Mocon Dansensor Lippke 4000 User Manual

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Package Test System

Lippke 4000/4500

User Guide

P/N 330654-E

01/2018

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Page 1 Package Test System Lippke 4000/4500 User Guide P/N 330654-E 01/2018...
Page 2 Lippke 4000/4500 User Guide Package Test System Lippke 4000/4500 User Guide Published by: Dansensor A/S Rønnedevej 18, DK-4100 Ringsted Denmark Tel.: +45 57 66 00 88 Fax: +45 57 66 00 99 E-mail: info@dansensor.com Internet: www.dansensor.com Dansensor A/S COPYRIGHT © P/N 330654-E 01/2018...
Page 4: Table Of Contents
Lippke 4000/4500 User Guide Table of contents 1. General Information ........7 Register your product .
Page 5 User Guide Lippke 4000/4500 Needles............31 Test head needles .
Page 6 Lippke 4000/4500 User Guide User administration ..........60 Create user .
Page 8: General Information
Lippke 4000/4500 User Guide 1. General Information Register your product Thank you for purchasing a Dansensor product, we hope that the product will fulfil your needs. In order to learn more about our customers and the markets we serve, we kindly ask you to fill out the product registration form available on-line at www.dansensor.com/register In return we can offer to send important product information to you.
Page 9: Notes, Cautions, Warnings And Tips
User Guide Lippke 4000/4500 Notes, cautions, warnings and tips! Throughout the manual notes, cautions, and warnings are indicated with various icons and written in bold like the example below: CAUTION! Never use hard tools or abrasive materials when cleaning any part of the device. Explanation NOTE! The operator should observe and/or act according to the information in order to obtain the best possible function of the equipment.
Page 10: Safety Instructions
Lippke 4000/4500 User Guide Safety Instructions Personnel operating and maintaining the device must be familiar with all aspects of its operation and be proficient in maintenance. Such personnel should review the following precautions to promote safety awareness. General • Always refer to the manual before operating or maintaining the equipment. •...
Page 12: Introduction
Lippke 4000/4500 User Guide 2. Introduction Lippke 4000/4500 The Lippke 4000/4500 is an integrated package test system that measures the seal strength and integrity of flexible, rigid or semi-rigid packages. The seal strength and integrity of the package is measured by inflating it using compressed air. The system consists of a console and one or more accessory kits, each of which is used to test the most commonly used types of packages such as closed packages, open packages, screw top tubes, and IV bags - see "3.
Page 13: Device Overview
User Guide Lippke 4000/4500 Device overview BURST-2 Supervisor Test result Device front  “Start” button (4000-models only) Use button to start a test  “Stop” button (4000-models only) Use button stop a test that is in progress  Key button (4000-models only) Use button to log out an operator when User Login is enabled.
Page 14 Lippke 4000/4500 User Guide BURST-2 Supervisor Test result  Display (4000-models only) Monochrome display for setting up of test parameters and for displaying test progresses and results.  LED indicators (4500-models only) The 3 LED indicators indicate the following: • Power (Red) Lit when the instrument is turned on •...
Page 15: Device Back
User Guide Lippke 4000/4500 Main Caution! Fuse 1AT Disconnect mains before opening! Accessory Port Air Supply max. 4 bar Clamp Feed Sense PC/Printer 9 10 11 12 13 15 16 Device back  “Clamp” connector The “Clamp” output is mainly used for automatic control of the lower clamp bar of the optional PPC 300 II unit and for controlling the valves on the MultiCheck test head.
Page 16: Accessories
Lippke 4000/4500 User Guide Accessories A variety of measurement accessory kits are available for the Lippke 4000/4500 test system. Each measurement accessory kit is specially designed for testing of the most commonly used types of packages, such as closed packages, open packages, screw top tubes and IV bags. The kits are: ...
Page 18: Measurement Accessory Kits
Lippke 4000/4500 User Guide 3. Measurement Accessory Kits Stand, basic The basic stand is used to test fully sealed (closed) rigid and semi rigid packages. There are various kits with different contents available depending on the application, but basically a kit consists of: ...
Page 19: Setting Up
User Guide Lippke 4000/4500 Setting Up    1. Mount the nut and the washer on the vertical rod , then screw the rod into the base plate    as far as it goes. Tighten assembly by screwing the nut against the base plate ...
Page 20: How Does It Work
Lippke 4000/4500 User Guide How does it work?    1. Prepare the package with a septum and place it on the base plate    2. Move the test head downwards to penetrate the package making sure that the needle ...
Page 21: Fixture For Astm Restraining
User Guide Lippke 4000/4500 Fixture for ASTM restraining This fixture is used to perform restrained tests on closed packages compliant with ASTM F2054. As the name says they restrain the package to ensure that the pressure affects the package sealings in the correct way.
Page 22: Setting Up
Lippke 4000/4500 User Guide Setting Up    1. Mount the nut and the washer on the vertical rod , then screw the rod into the base plate    as far as it goes. Tighten assembly by screwing the nut against the base plate ...
Page 23: How Does It Work
User Guide Lippke 4000/4500 How does it work? 1. Adjust the restraining height - see "Adjusting the restraining height (ASTM)" on page 23 for details.  2. Open the restraining plates by sliding them away from each other.   ...
Page 24: Adjusting The Restraining Height (Astm)
Lippke 4000/4500 User Guide Adjusting the restraining height (ASTM) The ASTM restraining fixture can be adjusted to various package restraining heights from 6.35 to 76.2 mm (¼” to 3”) in steps of 6.35 mm (¼”). The 12 different height settings are achieved by combining the side bars (A) and (B) as illustrated below. For each of the 3 combinations of the bar (B) (none, lying or standing) there is a matching set of screws ...
Page 25: Ppc 300 Ii
User Guide Lippke 4000/4500 PPC 300 II The PPC 300 II device is designed for performing burst tests on most types of packages, bags or pouches that are open on one side. The device seals the open side of the package, enabling a test to be performed according to the ASTM F1140 standard.
Page 26: Setting Up
Lippke 4000/4500 User Guide Setting Up   1. If the PPC 300 II is to be used together with the fixture for package restraining the two units  must be assembled using the screws  2. Connect the unit’s air supply (Feed) and pressure measurement (Sense) hoses to the Lippke 4000/4500.
Page 27: How Does It Work
User Guide Lippke 4000/4500 How does it work? 1. If necessary adjust the restraining height - see "Adjusting the restraining height (PPC 300 II)" on page 27 for details.  2. If the lower bar is controlled by the Lippke 4000/4500 it will already be lowered, otherwise use ...
Page 28: Adjusting The Restraining Height (Ppc 300 Ii)
Lippke 4000/4500 User Guide Adjusting the restraining height (PPC 300 II) The package restraining fixture for the PPC 300 II can be adjusted to various package restraining heights.   The restraining height is achieved by adjusting the distance between the two plates ...
Page 29: Valve Test Unit (Vtu)
User Guide Lippke 4000/4500 Valve Test Unit (VTU) The Valve Test Unit (VTU) can be used to perform tests on “Degassing Valves” Degassing valves are used on some coffee and food products to prevent a pressure build-up inside the product packaging. The VTU can be used either to test the cracking or burst pressure of the valve or to verify that there is no “reverse leakage”.
Page 30: How Does It Work
Lippke 4000/4500 User Guide How does it work?  1. Cut out the sample from the package. The sample should have a size of app. 60 x 60 mm (must  cover the O-ring ) and the valve must be placed in the centre of the sample. ...
Page 31: Iv-Bag Adapter
User Guide Lippke 4000/4500 IV-Bag adapter This is an adapter for testing of IV-Bags. The conical shape of the adapter’s mouthpiece allows for easy connection to most types of IV-bags. Connect air supply (Feed) and pressure measurement (Sense) hoses to the adapter. Sense Feed Tube adapter...
Page 32: Needles
Lippke 4000/4500 User Guide Needles A needle is used to penetrate and inflate a package with compressed air to perform a test. There are two types of needles: The test head needles and the handheld needles. Test head needles The test head needles are designed to be fitted to the test heads on the “Stand, basic” and the “Fixture f. ASTM restraining”...
Page 33: Handheld Needles
User Guide Lippke 4000/4500 Handheld needles The handheld needles can be used independently of any other accessory and are connected directly to the Lippke 4000/4500 by means of hoses.  The handheld needles come as a “Mono” needle (E) or a “Twin” needle (F) with a security cover To expose the needles of the “Twin”...
Page 34: Filter
Lippke 4000/4500 User Guide Filter When testing packages filled with powder or liquid substances, particles or fluids can move backwards into the system causing damage to the instrument. In these cases it is highly recommended to install the filter between the test head and the needle.
Page 35: Septa
User Guide Lippke 4000/4500 Septa In order to ensure a linear pressure increase in the package and to avoid unnecessarily high consumption of air it may be necessary to seal the package’s piercing point with a septum. A septum also protects the package from tearing at the piercing point.
Page 36: Tests
Lippke 4000/4500 User Guide 4. Tests Test types Standard tests The following standard tests can be performed: • Burst Test/Seal Strength – see page 36 • Leak Test/Pressure Loss – see page 39 Creep tests When the Creep Test option has been purchased, a Creep test or a Creep2Fail test can be performed according to ASTM F1140.
Page 37: Burst Test
User Guide Lippke 4000/4500 Burst test A Burst test checks the strength of a package sealing by increasing the pressure in the package until it bursts. The Burst test is compliant with ASTM F2054. CAUTION! As the bursting of the test package may lead to considerable noise, we recommend wearing hearing protection.
Page 38: Measurement Accessory Kits
Lippke 4000/4500 User Guide Measurement accessory kits The following measurement accessory kits can be used for a Burst test: • Stand, basic (with any test head and needle or tube adaptor, with or without filter) • Fixture f. ASTM restraining (with any test head and needle or tube adaptor, with or without filter) •...
Page 39 User Guide Lippke 4000/4500 Pressure drop [%] If there is a problem with false burst detections you can increase the (Stop-Threshold) pressure drop value. Also check that the prefill pressure is high enough. Recommended setting: 10% With oxygen measurement * Requires a PacCheck 3XX - If checked the O level is measured.
Page 40: Leak Test
Lippke 4000/4500 User Guide Leak test A Leak test checks a package for leaks. The package is inflated to a predetermined pressure (about 30- 50% of the package’s burst pressure) and then the pressure loss is monitored to determine whether or not there is a leak.
Page 41: Measurement Accessory Kits
User Guide Lippke 4000/4500 Measurement accessory kits The following measurement accessory kits can be used for a Leak test: • Stand, basic (with any test head and needle or tube adaptor, with or without filter) • Fixture f. ASTM restraining (with any test head and needle or tube adaptor, with or without filter) •...
Page 42 Lippke 4000/4500 User Guide With CO2 measurement * Requires a PacCheck 3XX - If checked the CO level is measured. Limit CO2 [%] * Upper limit for acceptable CO measurement. Displayed limits in chart: Pressure, upper limit in chart Upper pressure value for the [mbar] axis in the resulting graph chart [mbar] * Pressure, lower limit in chart Lower pressure value for the [mbar] axis in the resulting graph chart...
Page 43: Creep Test
User Guide Lippke 4000/4500 Creep test A Creep test can be used to evaluate the seals on a package. A Creep test inflates the package to a specific pressure (typically app. 80% of the burst pressure) and maintains this pressure for a specified time period.
Page 44: Measurement Accessory Kits
Lippke 4000/4500 User Guide Measurement accessory kits The following measurement accessory kits can be used for a Creep test: • Stand, basic (with any test head and needle or tube adaptor, with or without filter) • Fixture f. ASTM restraining (with any test head and needle or tube adaptor, with or without filter) •...
Page 45 User Guide Lippke 4000/4500 Displayed limits in chart: Pressure, upper limit in chart Upper pressure value for the [mbar] axis in the resulting graph chart [mbar] * Pressure, lower limit in chart Lower pressure value for the [mbar] axis in the resulting graph chart [mbar] * P/N 330654-E 01/2018 COPYRIGHT ©...
Page 46: Creep2Fail Test
Lippke 4000/4500 User Guide Creep2Fail test The Creep2Fail is test is similar to the Creep test, but it uses a test pressure between 95%-100% of the burst pressure. The test pressure should be high enough to cause a slow but progressive failure during the specified test time.
Page 47: Measurement Accessory Kits
User Guide Lippke 4000/4500 Measurement accessory kits The following measurement accessory kits can be used for a Creep2Fail test: • Stand, basic (with any test head and needle or tube adaptor, with or without filter) • Fixture f. ASTM restraining (with any test head and needle or tube adaptor, with or without filter) •...
Page 48 Lippke 4000/4500 User Guide Displayed limits in chart: Pressure, upper limit in chart Upper pressure value for the [mbar] axis in the resulting graph chart [mbar] * Pressure, lower limit in chart Lower pressure value for the [mbar] axis in the resulting graph chart [mbar] * Limits: Limit + [mbar]...
Page 49: Bubble Test
User Guide Lippke 4000/4500 Bubble test (Requires the Creep Test option) The Bubble test is only available for the Lippke 4500 and has two purposes; one is to locate the placement of a hole in a package. To do this place the package (with septum and needle) under water. Secondly you can test for example that a Tyvek package functions as intended, meaning that it only leaks within a specific pressure range.
Page 50: Measurement Accessory Kits
Lippke 4000/4500 User Guide Measurement accessory kits The following measurement accessory kits can be used for a Bubble test: • Stand, basic (with any test head and needle or tube adaptor, with or without filter) • Tube adapter • IV-Bag adapter •...
Page 52: Setting Up
Lippke 4000/4500 User Guide 5. Setting Up Compressed air connections Compressed air supply requirements The compressed air supply must be dry, clean and free from oil - see specifications in "Air supply" on page 71. CAUTION! If the specified maximum pressure is exceeded, there is a danger of bursting of tubing and other components.
Page 53: Correct Use Of Hose Connectors
User Guide Lippke 4000/4500 Correct use of hose connectors Follow procedure below to ensure correct and tight hose connections:   1. Unscrew the union nut from the hose connector  slide it onto the hose   2. Press the hose onto the hose connector as far as it goes.
Page 54: Connecting Hoses And Cables
Lippke 4000/4500 User Guide Connecting hoses and cables NOTE! The Lippke 4000/4500 device and the various accessories must be placed on an even and steady surface with sufficient working area for the type of packages to be tested. 1. You have 3 connection possibilities for the “Clamp” connector: - If you are using the device together with a PPC 300 II unit and you want the device to control the ...
Page 55: Connection Of External Control Device
User Guide Lippke 4000/4500 6. If a printer is to be used, unpack it and set it up using the provided instructions.  7. Connect one end of the interface cable to "PC/Printer" port.  8. Connect the “Null Modem” adapter to the other end of the interface 9.
Page 56: Operation
Lippke 4000/4500 User Guide 6. Operation General The Lippke 4500 uses the Package Test System Lippke 4500 PC software application to set up and perform all tests. Details on how to operate this software can be found in the Help section of the software.
Page 57: Start Up
User Guide Lippke 4000/4500 Start up Lippke 4500 1. Switch power on by means of the mains switch at the back of the device. 2. When power is applied to the unit, the red “Power” indicator on the front will be lit. 3.
Page 58 Lippke 4000/4500 User Guide Entering a correct PIN code will take you to the Main Menu. 5. From the Main Menu you can select each of the available tests and the Setup menu. 11:59:17 Main Menu Burst test Creep & Leak Leak Test...
Page 59: Setup
User Guide Lippke 4000/4500 Setup Selecting Setup from the Main menu will display the Setup Menu with the available setup parameters such as Data Transmission, User administration, Language etc. Setup Menu Security Language Settings Data Output Data Transmission User Administration Each menu item has a submenu with available set-up parameters for the selected item.
Page 60 Lippke 4000/4500 User Guide Ventilate Select how to ventilate the package after a test: auto, manual or Off. NOTE! If set to “auto” the package will be ventilated through the device. In this case you must make sure that the package does not contain a product that can be pulled back through the device.
Page 61: User Administration
User Guide Lippke 4000/4500 User administration Select User Administration from the Setup Menu to maintain the user database. You can see the list of existing users, create or delete users, and edit the settings for an existing user. Create user 1.
Page 62: Delete User
Lippke 4000/4500 User Guide Delete user 1. From the Setup Menu select User Administration. User Administr. Supervisor USER-1 2. Select the user you want to delete ex. USER-1. User Name USER-1 Select Tests Modify Tests Supervisor 0000 3. Select and press Delete. Delete File? 4.
Page 63: Test Setup
User Guide Lippke 4000/4500 Test setup Create a test record with parameter settings 1. Select ex. Burst test from the Main Menu. 11:59:17 Main Menu Burst test Creep & Leak Leak Test CreepLeakBurst Creep-Test Creep2FailTest Creep & Burst Setup 2. The display will change to show the Burst test records list, which will be empty when entering for the first time.
Page 64: Delete Test
Lippke 4000/4500 User Guide Delete test 1. From the Main Menu select the test type ex. Burst test. Burst test BURST-1 BURST-2 2. Select the test record you want to delete ex. BURST-2 and press Edit button. Burst test Name BURST-2 Fill pressure...
Page 65: Performing A Test
User Guide Lippke 4000/4500 Performing a test Before you start to perform tests, it is recommended that you familiarize yourself with the use of the various accessories as described in "3. Measurement Accessory Kits" on page 17 and the various test types as described in "4.
Page 66 Lippke 4000/4500 User Guide 7. Press Start button to start the test. The test starts and each test phase will be displayed while executed (Pre-filling, Pressure incr. etc.) together with the read-out of the current package pressure. BURST-2 Supervisor Pre-Filling 0000:12 BURST-2 Supervisor...
Page 67: Display Of Test Results
User Guide Lippke 4000/4500 Display of test results At the end of each test the test result will be displayed on the screen. Burst test result A Burst test can either be failed or passed. The test result is displayed as the pressure where the package bursts and whether the test is passed or failed.
Page 68: Cleaning And Maintenance
Lippke 4000/4500 User Guide 7. Cleaning and Maintenance General NOTE! Performing cleaning and maintenance regularly reduces the chances of equipment failure. CAUTION! Personnel performing any maintenance or cleaning must familiarize themselves with the "Safety Instructions" on page 9 before attempting any of these procedures. NOTE! For correct mounting/dismounting of fittings please see "Correct mounting/ dismounting of fittings"...
Page 69: Maintenance
User Guide Lippke 4000/4500 Maintenance Filter  The filter foam material in the optional filter should be replaced at regular intervals or if it is soiled. O-rings  The O-rings for the filter, needles and test heads guarantee tightness and functioning of the system and must therefore be replaced periodically.
Page 70: Troubleshooting
Lippke 4000/4500 User Guide 8. Troubleshooting NOTE! The following list of possible error causes and their remedies is not necessarily complete. If problems or errors occur, that are not described in this section, please do not hesitate to contact us. System Errors Problem Cause...
Page 71: Problems During Measurement
User Guide Lippke 4000/4500 Problems during Measurement Problem Cause Remedy The system does not build up - The package is leaking around - Check the connections pressure during a measurement the needle and or septum - Switch on printer - The Pressure Rise setting may - Switch printer ON line be too high - The package is very porous...
Page 72: Technical Information
Lippke 4000/4500 User Guide 9. Technical Information Technical specifications Electrical specifications Supply voltage 103-264 VAC, 47-63 Hz Power consumption 50 W Air supply Air supply pressure Devices w/ 5 bar “Feed” valve: max. 4.0 bar (58 psi) Devices w/ 10 bar “Feed” valve: 4.0 - 8.0 bar (58 - 116 psi) The input pressure must be at least 1 bar (14.5 psi) above measurement pressure Air quality...
Page 73: Accessories Data
User Guide Lippke 4000/4500 Accessories data Stand, basic Dimensions (H x W x D): 407 x 250 x 330 mm (16 x 9.8 x 13”) Weight: 3.6 kg (7.9 lbs) Fixture f. ASTM restraining Dimensions (H x W x D): 412 x 400 x 405 mm (16.2 x 15.7 x 15.9”) Weight: 13.5 kg (29.8 lbs)
Page 74: Connectivity
Lippke 4000/4500 User Guide Connectivity RS232 D-SUB 9 DTE interface (male connector) Machine I/O D-SUB 15 male Conformity • CE (RoHS) Dansensor A/S COPYRIGHT © P/N 330654-E 01/2018...
Page 76: 10. Consumables And Accessories
Lippke 4000/4500 User Guide 10. Consumables and accessories Ordering items When ordering any of the below listed items please state carefully the item number, the item specification and the number of items wanted and send the order to your spare parts dealer. Consumables •...

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