Millipore Exact-Air II Documentation
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Millipore Exact-Air II Documentation

Millipore Exact-Air II Documentation

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MILLIPORE
DOCUMENTATION OF THE SYSTEM
Reference:
Description:
Table of contents
TOC.fm
MSP008687
Exact-Air
TM
II
Exact-Air II
Page: 1

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Summary of Contents for Millipore Exact-Air II

  • Page 1 MILLIPORE Exact-Air II DOCUMENTATION OF THE SYSTEM Reference: MSP008687 Description: Exact-Air Table of contents Page: 1 TOC.fm...

  • Page 2: Table Of Contents

    MILLIPORE Exact-Air II TABLE OF CONTENTS Volume Chapter Page VOL. 1 INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -I-1...
  • Page 3 MILLIPORE Exact-Air II II.3 Start-up instructions . . II-17 1. Precaution . II-17 2. Start-up check list . II-17 3. Connection . . II-18 4. Instrument preparation . II-20 5. Power-up . II-20 6. Initial flushing procedure . II-20 7. Initial start-up and leak test .
  • Page 4 MILLIPORE Exact-Air II IX COMPONENTS DOCUMENTATION (ONLY AVAILABLE ON CD) IX.1 Instruments documentation 1. Pressure 1.1. PI004 2. Level 2.1. LSH001 3. Temperature (Option) 3.1. TE001 IX.2 Other components 1. Valves 1.1. XV001, XV002, XV003, XV004, XV005, XV006, XV007 2. Tank 2.1.

  • Page 5: Vol. 1

    MILLIPORE Exact-Air II I. Introduction Vol. 1 Introduction Page: I-1 Introduction-Notice.fm...

  • Page 6: Notice

    Copyright (2007), Millipore s.a.s. Printed in France. All rights reserved. These books or parts thereof may not be reproduced in any form without the written permission of the publisher.
  • Page 7 MILLIPORE Exact-Air II System Ref. : MSP008687 DOCUMENTATION CONTROL Revision code Approved List of changed paragraphs and changes & date Author description (month / year) 12/2007 R. Weber P. Scholz Initial doc. Vol. 1 Introduction I.1 Notice Page: I-3 Introduction-Notice.fm...

  • Page 8: Safety Recommendations

    MILLIPORE Exact-Air II I.2. Safety recommendations ANNEXE 4 , REV.B , SPEC N° 062 558 SO This user's manual includes important health and safety aspects, which ATTENTION require a specific training. Please make sure that all operators before first use of the equipment know the recommendations.
  • Page 9 Safety recommendations Generalities These general recommendations are provided by Millipore to assist in the safe and reliable operation of the equipment. They do not relieve the client of the need to understand use and maintain the equipment in a safe way.
  • Page 10 MILLIPORE Exact-Air II EXEMPLE ANNEXE 11 , REV.- , SPEC 0 062 646 SO Safety recommendations Electrical risks All electrical operation must be done by qualified personnel having the required accreditation. Preventive Maintenance: • Verify the good working condition of the emergency stops every day;...
  • Page 11 MILLIPORE Exact-Air II EXEMPLE ANNEXE 11 , REV.- , SPEC 0 062 646 SO Safety recommendations Mechanical risks All operation must be done by qualified personnel having the required accreditation. Before any dismantling or maintenance operation, make sure that all the sources of energy are shut down (fluid, gas, electricity).
  • Page 12 MILLIPORE Exact-Air II EXEMPLE ANNEXE 11 , REV.- , SPEC 0 062 646 SO Safety recommendations Chemical risks The chemical risks are related to the different products used. It is the responsibility of the client to ensure the adequate training of the operators and to put individual protection equipment according to the products used at their disposal.
  • Page 13 MILLIPORE Exact-Air II EXEMPLE ANNEXE 11 , REV.- , SPEC 0 062 646 SO Safety recommendations Thermal risks It is the responsibility of the client to ensure the training of the operators and to put individual protection equipment at their disposal.

  • Page 14: Glossary

    I.3. Glossary CIP (clean in place) Refers to procedures or equipment for cleaning membrane systems without dismantling the equipment. HydroCorr™ Millipore filter compression test for hydrophobic cartridge. Abbreviation for Integrity Tester. CONVERSION TABLE Length: 1 foot(ft. or ') =0.3048 m = 304.8 mm 1 inch(in.

  • Page 15: Before Using The System

    MILLIPORE Exact-Air II II. Before using the system Vol. 1 Before using the system Page: II-1 Exactair-description.fm...

  • Page 16: Ii.1 System Description

    Hence, Millipore has developed an automated system designed with a remote volume, so that only water is present in the critical temperature area.

  • Page 17: System Overview

    MILLIPORE Exact-Air II The automatic filter integrity test instrument that is to be coupled to the Exact-Air™ system is capable of producing a hard copy printout of the filtration system parameters and the generated test data, and indicates if a filter has passed or failed its specified integrity test.
  • Page 18 MILLIPORE Exact-Air II Note: The automatic filter integrity tester (like a Millipore Integritest® 4 instrument) is independent from the Exact-Air system and has to be ordered separately. LIST OF COMPONENTS Item n° Description and function TK001 10 L feed water tank equipped with quick connectors for air inlet, water outlet, venting and pressure relief valve.

  • Page 19: Operating Requirements

    MILLIPORE Exact-Air II II.1.5. OPERATING REQUIREMENTS II.1.5.1. Environment requirements Realising that Exact-Air™ system may be subjected to adverse environmental conditions in the field, it was designed and constructed using internal components that function properly at the following conditions: PARAMETER OPERATING...

  • Page 20: Description Of Test Sequences

    MILLIPORE Exact-Air II II.1.6. DESCRIPTION OF TEST SEQUENCES The filling operation and HydroCorr™ test is performed in an automatic sequence after starting the integrity tester. Using the touch screen starts the draining operation. The valve opening/shutting sequence is described in the table below.

  • Page 21: Ii.2 Control Panel Description

    MILLIPORE Exact-Air II II.2. Control panel description The electrical schematics are documented in the Electrical Documentation part. The electrical box is wired for 1 phase 100/230 V, 50/60 Hz and the international protection rating is IP54 (except for the power supply plug).

  • Page 22: Command Screen

    MILLIPORE Exact-Air II II.2.2.2. Command screen The Command screen provides status and control of cycles. The cycle selector buttons (Fill/Test, Drain, CIP) toggle from black text on white background to white text on black background when selected. Start: toggles from start to stop.

  • Page 23: Main Menu Screen

    MILLIPORE Exact-Air II II.2.2.3. Main menu screen The Command button opens the command screen. COMMAND It provides status and control of cycles. The P&ID button opens the P&ID screen. P&ID It provides a graphical schematic of the process along with device status.

  • Page 24: Setup Menu Screen

    MILLIPORE Exact-Air II II.2.2.4. Setup menu screen PROCESS This button opens the Process parameters screen. PARAMETERS It allows changing the parameters of the process. SETUP This button opens the Setup parameters screen. PARAMETERS It allows changing the Setup parameters. The Language button opens the language screen.
  • Page 25 MILLIPORE Exact-Air II II.2.2.5. P&ID screen The P&ID screen provides a graphical schematic of the process along with device status. Valve status: close = white / open = black TK002 status: empty = white / full = black Cycle in progress:...
  • Page 26 MILLIPORE Exact-Air II II.2.2.6. Alarm screen The alarms screen indicates which alarms are active or not acknowledged. Alarm buffer: opens the alarm history screen. Menu: opens the Main menu screen. Ack: allows acknowledgment of all cleared alarms. Checking alarm status 1/ To check alarm status, touch alarm screen button on the main menu to display the alarm status screen.
  • Page 27 MILLIPORE Exact-Air II Alarms interlocks A cycle can be start according to the table below. Cycle Alarm Conditions Filling Test Drain Emergency stop Emergency stop pushed alarm Low air pressure - Air pressure too low alarm - Delay timer expired...
  • Page 28 MILLIPORE Exact-Air II II.2.2.8. Process parameters screen This screen allows setting the timer values of the Filling, Drain and CIP cycles. Setup menu: opens the Setup menu screen. The alarm graphic symbol is only displayed when an alarm is - present or - absent and not acknowledged.
  • Page 29 MILLIPORE Exact-Air II The alarm graphic symbol is only displayed when an alarm is - present or - absent and not acknowledged. II.2.2.10. Screen utilities Adjusting the screen contrast Touch one of these buttons repeatedly until the desired contrast is achieved.

  • Page 30: Setup Screen

    MILLIPORE Exact-Air II II.2.2.11. Setup screen This screen allows setting the timer values of the opening and closing valves. Setup menu: opens the Setup menu screen. Remark: TI001 is an option. Vol. 1 II.2 Control panel description Page: II-16 Exactair-control-panel.fm...

  • Page 31: Ii.3 Start-Up Instructions

    MILLIPORE Exact-Air II II.3. Start-up instructions II.3.1. PRECAUTION • Vibrations due to transport may cause screws loosening in the electrical box. A general checking is necessary after unpacking and or transporting the system. • When the system arrives from transportation or comes out from the warehouse, it should rest for at least 3 hours in the room where it will be used in order to prevent condensation.

  • Page 32: Connection

    MILLIPORE Exact-Air II II.3.3. CONNECTION Exemple of Exact-Air™ connected to IT4 and to a product in order to test it (here a tank). A) Drain B) IT inlet C) IT outlet D) Air inlet E) Filter bottom F) Filter top Vol.
  • Page 33 MILLIPORE Exact-Air II CONNECTION OF EXACT-AIR™ SYSTEM TO GAS SUPPLY Connect the Exact-Air™ “Air inlet” to a regulated compressed air or N2 source. Gas supply must be clean and dry, at a minimum required pressure of 6 bar. CONNECTION OF THE AUTOMATIC FILTER INTEGRITY TESTER TO EXACT-AIR™...

  • Page 34: Instrument Preparation

    MILLIPORE Exact-Air II II.3.4. INSTRUMENT PREPARATION • Make sure the system is on a flat surface. Tighten the brakes of the wheels. • Check that the feed tank contains water at room temperature. • Check that the “emergency stop” push button is unlocked.
  • Page 35 MILLIPORE Exact-Air II 4/ Go to the Command screen and touch the CIP button to select the CIP cycle (The CIP button toggles in black, text in white). Then touch the Start button to start the flushing (cycle in progress shows CIP). Water will flow into the system and will be evacuated to the drain.

  • Page 36: Initial Start-Up And Leak Test

    MILLIPORE Exact-Air II II.3.7. INITIAL START-UP AND LEAK TEST A leak test is necessary prior to the first use to check for leak tightness of Exact-Air™, the connections to the tester device and the filter housing. This test is recommended to avoid false negative results caused by potential micro-leaks on the system during routine testing operations.
  • Page 37 MILLIPORE Exact-Air II 2/ When the cycle in progress shows Test, indicating that the filling operation has been successfully performed, start a test program for HydroCorr on the tester device. 3/ After testing, go to the Command screen and touch the Stop button to stop the Test cycle (cycle in progress shows stop).

  • Page 38: Operation

    MILLIPORE Exact-Air II III. Operation Vol. 1 Operation Page: III-1 Exactair-operating.fm...

  • Page 39: Iii.1 Operating Instructions

    MILLIPORE Exact-Air II III.1. Operating instructions III.1.1.INSTRUMENT SET-UP Set up the instrument as indicated on the P&ID. Ensure that all connection are made properly and that the system is leak tight Connect “Air inlet” from Exact-Air™ to the gas source.

  • Page 40: Starting A Test

    MILLIPORE Exact-Air II III.1.4.STARTING A TEST A 20 minutes warm-up period is recommended after power up, to allow for temperature stabilization prior to testing. 1/ Go to the Command screen and touch the Test button to select the Test cycle (The Test button toggles in black, text in white).
  • Page 41 MILLIPORE Exact-Air II 2/ When the cycle in progress shows “Test”, indicating that the filling operation has been successfully performed, start a test program for HydroCorr on the tester device. 3/ After testing, go to the Command screen and touch the Stop button to stop the Test cycle (cycle in progress shows stop).

  • Page 42: Draining Of The System

    MILLIPORE Exact-Air II III.1.5.DRAINING OF THE SYSTEM When the test is complete, go to the Command screen and touch the drain button to select the drain cycle (The drain button toggles in black, text in white). Then touch the Start button to start the draining (cycle in progress shows Drain).

  • Page 43: Cleaning In Place (Cip)

    MILLIPORE Exact-Air II III.1.6.CLEANING IN PLACE (CIP) As part of the maintenance program a CIP procedure is available on the Exact-Air™ system to clean and sanitise the internal piping of the system. It is recommended to clean and sanitise the system on a regular basis, especially when the system stays without operating for an extended time.

  • Page 44: Security Functions

    MILLIPORE Exact-Air II III.1.7.SECURITY FUNCTIONS EMERGENCY STOP The first security function available is the emergency stop. The “emergency stop” button can be activated at any moment to abort the cycle in progress. After the emergency stop function has been used, the alarm remains On (message in the alarm screen), indicating that the system is locked.

  • Page 45: Iii.2 Troubleshooting

    MILLIPORE Exact-Air II III.2. Troubleshooting PROBLEM ACTION The operator panel is not On. 1. Check that the system is connected to the correct electrical supply. 2. Put the power switch on “1”. The alarm symbol is displayed in the 1. Go to the alarm screen to see what the present alarms are.

  • Page 46: Iii.3 System Stopping

    MILLIPORE Exact-Air II III.3. System stopping If the system is shutdown for a long period, it is recommended: 1/ Disconnect and remove the IT Tester. 2/ Switch the main switch on position “0”. 3/ Unplug air and power 4/ Remove the air of the feed tank TK001 5/ Empty all the tanks.

  • Page 47: System Maintenance

    MILLIPORE Exact-Air II IV. System maintenance Vol. 1 System maintenance Page: IV-1 System-maintenance.fm...

  • Page 48: Iv.1 General Maintenance Of The System

    MILLIPORE Exact-Air II IV.1. General maintenance of the system PRIOR TO ANY WORK; READ THE SAFETY RECOMMENDATIONS PLACED AT THE BEGINNING OF THE USER'S MANUAL! IV.1.1. QUARTERLY CHECK RECOMMENDATION • Inspecting for leaks in valves and connectors; • Checking condition of gaskets (spot check only);...

  • Page 49: Iv.2 Recommended Spare Parts List

    Following list are the recommendations for one year maintenance but some spare parts are recommended in case of problems and need not to be purchased every year. Refer also to the technical documentation supplied by each component manufacturer. Millipore can supply all these spare parts. DESCRIPTION VENDOR Q.TY...

  • Page 50: P&Id - Flow Schematic

    MILLIPORE Exact-Air II V. P&ID - Flow schematic Piping & Instrumentation Diagram Click on diagram below in order to reach the flow schematic of the equipment. P&ID Vol. 1 Page: V-1 PID-symbols.fm...
  • Page 51 MILLIPORE MSP008687 COMPONENTS SYMBOLS OF FLOW SCHEMATIC: LETTER TYPE OF COMPONENT Valve Level sensor + function Pressure sensor + function Pressure reducer LETTER FUNCTION Indicator SYMBOL DESCRIPTION Tank Tank Liquid trap Aervant filter Valve Vol. 1 Page: V-2 PID-symbols.fm...
  • Page 52 MILLIPORE MSP008687 SYMBOL DESCRIPTION Pressure relief valve Air supply Sensor with local display + functions as described above Drain port Connection Line fall Vol. 1 Page: V-3 PID-symbols.fm...

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