators Manual PD22 OEM The value 0 will give no reversing but the value 10 will give maximum reversing ALWAYS make a recalibration if the reversing value is altered For other programming possibilities reference is made to the MC12 manual PD22 OEM OM 1 00 EN doc Version 1 01 Page 18 of 20 WATSON Operators Manual MARLOW P PD22 OEM 12 Cleaning and maintenance 12 1 Daily cleaning As PD22 is not in direct contact with the dispensed product daily cleaning will not be necessary except for the normal routine cleaning of production equipment Liquids must NOT be splashed onto the PD22 It may only be cleaned with a damp paper towel or a firmly wrung cloth The cabinet is made of stainless steel and anodized aluminium and normal cleaning agen
11. l ibie ee tetesssoqasagaciscaoctpatusaacua Gud b pv pUbIU Mu Metu baEe Abas 9d caduca cin uu iussa 17 11 2 PD22 pararmeters eee Dee n hee tee A Se eR ER CE tina Fett ea EE Pn Ete Fade RR DERE EYE Ye eb Eu CH Ed auis 17 12 Cleaning and maintenance sistas cece entere nes ehex nes ex ens en en RA DN MA a 19 121 Daly cleanings E e a E A 19 12 2 SterilizZatOM ee 19 123 chrome EE 19 13 Change Of Voltage ceieueeio bea n Ee Eo EE EUER PRRREEERe ERR ERR 20 14 Ce i c Ec 20 PD22 OEM OM 1 00 EN doc Version 1 01 Page 2 of 20 Operators Manual PD22 OEM 2 Declaration of incorporation We Watson Marlow Flexicon A S Frejasvej 2 6 DK 4100 Ringsted Declare on our sole responsibility that the product Peristaltic dispenser PD22 OEM Model 61 253 022 md Model PD220EM Serial No XXXX XXXX Supply 230V 50Hz 300W Year 2009 C Made in Denmark To which this declaration relates is in conformity with the following standard s DS EN ISO 12100 Safety of machinery Basic concepts general principles of design DS EN 60204 Safety of machinery Electrical equipment of machines According to the provisions in the Directives 2006 42 EC On the approximation of the laws of the Member States relating to machinery 2006 95 EC On the harmonization of the laws of Member States relating to electrical equipment designed for use within certain voltage limits 2004 108 E
12. n the dispenser head The Y connector must be situated to the right of the dispenser head It is important that the tubes are situated in the two notches 3 Now place the tube bridge in its tracks and engage the two locking pins Fig 10 4 The tube ends must always be kept below the liquid level of the suction vessel in order to keep the tubes from sucking air PD22 OEM OM 1 00 EN doc Version 1 01 Page 16 of 20 WATSON Operators Manual MARLOW P PD22 OEM 11 Programming 11 1 Programming principle In the following a parameter will be the value of a single function i e volume tube diameter or velocity Programming is done from a master controller like MC12P from Flexicon A program will be a complete set of parameters which together will constitute the PD22 work instructions The actual programming will be made on the MC12 and reference is made to the MC12 manual 11 2 PD22 parameters 1 Volume Value ml Range 10 9999 ml PD22 can dispense from 10 to 9999 ml but for volumes exceeding approx 1000 ml the capacity will drop significantly If the volume is changed a recalibration should be made 2 Tubes Value Inside diameter i d in mm Range 3 0 5 0 6 5 8 5 10 0 12 5 If the tube is changed a new calibration must always be made 3 Velocity Value Revolutions per minute rpm Range 30 250 rom If the velocity is changed a recalibration should be made 4 Ac
13. re the liquid only comes into contact with the flexible tube the tube connections and the filling needle The tubes are usually made of silicone but other materials can also be used The dispenser head is designed in such a way that sterilized tubes can be assembled in the head without affecting the sterility Watson Marlow Flexicon tubes are produced of raw materials medically approved by for instance the FDA The tubes are delivered in sealed packages and are provided with a batch number which makes it possible to trace the tubes all the way back to the raw material source For this reason the PD22 is specially suited for aseptic applications and for preventing cross contamination among different products The dispenser head is self priming and the dispenser head itself can stand to be run dry It is recommended not to let the dispenser head be run dry for a long period WITH CONNECTED TUBES since this will lead to particle release A peristaltic dispenser head is not suitable for viscous products PD22 OEM OM 1 00 EN doc Version 1 01 Page 8 of 20 WATSON Operators Manual MARLOW P PD22 OEM 7 Installation For installation of PD22 OEM into filling machine see separate PD22 OEM Installation Manual 7 1 Addressing of filling station 1 ON 0 OFF Address 1 2 3 4 5 6 7 8 9 10 11 12 13 114 15 16 SW1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0
14. ts such as alcohol and isopropanol may be used 12 2 Sterilization If PD22 is placed in an aseptic environment the sterilization may be made as described in section 5 1 or you may sterilize PD22 by gases observing the following precautions If you use gases that might injure and corrode contacts and other metals air slots and sockets MUST be covered with tape 12 3 Maintenance As all movable parts in PD22 are maintenance free no maintenance is required apart from normal cleaning of the equipment Should service be needed please contact Watson Marlow Flexicon or your supplier PD22 OEM OM 1 00 EN doc Version 1 01 Page 19 of 20 WATSON Operators Manual MARLOW P PD22 OEM 13 Change of voltage Fig 13 1 S can be converted to accept another supply voltage The conversion can be made inside the machine by moving the cables of the transformer clamps 14 COPYRIGHT Copyright c 2009 Watson Marlow Flexicon A S All rights to this manual belong to Watson Marlow Flexicon A S Neither the complete manual nor parts of it may be translated copied printed or published in any form or by any means without permission in writing from Watson Marlow Flexicon Watson Marlow Flexicon is convinced that the information of this manual is correct but Watson Marlow Flexicon cannot be held responsible for it Watson Marlow Flexicon reserves the right to update and amend this manual without previous notice Watson Marlow
15. ws PD22 for general descriptions covering both versions PD22 xx for descriptions specific to the xx version PD22 OEM OM 1 00 EN doc Version 1 01 Page 4 of 20 Operators Manual PD22 OEM 4 Caution This manual should be read before using the PD22 Explanations to the pictograms Warning against touching Warning against opening CAUTION CAA Warning against high voltage ON CAUTI aA N When operating the PD22 make sure that the dispenser head is closed The PD22 should only be used for dosing and filling of liquid fluids The PD22 must be placed on a stable bed plate and in such a way that it is not exposed to great humidity high temperatures or other abnormal operating environments It is not to be used in explosion hazardous environments It is prohibited to maintain or clean the PD22 when it is connected to the power supply It is prohibited for unauthorised personnel to open the cover of the PD22 s electrical parts Always remember that the PD22 must be earthed by way of the mains connector Handle the filling nozzles with caution The pump must not run dry PD22 OEM OM 1 00 EN doc Version 1 01 Page 5 of 20 Operators Manual PD22 OEM 5 Incorporation of PD22 OEM Before putting the PD22 OEM into service the following actions must be observed The tube bridge check sensor installed in the dispenser head must be connected to the control unit
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