Operators Manual Peristaltic Dispenser PD12 OEM
Contents
1. Operators Manual Peristaltic Dispenser PD12 OEM Cee PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 2 of 18 1 Table of Contents 1 Ta bleo f Contents sessiossa er nee eer eee eee eee eee 2 2 Declaration of iNCOrPOratiOn ccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeaaeaaeeeeeeeseeeeaaes 3 3 PD TZ important NOee sccicc ccsscssscscitiececescsesteaaebereeenececersdeseidedadenasdekedteetedelcceladetiestedeeouets 4 Be NCAT ON Selec E EE A E E E A eeceee st eecnie es connect neds eee 5 5 Incorporation of PD 12 OEM occ etcctiteset sie ciate tees 6 6 General information sssssssesssnnnnnnrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmn nnnnnnn nnana 7 6 1 Unpacking and inspection cccccecccccccccccceceeeeeeceeeeeeeeeeeeeeeeceeeeeeeceeeeeeeeeeeeeeeeeeeeeeeseeeseneesaeesags 7 6 2 The peristaltic prinCiple ccecceceeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeseeesegeseeeeeeeeeeeeeeeeeseeeneeeeseeeneees 8 7 2 MVS PANS OM sissecsctaessecesacccioesscentasansnscscsscesteastasesacacenstsentanscennscanstwatennncacsemunsaaceuscuccemnseansaxensase 9 7 1 Addressing of filling StAUON washes dsstsieneannteatntssrcaneh ot ategedccatanumenctenbentntancatian scctheutel nadia ndalanecuancnadse 9 e eae E RAA A TT E T TEET 10 8 1 Dispenser head cccccccceecceeccceeccecececceeeecececeseneeeeaecanecenecanecenecaueceaaensaesaaessaecsaessaeeaaanaaaeess 10 8 2 Status2. Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 17 of 18 12 Cleaning and maintenance 12 1 Daily cleaning As PD12 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 PD12 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 agents such as alcohol and isopropanol may be used 12 2 Sterilization If PD12 is placed in an aseptic environment the sterilization may be made as described in section 5 1 or you may sterilize PD12 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 PD12 are maintenance free no maintenance is required apart from normal cleaning of the equipment Should service be needed please contact Flexicon A S or your supplier File PD12 OEM OM 1 03 EN PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 18 of 18 13 Change of voltage Fig 13 1 The PD12 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 2007 Flexicon A S
3. 1 1 0 0 0 0 0 0 0 0 Fig 7 1 Address 1 is the factory setting of PD12 If the PD12 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 bottom of the PD12 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 File PD12 OEM OM 1 03 EN PD12 OEM Flexicon Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 10 of 18 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 MC12 3 busy 2 Red LED when dispenser is running File PD12 OEM OM 1 03 EN PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 11 of 18 9 Dispensing with PD12 For optimal dispensing with the PD12 the following should be observed 9 1 Vessel PIa C6mentiscsticcs oc Sets ene ane aE aA ied ede e
4. All rights to this manual belong to 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 Flexicon A S Flexicon A S is convinced that the information of this manual is correct but Flexicon A S cannot be held responsible for it Flexicon A S reserves the right to update and amend this manual without previous notice Flexicon A S is under no obligation to update manuals already published File PD12 OEM OM 1 03 EN
5. LED S ener E ep E E a EEEa Ea asne ENEE AEE EE E svass 10 9 Dispensing with PD12 ia sca eee eee ee eee 11 9 1 Vessel Placement e ricie cee ccccccccccececeecceee cece E 11 9 2 TUDE SIZG iste cccassvassssyareecieseins sasessdetasteenane EE NE saint rasa es aan adie nie seldavenreerivenaeanersiaes 12 9 3 Nature of fill Media oe ceccce cece cee ceeeeeeeeeeeeeeeeceaeeeaeseaaeeeaeeaaeaaaeeaaeeeaeeaaaneaanaaaneaaneaanaaanaaeess 13 9 4 PUIG OMEV OT WGI IGS act ex ect e aae ed secottnesdeatcedusiSasetiatesSeed yaad hededucansnidast A NE a SAnS 13 9 5 DVD cczrvezcesciteevcsesscestcctccetcccmtactscetcneetcerecerteetseeteece a E a a 13 9 6 Hard Feed eranen a a Gols cadena deeded Pests taeeeeeastees 13 10 T be assembly sac aiccndiedncicte cisincisencenetavaceeecezecnsetssnapaceseadsseigsedaeedazeiecedse cneeepsneseeigendseecaraceenie 14 10 1 Assembly of Y COMMS CIS ccc c6i ood wide ett eect denne sdocde tedceintdnc en dbtenedaenecutussd ccnaeedeaetdevheeetottets 14 10 2 Placing tubes in the pump head cece cc ccccccccccecceeeeeceeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeess 14 11 Programming cece reais ac cae acne ase ced ewe 16 11 1 Programming principle sicncsissicoorscenmarsasctecneneentecaanartauhcontaceunecud sascanaccesnnnnasetccunkiateneeastinanateans 16 11 2 PD12 parameter ccccccccccccccece cece cence eect ence a e E e a a E aae eaa Eini 16 12 Cleaning and maintenance a ccccccdcececccccteccccecscecncsdcaedecsesdecedeedeene
6. PD12 OEM IS PUT INTO SERVICE Flexicon as Model PD12 OEM Serial No XXXX XXXX Supply 230V 50Hz 150W Year 2007 CE Ringsted October 2007 Flemming J rgens File PD12 OEM OM 1 03 EN Cee PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 4 of 18 3 PD12 important notice There are 4 versions of the PD12 The PD12 Individual The PD12 P Panelmount The PD12 PS Panelmount with shaft seal The PD12 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 PD12 has its own separate cabinet for placing the machine on a table the PD12 P and PD12 PS are mounted through a panel and the PD12 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 pump controller MC12 In the last sections of the manual we will describe the connections and interfaces For the remainder of this manual the PD12 will be designated as follows PD12 for general descriptions covering both versions PD12 xx for descriptions specific to the xx version File PD12 OEM OM 1 03 EN PD12 OEM Operators ma
7. 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 Flexicons 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 PD12 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 File PD12 OEM OM 1 03 EN PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 9 of 18 7 Installation For installation of PD12 OEM into filling machine see separate PD12 OEM Installation Manual 7 1 Addressing of filling station Address 1 2 3 4 5 6 7 8 9 10 11 12 13 114 15 16 SWw1 1 0 1 0 1 0 1 0 1 0 0 1 0 1 1 0 SW2 1 1 0 0 1 1 0 0 1 1 0 1 1 0 0 0 SW3 1 1 1 1 o lo lO JO 1 1 1 0 0 0 0 0 SW4 1 1 1 1 1 1
8. antly If the volume is changed a recalibration should be made 2 Tubes Value Inside diameter i d in mm Range 0 5 0 8 1 6 3 2 4 8 6 0 8 0 The tubes can be measured with the supplied tube gauge If the tube is changed a new calibration must always be made 3 Velocity Value Revolutions per minute rpm Range 30 400 rpm for tubing above 1 6 id 30 500 rpm for 3 2 id tubing 30 600 rpm for tubing smaller than 1 6 id If the velocity is changed a recalibration should be made 4 Acceleration deceleration Value An integral number Range 1 100 for tubing larger than 3 2 id 1 150 for 3 2 id tubing 1 200 for tubing up to 01 6 id The acceleration and the deceleration will always be the same The lowest value 1 will give the slowest acceleration The highest value 200 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 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 File PD12 OEM OM 1 03 EN PD12 OEM
9. e et ae 11 9 2 TUDO SZO eee Pe Oo a nee 12 9 3 Nature of fill media oo cece cca eecceeeseueeeeueeeeaeeseeeeeeeaeeesaueeaeeseeaeeesaueeeaaeeeaneeeaeeeaeeenens 13 9 4 Priming OMENS suorassa a aaa AEA Ekai 13 9 5 DIP E a E 13 9 6 Hard Fedes A a a E a a 13 9 1 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 l 1 Sef Bites AS Pump Head Ta a S NS n Flexicon is ay Normal Placement of container Fig 9 1 File PD12 OEM OM 1 03 EN PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 12 of 18 9 2 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 PD12 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 a
10. edtcsenedesdeesdeeeeseeaeeeeeeeeds 17 1 amp 2 Dally cleaning iinan ein aE a aae neta e EEEO EEEE AAEE f 17 12 2 Sterilization eseti e rE e ae ee eA 17 12 3 MalntONaNnCe seenen ane e a caves E E E E Ee Eee a aa Ea 17 13 Change of VOM AS ascii acetate acc cease ated ae cee aed eae ed eee eee 18 14 COPYRIGHT isso sesececet piss ctcsetentasetephate deck pad ated ete dames ata mine aes 18 File PD12 OEM OM 1 03 EN PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 3 of 18 2 Declaration of incorporation We Flexicon A S Frejasvej 2 6 DK 4100 Ringsted declare on our sole responsibility that the product Peristaltic Dispenser PD12 OEM Model 61 153 014 to which this declaration relates is in conformity with the essential health and safety requirements and the following standard s DS EN 60204 Safety of machinery Electrical equipment of machines according to the provisions in the Directive 2006 42 EC On the approximation of the laws of the Member States relating to machinery 73 23 EEC On the harmonization of the laws of Member States relating to electrical equipment designed for use within certain voltage limits 2004 108 EC On the approximation of the laws of the Member States relating to electromagnetic compatibility AS THE PD12 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
11. ing 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 File PD12 OEM OM 1 03 EN PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 15 of 18 Fig 10 3 Mount he correct tube lock 1 on its dowel pin and place the tubes 2 in 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 File PD12 OEM OM 1 03 EN PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 16 of 18 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 A program will be a complete set of parameters which together will constitute the PD12 work instructions The actual programming will be made on the MC12 and reference is made to the MC12 manual 11 2 PD12 parameters 1 Volume Value ml Range 0 01 9999 9 ml ml PD12 can dispense from 0 5 to 9999 ml but for volumes exceeding approx 250 ml the capacity will drop signific
12. lso the value to be entered in function 2 at the MC12 master controller PD12P can operate with the tubing and Y connectors listed in the table below In order to obtain stable and good results the choice of tubing may be made according to the following guidelines Volume Nozzle Flexicon Tubing Flexicon spare part no Y Connector lexicon ae eee o part Imm i d peroxide Platnum 0 0 KA par ae 7 0 6 30 030 006 10 5 84 301 005 84 102 005 2 4 84 01 1 002 a 1 0 30 030 010 10 8 84 301 008 84 102 008 2 4 384 011 002 Ken 7 1 6 30 030 016 1 2 84 301 012 84 102 012 3 6 84 01 1 004 ape p 3 2 30 030 032 11 6 84 301 016 84 102 016 3 6 84 011 004 ine 4 5 30 030 045 13 2 84 301 032 84 102 032 5 9 84 01 1 006 es 7 6 0 30 030 060 4 8 84 301 048 84 102 048 7 2 84 011 008 re 8 0 30 030 080 16 0 84 301 060 84 102 060 9 5 84 011 010 gt 44 0 mi 8 0 30 030 080 18 0 84 301 080 84 102 080 12 4 84 011 012 e use non return valve e Fig 9 2 Above mentioned tubes are silicone tubes and supplied by Flexicon A S 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 Av
13. nual Re Operation Rev 1 03 Date 2008 06 04 Page 5 of 18 4 Caution This manual should be read before using the PD12 Explanations to the pictograms Warning against touching Warning against opening CAUTION EA aa Warning against high voltage f ON CAUTI aA N When operating the PD12 make sure that the dispenser head is closed The mains switch is used for emergency stopping The PD12 should only be used for dosing and filling of liquid fluids The PD12 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 PD12 when it is connected to the power supply It is prohibited for unauthorised personnel to open the cover of the PD12 s electrical parts Always remember that the PD12 must be earthed by way of the switch Handle the filling needles with caution The pump must not run dry File PD12 OEM OM 1 03 EN PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 6 of 18 5 Incorporation of PD12 OEM Before putting the PD12 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 as described in PD12 OEM Installation Manual OR External safety switch fo
14. oid having tubes close to the bottom of product vessel File PD12 OEM OM 1 03 EN PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 13 of 18 9 3 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 PD12 should be used and the product is of viscous nature then heating the product before dispensing with PD12 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 with large volume and high surface tension might have tendency to suck air back in the filling line 9 4 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 9 5 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 las
15. r means of preventing pinching hazards in the dispenser head must be connected to the control unit as described in PD12 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 File PD12 OEM OM 1 03 EN PD12 OEM Flexicon Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 7 of 18 6 General information 6 1 Unpacking and inspection PD12 is a peristaltic filler in the Flexicon Multi Filling System FMFS The PD12 can not do fillings by itself but must be connected to Flexicons control unit the MC12 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 Flexicon A S or your supplier immediately When ordering spare parts or accessories for the PD12 please state the serial number stamped The serial number is stamped on the label on the control unit of the PD12 OEM Fig 6 1 ALWAYS REMEMBER that this machine must be earthed File PD12 OEM OM 1 03 EN Cee PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 8 of 18 6 2 The peristaltic principle PD12 operates with a peristaltic dispenser head tube pump where the liquid only comes into contact with the flexible tube the tube connections
16. t 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 9 6 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 File PD12 OEM OM 1 03 EN Cee PD12 OEM Operators manual Re Operation Rev 1 03 Date 2008 06 04 Page 14 of 18 10 Tube assembly 10 1 Assembly of Y connectors Since the dispenser head of PD12 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 Fig 10 1 Since the Y connectors are made from polypropylene the total tube system can be sterilized in an autoclave 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 Q Z Q Fig 10 2 Open the dispenser head by turn
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