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EG Xcellerex XDUO 2500, Operating Instructions Manual

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EG Xcellerex XDUO 2500 Operating Instructions Manual Download Page 62

3.3.2

I/O Cabinet

Description of the I/O Cabinet

The I/O Cabinet contains instrumentation for the measurement and control of all system
process parameters. The I/O Cabinet is attached to XDUO 2500 Mixer.

The following optional equipment can be connected to the I/O Cabinet:

•

pH/conductivity measurement

•

Pumps for automated pH control

•

Temperature measurement

•

Temperature control (jacketed models only)

•

Weight measurement

62

Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH

3 System description

3.3 Mixer vessel components
3.3.2 I/O Cabinet

Summary of Contents for Xcellerex XDUO 2500

Page 1: ...Xcellerex XDUO 2500 Mixer Operating Instructions Original instructions...

Page 2: ...2 5 Security levels 42 2 6 Recycling information 44 2 7 Declaration of Hazardous Substances DoHS 46 3 System description 47 3 1 Safety system 49 3 2 System overview 50 3 2 1 System hardware 52 3 2 2...

Page 3: ...jacking bolts 150 6 2 2 Use leveling feet 153 6 3 Prepare the disposable bag 154 6 3 1 Unpack the disposable bag assembly 162 6 3 2 Install the disposable bag 175 6 4 Prepare and install the probes 17...

Page 4: ...s 274 9 8 Temperature control 275 9 9 Temperature monitoring 276 9 10 Weight monitoring 278 10 Reference information 279 10 1 System specifications 281 10 2 SP CV and PV units and ranges 282 10 3 Pump...

Page 5: ...on and regulatory information about Xcellerex XDUO 2500 Mixer In this chapter See page Section 6 1 1 About this manual 7 1 2 Important user information 9 1 3 Regulatory information 15 1 4 Abbreviation...

Page 6: ...ystem is either CE classified or UL classified The system configuration for your system is described in the General Specification and on the system label Typographical conventions Software items are i...

Page 7: ...a plug and play single use mixing system for production of biophar maceuticals vaccines and other biologics XDUO 2500 Mixer is configurable to meet a broad range of mixing requirements XDUO 2500 Mixe...

Page 8: ...ortant not to proceed until all stated conditions are met and clearly understood CAUTION CAUTION indicates a hazardous situation which if not avoided could result in minor or moderate injury It is imp...

Page 9: ...irement GE Healthcare Bio Sciences AB Name and address of manufacturer Bj rkgatan 30 SE 751 84 Uppsala Sweden In this section See page Section 10 1 3 1 EU directives 11 1 3 2 Eurasian Customs Union 12...

Page 10: ...Machinery Directive MD 2006 42 EC Electromagnetic Compatibility EMC Directive 2014 30 EU CE marking The CE marking and the corresponding EU Declaration of Conformity is valid for the in strument when...

Page 11: ...ontent Requirement GE Healthcare Bio Sciences AB Name and address of manufacturer Bj rkgatan 30 SE 751 84 Uppsala Sweden Telephone 46 771 400 600 GE Healthcare LLC Importer and or company for obtain i...

Page 12: ...perate the equipment Note This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to part 15 of the FCC Rules These limits are designed to provide rea...

Page 13: ...nt has been evaluated for its suitability for use in a business environment When used in a residential environment there is a concern of radio interference A Xcellerex XDUO 2500 Mixer Operating Instru...

Page 14: ...na RoHS Standards machinery and electrical equipment Standard requirements fulfilled by this product are summarized in the table below Description Standard Safety of machinery General principles for d...

Page 15: ...e HMI Input Output Cabinet I O Cabinet Open Platform Communications OPC proportional integral derivative PID A PID controller tries to minimize the difference between a measured PV and a defined SP Th...

Page 16: ...oint high limit SPHL setpoint low limit SPLL hygienic tubing connection TC temperature control unit TCU uninterruptible power supply UPS 16 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH...

Page 17: ...tion regarding recycling and security levels are also described In this chapter See page Section 18 2 1 Safety precautions 27 2 2 Labels 31 2 3 Emergency procedures 40 2 4 Interlocks 41 2 5 Security l...

Page 18: ...of this chapter to become aware of the hazards involved Failure to do this may cause human injury or death or damage to the equipment WARNING Operate as described Do not operate XDUO 2500 Mixer in an...

Page 19: ...use human injury or death CAUTION Use caution Use caution close to moving parts stored energy pressurization and electrical sources CAUTION Moving parts Do not place objects or fingers into valves rot...

Page 20: ...nal safety during the transportation installation operation and maintenance of the system always use protective glasses and other personal protective equipment appropriate for the current application...

Page 21: ...lators from getting too close to the magnets Installation WARNING Installation Installation and relocation of the instrument must be performed by GE personnel or a third party authorized by GE WARNING...

Page 22: ...nly The product is designed for indoor use only CAUTION Check floor safety limits Before filling the TCU and the mixer with liquid verify that the total system weight is below the established floor lo...

Page 23: ...nd bases Acids and bases are dangerous if not handled correctly Properly tune PID control loops to avoid unwanted release of acids or bases WARNING Secure jacking bolts Do notmove theinstrumentwithout...

Page 24: ...to avoid pinching fingers between the impeller baseplate and the magnetic drive head CAUTION Heavy object The container with solid ingredients is heavy Use caution to avoid personal injury when filli...

Page 25: ...ON Tuning PID control loops Make sure that personnel tuning PID control loops are qualified to perform this task Incorrectly tuned PID loops could cause injury to personnel and damage the instru ment...

Page 26: ...sure that the instrument surface temperature is equal to room temperature before cleaning CAUTION Cleaning Always clean the equipment in a well ventilated area Never immerse any part of the equipment...

Page 27: ...llowing illustration shows the lo cation of the system label System label The system label is located near the I O Cabinet The label shown below is an example Actual data printed on the system label i...

Page 28: ...mage Jacketed or non jacketed Vessel Type Part number of the system Code Number Serial number of the system System Number The year and month the system was built Manufacturing Year Month Electrical po...

Page 29: ...directives This symbol indicatesthat the product contains hazardous materials in excess of the limits established by the Chinese standard GB T 26572 Requirements of concentration limits for certain h...

Page 30: ...prior to maintenance Do not per form any maintenance work until the magnetic shaft has stopped completely High Voltage Hazardous voltage can cause se vere injury or death Turn off power and Lock Out...

Page 31: ...lt of power failure and the procedure for restarting XDUO 2500 Mixer In this section See page Section 32 2 3 1 System power switch and Emergency Stop button 34 2 3 2 Emergency shutdown 38 2 3 3 Power...

Page 32: ...e following illustration The system power switch positions are described in the following illustrations Description Illustration The system power switch in the O OFF position Power is disconnected fro...

Page 33: ...ton is shown in the following illustration The EMERGENCY STOP button is engaged by being pushed To reduce the risk of injury all power is removed from the pumps when the EMERGENCY STOP button is engag...

Page 34: ...ain in a safe state Agitator motors are turned off TCU is turned off E Stop Pressed is displayed on every local control software screen Data logging continues if enabled If XDUO 2500 Mixer is a FlexFa...

Page 35: ...on Disconnect the power cord Turn off the main circuit breaker Note The main circuit breaker is provided by the user The location of the circuit breaker depends on the facility Xcellerex XDUO 2500 Mix...

Page 36: ...that caused the emergency shutdown is cor rected 1 Turn on the mains power supply by turning the system power switch to I ON position 2 Disengage the EMERGENCY STOP button by turning it clockwise 3 R...

Page 37: ...ry Mixer overview screen FlexFactory connect ed system If a batch was running prior to when the EMERGENCY STOP was pushed the system is set in the Held state If a batch was not running XDUO 2500 Mixer...

Page 38: ...DUO 2500 Mixer after power failure Action Step Connect the main power cord 1 Turn on the mains power supply by turning the system power switch to I ON position 2 Tap RESET on the local control softwar...

Page 39: ...rol and temperature control stop Communication recovery pH control and temperature control loops stay in a safe state The agitator remains turned off XDUO 2500 Mixer remains disconnected from FlexFact...

Page 40: ...ocks stop the pumps The temperature and the pH control loops go into Manual mode The TCU setpoint is set to the vessel temper ature PV value The agitators are shut off when temperature control or pH c...

Page 41: ...0 Mixer local control software has three security levels Operator Supervisor Administrator The following table shows the access levels for individual system functions in the local control software Sec...

Page 42: ...according to national and local environmental regulations Recycling of hazardous substances XDUO 2500 Mixer contains hazardous substances Detailed information is available from your GE representative...

Page 43: ...strips power supplies trans mitters pumps probes sensors etc from the I O Cabinet and the XDUO vessel 2 Decontaminate the probes and sensors that have come into contact with the process fluid Dispose...

Page 44: ...o that the use of such electrical and electronic products will not result in any severe environmen tal pollution any bodily injury or damage to any assets The unit of the period is Year In order to ma...

Page 45: ...substance contained in all of the homogeneous materials for this part is below the limit requirement in GB T 26572 X Indicates that this hazardous substance contained in at least one of the homogeneou...

Page 46: ...iew of its compo nents In this chapter See page Section 47 3 1 Safety system 49 3 2 System overview 55 3 3 Mixer vessel components 73 3 4 XDUO 2500 Mixer control 78 3 5 Temperature control unit 79 3 6...

Page 47: ...top is to stop the system in an emergency situation such as an accident or a sudden unexpected release of the disposable bag contents The emergency stop button is located on the side of the I O Cabine...

Page 48: ...ching the accepted test pressure much lower than the operating pressure This prevents catastrophic failure of the vessel jacket Any leaking or dripping from the vessel jacket should immediately be rep...

Page 49: ...ilable options and information about XDUO 2500 Mixer connectivity to other systems In this section See page Section 50 3 2 1 System hardware 52 3 2 2 System options 54 3 2 3 System connectivity Xcelle...

Page 50: ...a UPS power backup Operating principle A sterile single use bag is installed in the vessel and the mixing process is performed inside the disposable bag The liquid ingredients are introduced through s...

Page 51: ...3 Description Part Mixer vessel 1 Communication cable 2 Coolant tubing 3 Temperature control unit TCU 4 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 51 3 System description 3 2 System...

Page 52: ...ted XDUO 2500 Mixer Temperature monitoring Temperature control Optional functions The following optional functions are available for XDUO 2500 Mixer Audit trail Conductivity monitoring pH monitoring p...

Page 53: ...eight XDUO 2500 Mixer can optionally be equipped with load cells which measure and record the weight of the mixer vessel Monitoring and control of temperature XDUO 2500 Mixer provides the following te...

Page 54: ...ely a daisy chain scheme can be used The communication to each mixer is independent of the presence of other mixers and is not interrupted if one of the mixers is turned off Connection via OPC interfa...

Page 55: ...the components of the mixer vessel In this section See page Section 56 3 3 1 Mixer vessel 62 3 3 2 I O Cabinet 65 3 3 3 Agitators 69 3 3 4 Load cells 71 3 3 5 Pumps Xcellerex XDUO 2500 Mixer Operatin...

Page 56: ...e contents A combined probe support and test tube rack is attached to the probe window The bottom of the mixer vessel is sloped in two planes to enable efficient draining of the product XDUO 2500 Mixe...

Page 57: ...4 6 8 9 7 7 3 5 2 Function Part I O Cabinet 1 Side access door 2 2 Cable holder 2 3 Push bar 4 4 Load cell 4 5 Probe window and probe support bar 6 Agitator handle 2 7 Test tube rack 8 Caster 4 9 Xcel...

Page 58: ...DUO 2500 Mixer 1 2 3 4 5 6 7 5 8 9 10 10 11 1 7 Function Part Vessel frame 1 Viewing window 2 Push bar 4 3 I O Cabinet 4 Cable holder 2 5 Load cell 4 6 Side access door 2 7 Caster 4 8 58 Xcellerex XDU...

Page 59: ...nction Part Handle 1 Lid part 4 2 Opening for liquid addition lines 3 Opening for powder addition port1 4 1 Powder addition port is designed for connecting hopper or powder bag to the disposable bag X...

Page 60: ...vessel 6 1 2 3 5 4 Function Part Coolant outlet Return 1 Vent valve 2 Burst disc 3 Safety valve outlet 4 Drain valve 5 Coolant inlet Supply 1 6 1 The coolant inlet is also used to drain the coolant 60...

Page 61: ...rs to enable simultaneousand convenient access to the mixer vessel from the opposite ends The step ladders are attached to the mixer vessel on both short sides of the vessel A set of two step ladders...

Page 62: ...s attached to XDUO 2500 Mixer The following optional equipment can be connected to the I O Cabinet pH conductivity measurement Pumps for automated pH control Temperature measurement Temperature contro...

Page 63: ...touchscreen 2 EMERGENCY STOP button 3 Door lock 4 pH conductivity transmitter display 5 Power probe and network connections connection ports underneath 6 Ventilation hood 7 System power switch 8 Pump...

Page 64: ...on port The USB memory stick should be removed and the protective cover in place when not actively using the port or during cleaning 64 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 3 S...

Page 65: ...hen the protective collar is lowered during the installationof the disposable bag the impeller baseplate magneticallyengages with the agitator drive head and is ready for operation The protective coll...

Page 66: ...or system The following illustration shows the location of the agitator motors Xcellerex XDUO 66 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 3 System description 3 3 Mixer vessel comp...

Page 67: ...drive head 1 2 3 Function Part Agitator motor 1 Agitator drive head 2 Telescopic handle 3 The following illustration shows a close up view of the impeller Xcellerex XDUO 2500 Mixer Operating Instruct...

Page 68: ...itator direction Fluid swirls downwards reverse agitation Clockwise Fluid swirls upwards forward agitation Counterclockwise If the instrument is connected into FlexFactory system clockwise agitation i...

Page 69: ...or example during re arrangement of a manu facturing line The jacking bolts lift the mixer vessel up secure it and take the load off from the load cells thereby preventing the damage to the load cells...

Page 70: ...ll 1 2 3 4 5 Description Part Top nut 1 Bottom nut 2 Jacking bolt 3 Vessel frame 4 Load cell 5 70 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 3 System description 3 3 Mixer vessel com...

Page 71: ...Two Watson Marlow peristaltic pumps model 520 can be included in the configuration of XDUO 2500 Mixer The pumps operate at variable speed Changing the CV between 0 and 100 increases the speed linearly...

Page 72: ...2 2 3 3 4 5 6 Description Part Tube clamp 1 Retention pin 2 Roller 3 Tube guide roller 4 Follower roller 5 Cover 6 72 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 3 System description...

Page 73: ...ystem control and automation possibilities In this section See page Section 74 3 4 1 XDUO 2500 Mixer automation and control 76 3 4 2 Local control panel 77 3 4 3 Data access Xcellerex XDUO 2500 Mixer...

Page 74: ...operated via the local control panel Output process variables are displayed on the local control panel The mixer can perform process monitoring and control The following features describe local contro...

Page 75: ...Local control with historization The process control is centralized The process control is local The process variables are controlled from M Station OIT The process variables are controlled us ing loc...

Page 76: ...rocess The user communicates with PLC using an integrated touchscreen The PLC can act as a controller or as a remote input output system depending on XDUO 2500 Mixer mode of operation The local contro...

Page 77: ...has to be connected to the Historian server of FlexFactory Historical data is still accessible when XDUO 2500 Mixer has been disconnected from FlexFactory Data stored on the Historian server can be ex...

Page 78: ...ate temperature control unit TCU The TCU keeps the circulating fluid at the designated temperature The TCU setpoint is provided by the XDUO 2500 Mixer PLC system The TCU gets a remote input from the m...

Page 79: ...out the disposable components that are needed for a mixing process In this section See page Section 80 3 6 1 Disposable bag assembly 85 3 6 2 Probe sheath assembly Xcellerex XDUO 2500 Mixer Operating...

Page 80: ...sembly contains two more liquid addition lines for acid and base solutions one liquid addition line for adjustments two probe ports and a thermowell Connection to the entry points is performed via bul...

Page 81: ...e Plus bag 1 2 2 3 Function Part Drain and addition lines probe ports1 1 Impeller inside the disposable bag 2 Powder addition port i d 3 capped 3 1 See separate images for more details Xcellerex XDUO...

Page 82: ...ows a detailed view of the drain and addition lines of the Plus bag 1 2 3 4 5 6 7 8 9 6 82 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 3 System description 3 6 Disposable components 3...

Page 83: ...dition of acid and base solutions The lines can be directly installed in the pump heads 2 This addition line can be used for final adjustment of liquid volume in the disposable bag The Basic bag is si...

Page 84: ...the disposable bag assembly The recommended storage temperature for the disposable bag assembly is between 10 C and 34 C Information about the storage temperature is shown on the bag label Operating...

Page 85: ...an aseptic connec tion device ACD The probe sheath is compatible with the following 12 225 mm probes Conductivity probe pH probe The probe sheath utilizes a PG 13 5 thread type connector The probe she...

Page 86: ...brane 2 Anti actuation ring 3 Bellows 4 End plug 5 Illustration of the probe sheath with inserted probe The following illustration shows a probe sheath assembly with the inserted probe 86 Xcellerex XD...

Page 87: ...e described in Chapter 7 Operation on page 204 In this chapter See page Section 88 4 1 General description 95 4 2 Adjustment and control screens 98 4 3 Alarm screens 102 4 4 pH and conductivity overvi...

Page 88: ...start screen is provided to act as a gateway and general overview of the process Buttons on the home screen display the current values of the relevant process variables Tapping the button opens the c...

Page 89: ...p pH Detail TREND ALARM CONFIG ALARMS CONTROL CONTROL PANEL SET CLOCK XDUO Mixer System Info TREND ALARM CONFIG ALARMS Agitator Detail Synced Motors Agitator Detail Individual Motors Temperature Detai...

Page 90: ...tings See Section 7 3 Operate agitator motors on page 212 Agitation 1 Displays the agitator speed in rpm Displays if Local Control mode or FlexFactory Control mode is in use Local Control 2 If there i...

Page 91: ...Control mode on page 97 CONTROL 10 Tapping OFFSETS opens the Transmitter Offsets screen see Section 4 6 Transmitter Offsets screen on page 118 OFFSETS 11 Tapping ALARMS opens the alarm overview screen...

Page 92: ...ble The following illustration shows an example of a process variable button display 4 1 2 3 Function Part Tag name 1 Current value of the process variable 2 Unit of measurement1 3 Parameter name 4 1...

Page 93: ...or motors run counterclockwise Tap the button to change the agitator motor direction If Individual Agitators is displayed the agitator motors are controlled individual ly If Synced Agitators is displa...

Page 94: ...a general purpose timer It is a manually operated function and works as an ordinary stopwatch Batch Timer is accessible from the following screens Agitator Detail Individual Motors Agitator Detail Syn...

Page 95: ...er 3 The display of instrument control option FlexFactory or local control FF Control Option 4 PROFIBUS node number applicable if the system is controlled by FlexFactory Profibus Node 5 Version number...

Page 96: ...ktop EXIT PROGRAM 13 1 This button is visible only for administrators 2 This screen is for GE use only Set time and date The screen for setting time and date is accessible from the XDUO Mixer System I...

Page 97: ...art Display of the currently active mode 1 Local Control FlexFactory Control Toggle button to change the mixer control mode 2 If the button text displays Request FlexFactory Control the mixer is in th...

Page 98: ...n of the alarm overview screen and alarm configuration screens In this section See page Section 99 4 3 1 Alarm overview screen 100 4 3 2 Alarm configuration screens 98 Xcellerex XDUO 2500 Mixer Operat...

Page 99: ...om this list the user needs to clear the alarm condition for example drain the excess liquid from the mixer to clear the weight High High Alarm Illustrationofthealarm overview screen The following ill...

Page 100: ...gured for each function High High Alarm critical high limit High Alarm warning high limit Low Alarm warning low limit Low Low Alarm critical low limit Alarm configuration screens are reached from Agit...

Page 101: ...of text boxes are present on the relevant alarm configuration screen The columns are labeled at the top 1 2 3 4 Function Display Part Critical high limit alarm High High Alarm SP 1 Warning high limit...

Page 102: ...onitoring pH 1 Tapping the button opens the pH Detail screen see pH Detail screen on page 109 Displays current process variable PV value for conductivity Conductivity 2 Tapping the button opens the Co...

Page 103: ...s shown as follows Description Interlock button The interlock is active The interlock is not active Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 103 4 User interface 4 4 pH and conduct...

Page 104: ...ail screens for agitators pH conductivity and temperature In this section See page Section 105 4 5 1 Agitator screens 109 4 5 2 pH screens 113 4 5 3 Conductivity screen 114 4 5 4 Temperature screens 1...

Page 105: ...for each agitator motor 1 Agitator state indicators Running or Stopped 2 Toggle buttons to change agitator motor direction 1 3 If the button text displays CCW the agitator runs in counterclockwise di...

Page 106: ...ator modes 7 If the button text displays Individual Agitators the agitator motors are controlled individually If the button text displays Synced Agitators the agitator motors are in synchronized mode...

Page 107: ...on to change the direction of both agitator motors 1 3 If the button text displays CCW the agitators run in counterclockwise direction If the button text displays CW the agitators runs in clockwise di...

Page 108: ...Stopped the agitator motor drive is defective Agitator state indicators Running or Stopped 7 Process variable PV value displays for each agitator 8 1 See Agitation direction on page 68 for more infor...

Page 109: ...125 pH SP 1 Current pH value PV display for probe 1 AIT_121 pH PV 2 Current pH value PV display for probe 2 AIT_122 pH PV 3 The value is shown only if XDUO 2500 Mixer has dual pH monitoring pH PID con...

Page 110: ...ntly controlled process variable Arrows 7 Button for setting the pH control to Auto or Manual mode Auto Manual 8 If Auto is displayed the mixer is in Auto mode If Manual is displayed the mixer is in M...

Page 111: ...utput SP 1 pH value process variable PV display for currently selected probe PV 2 PID tuning parameters text boxes for input and output P Term proportional 3 I Term integral D Term derivative pH PID c...

Page 112: ...er does not act Button for setting the mixer pH PID control to Auto or Manual mode PID Mode Auto 7 If Auto is displayed the mixer is in Auto mode If Manual is displayed the mixer is in Manual mode Pum...

Page 113: ...and con ductivity overview screen The following illustration shows an example of the Conductivity Detail screen The data in the text box shows the process variable PV value for the conductivity probe...

Page 114: ...erature setpoint SP the designated temperature of the disposable bag contents TC_163 Temperature SP 1 Process variable PV values for temperature probe sensors 1 and 2 TE_161 Temperature PV TE_162 Temp...

Page 115: ...n in Manual mode Button for changing the temperature probe sensor Probe 1 5 Indicator of currently controlled process variable Arrows 6 Button for setting the temperature control to Auto or Manual mod...

Page 116: ...for currently se lected temperature sensor PV 2 Note The sensor is selected on the Temperature Detail screen PID tuning parameters text boxes for input and output P Term proportional 3 I Term integra...

Page 117: ...its for temperature PID controller output controlled variable CV Text boxes for input and output Note The CV limits specify the allowed temperature range for the TCU Temp Limits CV HiLimit Temp Limits...

Page 118: ...rs is displayed on the Transmitter Offsets screen The following illustration shows an example of the Transmitter Offsets screen 1 2 3 Function Description Part Displays of the actual process variable...

Page 119: ...and cannot be printed For a FlexFactory connected system trending is available on FlexFactory inter face for the whole elapsed time since connected to FlexFactory Note Trend screens are reached from...

Page 120: ...creen If two probes are available for a functionality two process variable PV curves are shown on the relevant Trend screen 1 2 3 Description Part Measurement unit 1 Graph area 2 Legend 3 120 Xcellere...

Page 121: ...ts not covered in this manual must not be installed by the customer In this chapter See page Section 122 5 1 Safety precautions 124 5 2 Site requirements 128 5 3 Installation of the system 130 5 4 Ins...

Page 122: ...GE WARNING Strong magnets Magnets may interfere with functioning of pacemakers or implanted heart defibrillators and cause DEATH or SERIOUS INJURY Magnets are located on the bottom of XDUO 2500 Mixer...

Page 123: ...for Lock Out Tag Out LOTO CAUTION Tripping hazard Make sure that all tubing hoses and cables are placed so that the risk for tripping accidents is minimized CAUTION Indoor use only The product is des...

Page 124: ...nd floor The following illustration shows the dimensions of the jacketed XDUO 2500 Mixer For the weights see Section 10 1 System specifications on page 279 2610 mm 102 in 1670 mm 65 in A 1260 mm 49 in...

Page 125: ...uded NOTICE At least 100 cm 40 in free working space is needed around each unit during installation NOTICE In order to allow convenient working conditions during the use sufficient space should be pro...

Page 126: ...following specifications Specification Parameter Indoor use only Allowed location 5 C to 30 C Ambient temperature operation 20 to 85 RH non condensing Relative humidity operation 25 C to 60 C Ambient...

Page 127: ...unit For temperature control of the jacketed XDUO 2500 Mixer a temperature control unit TCU is required See the manufacturer s manual for specified environmental conditions and electrical power requi...

Page 128: ...g when unpacked XDUO 2500 Mixer can be rolled by hand on hard and level surfaces with wheel brakes released WARNING Squeezing or crushing injuries Because of the significant weight of the instrument g...

Page 129: ...igure the Administrator account when the instrument hard ware has been installed See Manage the administrator account on page 295 for more information Xcellerex XDUO 2500 Mixer Operating Instructions...

Page 130: ...on the XDUO 2500 Mixer by the manufacturer The accessory hangs on two screws The following illustration shows an installed probe support and test tube rack To remove or install the accessory follow t...

Page 131: ...t the accessory up and pull it off the screws Remove Hang the accessory on the two screws on the mixer vessel Install Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 131 5 Installation 5...

Page 132: ...not to cause squeezing or crushing injuries during lifting Follow the instructions below to attach the step ladder to the mixer frame Action Step Together with your assistant lift the step ladder and...

Page 133: ...the bolts until the step ladder is correctly set in position on the mixer frame 4 Follow the same procedure for the second step ladder 5 The following illustration shows the correctly installed step...

Page 134: ...s that can lead to personal injury and you may cause damage to the equipment Connect TCU CAUTION Check floor safety limits Before filling the TCU and the mixer with liquid verify that the total system...

Page 135: ...hen filling the vessel jacket with the coolant Spilling the coolant on the floor makes the floor slippery and may cause acci dents At least 39 5 L liquid is needed to fill the XDUO 2500 Mixer vessel j...

Page 136: ...on Step Connect the TCU outlet tubing to coolant inlet Supply under the mixer vessel 2 136 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 5 Installation 5 5 Connect temperature control u...

Page 137: ...Action Step Connect the TCU inlet tubing to the coolant outlet Return 3 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 137 5 Installation 5 5 Connect temperature control unit...

Page 138: ...ing b Push both parts of the connector together c Release the locking ring Result The locking ring moves back and emits a click The connector is locked Remove the reservoir cap on the TCU and and fill...

Page 139: ...lant and reinstall the cap 8 Empty the vessel jacket CAUTION Slippery surface Use caution when emptying the vessel jacket and when filling the vessel jacket with the coolant Spilling the coolant on th...

Page 140: ...outlet tubing Return to drain the content of the tubing into the vessel jacket 7 Prepare the tubing for draining the vessel jacket bottom 8 a Attach a Snap tite connector to the tubing b Put the end...

Page 141: ...0 Mixer for operation In this chapter See page Section 142 6 1 Safety precautions 143 6 2 Stabilize the mixer vessel 153 6 3 Prepare the disposable bag 175 6 4 Prepare and install the probes 200 6 5 P...

Page 142: ...s and cause DEATH or SERIOUS INJURY Magnets are located on the bottom of XDUO 2500 Mixer and in the impeller assembly of the disposable bags OBSERVE and follow instructions for installation operation...

Page 143: ...to make sure that XDUO 2500 Mixer is in stable position during preparation and operation In this section See page Section 144 6 2 1 Use jacking bolts 150 6 2 2 Use leveling feet Xcellerex XDUO 2500 Mi...

Page 144: ...ICE Securing the jacking bolts in a way other than described in this manual may damage the load cells Introduction The jacking bolts lift the instrument body up secure it and take the load off from th...

Page 145: ...The jacking bolt threads are undamaged The jacking bolts are fully engaged in the mixer vessel frame Each of the nuts turns freely using fingers alone Turn each top nut to the highest point on the ja...

Page 146: ...ers 3 1 Tighten the bottom nuts with 0 5 to 1 turn of a wrench 4 Turn the top nuts down the bolts to the support plates with your fingers 5 146 Xcellerex XDUO 2500 Mixer Operating Instructions 2914666...

Page 147: ...cted from the possible damage caused by movement Disengage jacking bolts Follow the instructions below to disengage the jacking bolts Action Step Loosen each top nut with a wrench 1 Xcellerex XDUO 250...

Page 148: ...the highest point on the jacking bolts with your fingers 2 Loosen each bottom nut with the wrench 3 148 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 6 Preparation 6 2 Stabilize the mix...

Page 149: ...starting batch operations Before starting batch operations verify that the instrument is clear of obstructions De pending on site requirements a functional check or load cell calibration might be requ...

Page 150: ...ight load is removed from the casters before filling the mixer Lower the leveling feet Follow the instructions below to lower the leveling feet Action Step Turn the nut 1 counterclockwise to move the...

Page 151: ...is lifted from the ground and the leveling foot 2 supports the weight of the mixer vessel 2 2 3 Verify that the vessel frame is level 3 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 151...

Page 152: ...from the ground and the wheel starts to support the weight of the mixer vessel 1 1 2 Continue to turn the nut using your fingers until the leveling foot reaches the highest position and the wheel 3 fu...

Page 153: ...how to unpack and install the disposable bag assembly In this section See page Section 154 6 3 1 Unpack the disposable bag assembly 162 6 3 2 Install the disposable bag Xcellerex XDUO 2500 Mixer Opera...

Page 154: ...r to unpacking Inform your GE representative about the damage Before unpacking the disposable bag assembly prepare a stainless steel table which is large enough to accommodate the bag which is 3 1 m 1...

Page 155: ...g materials 1 Take out the disposable bag assembly and place the bag on the inspection table 2 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 155 6 Preparation 6 3 Prepare the disposable...

Page 156: ...pen the outer protective bag and take out the disposable bag assembly 3 156 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 6 Preparation 6 3 Prepare the disposable bag 6 3 1 Unpack the d...

Page 157: ...wrap from the tubing ports tubing connectors and filters These items need protection during bag installation The wrap can be removed after the bag has been installed Xcellerex XDUO 2500 Mixer Operati...

Page 158: ...s com certificates Made in USA GE Healthcare Bio Sciences Corp 14 Walkup Drive Westborough MA 01581 Patents www pall com patents DESCRIPTION 1 2 Note The label above is an example Actual data printed...

Page 159: ...TICE Do not remove the protective bags from the probe ports tubing connectors and filters Unprotected connectors may be damaged or contaminated during the installation of the disposable bag Remove the...

Page 160: ...e zip ties that hold the lines together Loose lines can be damaged during bag installation Remove the bubble wrap from the drain line 3 160 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH...

Page 161: ...indicate failed bag integrity 5 Verify that the clamps on all lines are closed 6 Carefully turn over the bag assembly and remove the bubble wrap and foam from the impeller baseplate 7 Remove any addit...

Page 162: ...bag to avoid personal injury NOTICE Before starting the disposable bag installation wipe clean and dry the vessel wall if necessary Water on the vessel wall might be mistaken for bag leakage Follow th...

Page 163: ...Action Step Remove the lid parts from the mixer 1 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 163 6 Preparation 6 3 Prepare the disposable bag 6 3 2 Install the disposable bag...

Page 164: ...with drain plate at the bottom corner of the vessel 2 Probe window at the side corner of the vessel 3 Access doors at both sides of the vessel 4 1 1 2 3 4 4 Check that the drain plate is in place 3 16...

Page 165: ...er the bag into the vessel 4 If you are installing a Plus bag assembly make sure that the probe connec tors 1 face the probe window 2 2 1 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 1...

Page 166: ...p Position the impeller baseplates above the magnetic drive heads 5 166 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 6 Preparation 6 3 Prepare the disposable bag 6 3 2 Install the disp...

Page 167: ...th sides as follows 6 a Hold the door handle tightly b Turn the door counterclockwise c Remove the door Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 167 6 Preparation 6 3 Prepare the d...

Page 168: ...djust all bag corners to vessel corners Stretch out the bag to avoid wrinkles 7 CAUTION Pinch hazard Use caution to avoid pinching fingers between the impellerbaseplateand the magneticdrive head Re in...

Page 169: ...refully pull the line through the opening Tip The drain line is more easily reached from the underside of the vessel 9 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 169 6 Preparation 6...

Page 170: ...connects magnetically with the agitator drive head A click is heard when the contact is made c Keep holding the handle and let the spring retract the handle back under the mixer vessel Use light forc...

Page 171: ...able bag is higher than the impeller baseplate Action Step Disengage the impellers as follows one by one 1 a Pull out the agitator handle completely from under the mixer vessel as described above b Pr...

Page 172: ...4 Insert probes into the disposable bag on page 186 for detailed instructions Follow the instructions below to finish the installation of the disposable bag assembly Action Step Pull all lines away f...

Page 173: ...lamp from the disposable bag powder addition port 2 B Make sure that the O ring stays in place on the powder addition port Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 173 6 Preparatio...

Page 174: ...e the hopper onto the powder addition port and secure it with the TC clamp 174 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 6 Preparation 6 3 Prepare the disposable bag 6 3 2 Install t...

Page 175: ...ag This section is relevant for the Plus bag assembly In this section See page Section 176 6 4 1 Calibrate the pH probe 181 6 4 2 Prepare the conductivity probe 183 6 4 3 Autoclave probe sheath assemb...

Page 176: ...bottle Prepare for calibration Prepare the pH probe as follows Action Step Take a pH probe out of the packaging 1 Rinse the sensor end of the pH probe with de ionized water 2 Connect the pH probe wit...

Page 177: ...itterdisplay on the transmittercabinet Press MENU 1 1 1 2 3 Result A menu is displayed on the transmitter screen Use the navigation keys to make selections in the menu 2 Xcellerex XDUO 2500 Mixer Oper...

Page 178: ...e the probe at pH 10 as follows 5 1 Put the probe in the pH 10 buffer Stir approximately ten times and make sure no air bubbles are present on the probe 2 Press ENTER to start the calibration When the...

Page 179: ...lowing has been completed before pH probe standardization The disposable bag has been filled The contents of the disposable bag have been equilibrated to the process tempera ture The temperature probe...

Page 180: ...2 2 Select Sensor 1 and press ENTER 3 Select pH and press ENTER 4 Select Standardize and press ENTER 5 Enter the externally measured pH value of your sample and press ENTER 6 Press EXIT 3 repeatedly...

Page 181: ...h de ionized water 2 Connect the conductivity probe with the probe cable so that no thread is visible on the probe 3 NOTICE Do not cross thread the probe cable In the accompanying manual locate the ce...

Page 182: ...EXIT 3 Result The main screen is displayed The conductivity probe is now ready to be used Disconnect the probe cable from the probe 7 This procedure is sufficient for most applications If additional...

Page 183: ...utoclave ratchet clamps Prepare for autoclaving Before autoclaving the probe sheath assembly prepare the following Disposable pipette Deionized water Follow the instructions below to prepare the probe...

Page 184: ...des the steam inside the probe sheath assembly during autoclaving 4 Remove the pipette 5 Verify that the O rings are present on the probe 6 Insert the probe into the probe sheath assembly through the...

Page 185: ...ath assembly is ready to be placed in the autoclave Place the probe sheath assembly into the autoclave The paper membrane end of the probe sheath assembly 1 should be lower than the plug end of the as...

Page 186: ...posable bag NOTICE Ratchet clamps may break if they are overtightened A ratchet clamp can be released from its tightened state by sliding the interlocked clamp fingers sideways with respect to each ot...

Page 187: ...in the following illustration 1 Using your fingers loosely tighten the ratchet clamps until the teeth on the clamp are engaged enough to hold the clamp in position 2 to 3 teeth en gaged 2 NOTICE Do no...

Page 188: ...in position 2 to 3 teeth en gaged 4 NOTICE Do not tighten the clamps too much otherwise they prevent the insertion of the probe into the disposable bag Install probe sheath assembly Before inserting t...

Page 189: ...ACD connectors 3 Hold the male ACD connector on the probe sheath assembly and align it with the female connector on the probe port on the disposable bag so that the white membrane strips are facing ea...

Page 190: ...ng the bodies of both connectors with one hand grip both white membrane strips with the other hand and pull them perpendicular to the connectors simultaneously away from the bodies of the connectors i...

Page 191: ...sheath assembly on the short section of silicone tubing between the dispos able bag and the female ACD connector Remove the anti actuation ring which prevents unintentional engagement before the ACD c...

Page 192: ...f the connector until the thumb rest meets the body 8 Note A ratchet sound is heard from the male ACD connector during this motion 192 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 6 Pr...

Page 193: ...is any indication that the connection might not be aseptic immediately clamp off this probe sheath assembly on the short section of silicone tubing be tween the disposable bag and the female ACD conne...

Page 194: ...toward the disposable bag compressing the bellows section of the probe sheath assembly 10 Result The bellows section is fully compressed as shown below 194 Xcellerex XDUO 2500 Mixer Operating Instruc...

Page 195: ...has shown that even if a ratchet clamp breaks the probe itself would not be damaged even if it is a pH probe with a glass body Result The tip of the probe extends above the surface at the inside of t...

Page 196: ...xt probe 12 Collect all loose probe cables and place the cables into the cable holders on the short side of the mixer vessel 13 Clamp off any unused probe port connections 14 196 Xcellerex XDUO 2500 M...

Page 197: ...s No additional measures are needed to prevent the probe from sliding out of the disposable bag Install the temperature probe Follow the instructions below to install the temperature probe into XDUO 2...

Page 198: ...efully insert the temperature probe into the thermowell adjacent to the probes 3 Attach the temperature probe cable to the probe support bar for example with a zip tie to prevent operators from accide...

Page 199: ...probe cable into the cable holders on the short side of the mixer vessel 5 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 199 6 Preparation 6 4 Prepare and install the probes 6 4 4 Inse...

Page 200: ...uid addition lines can be directly installed in the pump heads The following table explains the pump labels Specification Label Addition of acid solution P 201 ACID PUMP Addition of base solution P 20...

Page 201: ...that the tubing is firmly seated in the clip 3 Align the roller assembly so that it is not blocked by the retention pin on the roller assembly 4 Push the tubing into the space around the roller assem...

Page 202: ...e the insertion space forward all the way around the roller assembly 6 Press up the second lever with your thumb and firmly insert the tubing 7 202 Xcellerex XDUO 2500 Mixer Operating Instructions 291...

Page 203: ...Action Step Close the pump head and lock it using the screwdriver 8 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 203 6 Preparation 6 5 Prepare the pumps...

Page 204: ...Safety precautions 207 7 2 Start up the system 212 7 3 Operate agitator motors 219 7 4 Prepare the pump 221 7 5 Control the pH 225 7 6 Control the temperature 229 7 7 Manage mixer weight 231 7 8 Add...

Page 205: ...onal code of practice for biosafety WARNING Acids and bases Acids and bases are dangerous if not handled correctly Properly tune PID control loops to avoid unwanted release of acids or bases WARNING C...

Page 206: ...nnel and damage the instru ment CAUTION Pinch hazard Do not operate the pumps without the covers in place CAUTION Secure pump tubing Make sure that the pump tubing is secure and in good condition befo...

Page 207: ...below to start local control on XDUO 2500 Mixer Action Step Make sure that the EMERGENCY STOP button is disengaged 1 Turn the system power switch to I ON position 2 Xcellerex XDUO 2500 Mixer Operating...

Page 208: ...ogin dialog box opens Type your user name and password in the text boxes Tap OK 2 Result The user is logged in The LOGON button text changes to LOGOFF Tap RESET on local control software home screen 3...

Page 209: ...to local control software as described in Log in on page 208 1 Log in to FlexFactory software as described in FlexFactory Automation User Manual 2 When the XDUO Mixer screen is visible on the M Statio...

Page 210: ...trol of XDUO 2500 Mixer is enabled Start and stop data logging Data logging saves the data to the non system memory card on the HMI The data can then be transferred manually to the USB Follow the inst...

Page 211: ...reen to log data locally 1 Result Data logging starts The START LOGGING button text changes to STOP LOGGING To stop logging tap STOP LOGGING 2 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667...

Page 212: ...rview screen 1 Make sure that Mixer Weight Interlock and Mixer Overweight Interlock are not active 2 Note The button is selected when an interlock is active If Agitators On Interlock is active it is d...

Page 213: ...lue into the SP text box 3 6 3 4 Tap Start 4 7 Result The agitator motors start in synchronized mode Operating the agitator in viscous solutions may cause the agitator blade to decouple A clicking or...

Page 214: ...Make sure that Mixer Weight Interlock and Mixer Overweight Interlock are not active 2 Note The button is selected when an interlock is active If Agitators On Interlock is active it is deactivated when...

Page 215: ...otor 6 3 4 3 Tap Start 4 to start each agitator motor 7 Result The selected agitator motor starts Each motor runs at the individu ally specified speed Operating the agitator in viscous solutions may c...

Page 216: ...ed motors or Agitator Detail Individual Motors screen 1 On the Agitator Detail Individual Motors screen tap Stop to stop each agitator motor 2 On the Agitator Detail Synced Motors screen tap Stop to s...

Page 217: ...ction Step On the home screen tap Agitation to open the Agitator Detail Synced motors or Agitator Detail Individual Motors screen 1 Find the agitator direction buttons 2 On the Agitator Detail Synced...

Page 218: ...se direction To set the agitator working in counterclockwise direction tap CW If the button text displays CCW the agitator is running in counterclock wise direction To set the agitator working in cloc...

Page 219: ...screen opens If the button text displays CW the pump is running in clockwise direction If the button text displays CCW the pump is running in counterclockwise direction 4 Tap CW CCW to change pump dir...

Page 220: ...e acid pump tap and hold Acid To prime the base pump tap and hold Base 4 Result The pump rotates at the 35 of maximum speed CV 35 while the button is pressed Release the button when the pump is primed...

Page 221: ...e PLC keeps the pump speed at the manually defined CV value of total pump speed range See Work in Manual mode on page 223 for more information Work in Auto mode To set the pH control to work in Auto m...

Page 222: ...base pump the pH value should be above the current pH PV value shown on the screen for the selected probe Type the chosen pH value into the PHC_125 pH SP text box 6 Result The pH of the disposable ba...

Page 223: ...ow the instructions below Action Step On the home screen tap pH Cond to open the pH and conductivity overview screen 1 Tap pH on the pH and conductivity overview screen to open the pH Detail screen 2...

Page 224: ...the PHC_125 Manual CV text box 5 Result The instrument keeps the pump speed as specified using a split range control loop Note Other text boxes on the screen are inaccessible in Manual mode 6 224 Xcel...

Page 225: ...tes a setpoint SP using the configured range that is specific for the TCU model Work in Auto mode To set the temperature control to work in Auto mode follow the instructions below Action Step On the h...

Page 226: ...tton is shown tap the button to set the pH control to Auto mode 6 Type an applicable temperature setpoint value into the TC_163 Temperature SP text box 7 Result The control of mixer vessel temperature...

Page 227: ...no interlocks are active 2 Note The button is selected when an interlock is active Tap HOME to go back to the home screen 3 Tap Temperature on the home screen to open the Temperature Detail screen 4...

Page 228: ...mode 6 Type an applicable value of total TCU remote setpoint range into the TC_163 Manual CV text box 7 Result The control of mixer vessel temperature is enabled Note Other text boxes on the screen a...

Page 229: ...uctions below to tare the mixer vessel weight Action Step Make sure that the disposable bag is empty before starting the tare proce dure The mixer vessel jacket can be filled with the coolant 1 On the...

Page 230: ...n dialog box stays open Verify that the WT_176 Weight PV value is reset to approximately 0 0 kg 5 Tap No Return 2 to close the tare confirmation dialog box 6 Tap HOME to go back to the home screen 7 2...

Page 231: ...for small liquid amounts Use this line for final volume adjustment 2 Prepare the mixer Before adding the liquids make the following preparations Action Step Verify that the liquid addition lines are...

Page 232: ...to the addition line of the bag assembly 5 If your mixer has a weight monitoring option tare the mixer weight See Tare mixer weight on page 229 for instructions 6 Add liquids into the disposable bag C...

Page 233: ...e liquid addition line i d 1 1 Stop filling when the liquid level has reached 3 to 5 cm and the bag begins to adjust to the shape of the mixer vessel 2 Verify that the following conditions are met 3 N...

Page 234: ...above the lowest edge of the side access opening Finish the addition of liquids To finish the addition of liquids follow the instructions below Action Step Continue filling the disposable bag with li...

Page 235: ...ntrol software home screen When the weight approaches the designated level decrease the filling speed 3 Stop filling the bag when the designated liquid weight is reached 4 Set the lid with the center...

Page 236: ...n place 2 to secure the powder addition port in the opening keeping the TC clamp above the lids 6 Pull the lines through the rectangular lid opening 7 If needed clamp the fill lines and disconnect the...

Page 237: ...d material Add solid material into disposable bag Any addition port with 3 connectionor a powder bag with gasket can be used for addition of solid material Follow the instructions below to add solid c...

Page 238: ...ction in place 2 to hold the powder addition port in place keeping the TC clamp above the lids 2 Disconnect the TC clamp from the powder addition port 3 Remove the protective cap from the powder addit...

Page 239: ...in place on the powder addition port 5 Place the hopper onto the powder addition port 1 and attach the hopper to the port with the TC clamp 2 6 Xcellerex XDUO 2500 Mixer Operating Instructions 2914666...

Page 240: ...gh the hopper 8 When the addition is complete remove the hopper Tip Slide the vessel lid section outwards for easier access to the powder addition port 9 Install the protective cap on the powder addit...

Page 241: ...ation how to finish a batch run In this section See page Section 242 7 10 1 Collect the product 243 7 10 2 Remove the disposable bag 247 7 10 3 Shut down the system Xcellerex XDUO 2500 Mixer Operating...

Page 242: ...ctory 2 Remove the mixer vessel lids 3 Open the clamp on the drain line 4 Monitor the draining process to make sure that it proceeds as expected 5 During the draining procedure gently adjust the dispo...

Page 243: ...move the mixer vessel lid 3 Remove the temperature probe from the disposable bag 4 Disconnect the pH and conductivity probe cables and the temperature probe cable as applicable 5 Remove and clean the...

Page 244: ...om XDUO 2500 Mixer Action Step Remove the side access door as follows 1 a Hold the door handle tightly b Turn the door counterclockwise c Remove the door 244 Xcellerex XDUO 2500 Mixer Operating Instru...

Page 245: ...impeller baseplate is disconnected from the agitator drive head c Keep holding the handle and let the spring retract the handle back under the mixer vessel Use light force to control the movement Lift...

Page 246: ...se of the bag assembly according to national and local environmental regulations 2 246 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 7 Operation 7 10 Finish a batch run 7 10 2 Remove th...

Page 247: ...position 1 If required 2 Disconnect the power cord or Turn off the power supply circuit breaker The main circuit breaker is provided by the customer The location of the circuit breaker depends on the...

Page 248: ...Mixer In this chapter See page Section 249 8 1 Safety precautions 250 8 2 Maintenance schedules 253 8 3 Lock Out Tag Out LOTO turn off procedure 255 8 4 Lock Out Tag Out LOTO turn on procedure 257 8...

Page 249: ...ipment Turn off the system and Lock out Tag out LOTO the electrical equipment before doing maintenance CAUTION Contamination hazard Before performing any service work on XDUO 2500 Mixer make sure that...

Page 250: ...nd work areas must be clean and free of any hazardous contaminants before a Service Engineer starts maintenance work Please complete the checklist in the On Site Service Health and Safety Declaration...

Page 251: ...ned person nel Inspect cables and con nectors Annuallyandafter system relocation Inspect hinges and han dles Inspect jacking bolts on page 259 Properly trained person nel Inspect jacking bolts If anyt...

Page 252: ...obe calibration Beforeeachbatch Section 10 5 Temperature probe calibration on page 287 Calibration technician Temperature probe cali bration Beforeeachbatch at least semi an nually See the manufacture...

Page 253: ...G High voltage It is essential for the safety of personnel working in or around electrically powered equipment to follow a company policy and procedure for Lock Out Tag Out LOTO Turn off the instrumen...

Page 254: ...Empty the mixer vessel jacket as described in Empty the vessel jacket on page 139 4 Attach a tag out device onto the XDUO 2500 Mixer coolant inlet 5 254 Xcellerex XDUO 2500 Mixer Operating Instruction...

Page 255: ...in or around electrically powered equipment to follow a company policy and procedure for Lock Out Tag Out LOTO Turn on the instrument Follow the instructions below to turn on XDUO 2500 Mixer Action S...

Page 256: ...Action Step Turn the system power switch to I ON position 4 256 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 8 Maintenance 8 4 Lock Out Tag Out LOTO turn on procedure...

Page 257: ...nt and injury to operators WARNING Improper use of jacking bolts Improper use of jacking bolts may cause the instrument to collapse on the operator CAUTION Hot surface Make sure that the instrument su...

Page 258: ...Undiluted Klercide CR 25 NH4OH 2 M NaOH 70 2 propanol Instructions for cleaning Action Step Use a non abrasive cloth with mild detergent and water to clean the exterior of the mixer vessel and the I...

Page 259: ...nd practices as estab lished within the country where the equipment is installed Local provincial bylaws must be followed The owner of the instrument is responsible that relevant standards and practic...

Page 260: ...ds and remove the ruptured burst disc 3 Insert the new burst disc See the manufacturer s documentation for more information 4 Attach the clamp 5 Close the clamp with the screw 6 260 Xcellerex XDUO 250...

Page 261: ...the mixer weight See Section 7 7 Manage mixer weight on page229 for instructions 2 Use water or weights to increase the mixer weight 3 Add a known quantity of water into the disposable bag installed...

Page 262: ...re sponds to the added weight 4 Result Mixer weight monitoring functionality is verified Note If the weight reading is not correct contact your GE representative for assis tance 262 Xcellerex XDUO 250...

Page 263: ...stallation Contact your GE representative for instructions on how to store move and re install the instrument Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 263 8 Maintenance 8 7 Storage...

Page 264: ...the problem is not covered by this guide contact your GE representative for advice In this chapter See page Section 265 9 1 Agitation 267 9 2 Burst disc 268 9 3 FlexFactory connectivity 269 9 4 Local...

Page 265: ...the state of E Stop Pressed Enable the agitator See FlexFactory Automation User Manual for more information The agitator is not enabled The agitator does not start on FlexFactory controlled mixer Tap...

Page 266: ...e The agitator is not properly aligned The agitator assembly does not fit properly in place The agitator drive head rubs against the agitator base plate support and a grinding sound is emitted Plastic...

Page 267: ...place burst disc onpage259forinstructions 1 If the cause for the rupture is not known contact your GE representative for sup port Burst disc has ruptured Liquid is leaking or dripping from the vessel...

Page 268: ...erminat ing resistor in the spur is turned on A terminating resistor in the network upstream of the sys tem is switched on Use a terminating resistor on the last system in the network Reflections are...

Page 269: ...el al though the system is plugged in Contact your GE representative for possible replacement A circuit breaker is tripped Contact your GE representative for possible replacement The local control pan...

Page 270: ...ply is empty Prime the pumps The pumps are not primed Free the feed line Feed line before or after the pump is kinked Free the feed line Feed line before or after the pump is clamped Conductastudytove...

Page 271: ...us es and clean them with a solu tion designed to maintain their properties Replace probes regu larly The pH sensor needs cleaning pH sensor changes are very slow two sensors change their readings at...

Page 272: ...r more informa tion The pH probe was not calibrated prior to installation to XDUO 2500 Mixer See the manufacturer s docu mentation The conductivity probe offset value should be changed 1 Remove and re...

Page 273: ...he cause of the E Stop Ac tive condition is eliminated and clear the E Stop Active Try to use the pumps again The system is in E Stop Active mode FlexFactory controlled mixer only The pump is not turn...

Page 274: ...e clock button repeatedly until CC appears on the left dis play 3 If the display message is yes the connection is working properly 4 If the display message is no the connection is not functioning Chec...

Page 275: ...put is not present or is not working replace the probe Temperature probe has failed Temperature monitor ing is not working as expected Insert temperature probe into the thermowell Temperature probe is...

Page 276: ...while the jacking bolt was engaged the weight measurements of the batch will not be accurate Jacking bolt is engaged Contact the metrology depart ment to do a test cornering test and determine which l...

Page 277: ...l range Disengage the jacking bolt See Disengage jacking bolts on page 147 for instructions Note If the mixer was filled while the jacking bolt was engaged the weight measurements of the batch will no...

Page 278: ...Safety Declaration Form for service and ordering information In this chapter See page Section 279 10 1 System specifications 281 10 2 SP CV and PV units and ranges 282 10 3 Pump characteristics 283 1...

Page 279: ...pport included Dimensions W H D 2610 1670 1260 mm 102 65 49 in XDUO 2500 Mixer probe support excluded 1200 kg XDUO 2500 Mixer Weight 39 5 L XDUO 2500 Mixer Jacket volume Stainless steel Vessel Constru...

Page 280: ...s W H D 2540 1670 1290 mm 100 65 50 in XDUO 2500 Mixer probe support excluded 1000 kg XDUO 2500 Mixer Weight Stainless steel Vessel Construction material Polycarbonate Lid Stainless steel polyamide Ca...

Page 281: ...revolutions per minute rpm Agitator speed 0 to 150 mS cm Not applicable Not applicable Conductivity 0 to 14 0 to 100 0 to 14 pH 0 to 100 0 to 100 Not applicable Pumps 0 C to 60 C 0 to 70 0 C to 60 C...

Page 282: ...pumps model 520 Value Parameter 190 rpm Maximal speed 1 3 L min1 Maximal flow rate 1 This value is valid for the liquid addition lines on the disposable bag i d 282 Xcellerex XDUO 2500 Mixer Operating...

Page 283: ...ents and specifications for TCU In this section See page Section 284 10 4 1 TCU requirements 285 10 4 2 Temperature control optimization 286 10 4 3 TCU coolant specifications Xcellerex XDUO 2500 Mixer...

Page 284: ...in Fluid outlet flow 0 C 0 C Fluid outlet minimum temperature 65 C 65 C Fluid outlet maximum temperature 1 5 1 5 Connector size 4 to 20 mA 4 to 20 mA Setpoint Remote control interface Required Require...

Page 285: ...ts weight or if a different TCU is used the vessel temperature control can be optimized for these conditions The PID parameter values shown in the table below are given as starting points for further...

Page 286: ...ufacturer for additional information Specification Parameter None Suspended solids 50 to 600 S cm Conductivity 80 dH Hardness 7 8 pH None CO2 aggressive 0 3 mg L Iron 0 05 mg L Manganese 250 mg L Sulf...

Page 287: ...nding on your instrument configuration Both sensors have to be calibrated simulta neously Note Preparation Before you start to calibrate the temperature probe prepare the following Temperature calibra...

Page 288: ...mm apart Make sure that the temperature probe is inserted into the liquid by at least 7 5 cm Note Do not wet the probe connector 3 Wait until the system reaches the equilibrium 4 Record the data for...

Page 289: ...r Adjustment If the temperature probe is out of tolerance follow the steps below to adjust the probe Action Step Using the data obtained during the calibration procedure calculate the offset to adjust...

Page 290: ...ent of the temperature probe at the operating temperature does not bring the system into tolerance replace the temperature probe and repeat the calibration procedure If the calibration of the new temp...

Page 291: ...commendations Literature Service Training Ordering information Contact information Contact information can be found on the back page of this document For more advanced technical information contact th...

Page 292: ...thersuitablesurvey Adequate space andclearance is providedto allowsafe access forinstrumentservice repairor installation Insome cases this mayrequirecustomerto move equipmentfrom normaloperatinglocati...

Page 293: ...rdous biological substances pleasespecify OtherHazardous Chemicals please specify Equipment must be decontaminatedpriortoservice return Pleaseprovide atelephone number whereGE cancontact youfor additi...

Page 294: ...llowing this information section the following appendices are found in this manual Appendix B Add and remove users in local control software on page 295 Appendix C Download audit and data logs on page...

Page 295: ...vailable to Supervisor and Administrator Manage the administrator account The factory settings for administrator account in XDUO 2500 Mixer local control software are as follows User ID Administrator...

Page 296: ...in the User column 1 and tap the button in the Password column 2 to open a dialog box Type the user password in the text box and tap Return 5 Result The password dialog box re opens Close the dialog...

Page 297: ...ose the dialog box by tapping the close button 5 Result The new password is saved and hidden Tap a button in the Group column 3 to open the group list 6 In the group list tap the applicable group name...

Page 298: ...ser 1 1 2 3 4 Type the new entry in the dialog box and tap Return 2 Result The new entry is recorded in the software The user cannot log in with previous name or password anymore Tap the user group bu...

Page 299: ...the Group column 3 for the locked user to open the group list 1 1 2 3 4 In the group list tap the applicable group name Tap Return 2 Result The user account is unlocked Delete a user account Follow th...

Page 300: ...ser name and tap Return 2 Result The user account is deleted NOTICE Do not delete the HMIAdmin account This account is used by GE service personnel 300 Xcellerex XDUO 2500 Mixer Operating Instructions...

Page 301: ...ump 1 speed Acid_PID_Output 0 to 100 Pump 2 speed Base_PID_Output Not applicable pH AIT121_PH1_PV Not applicable pH1 AIT122_1_PH2_PV millisiemens per centimeter mS cm Conductivity2 AIT122_2_Conductiv...

Page 302: ...1 Open a web browser on the computer 2 Type 172 20 42 152 into the web browser address bar 1 and tap Enter 3 Result The HMI Miniweb start screen opens 1 2 Click the Login link in the upper left corne...

Page 303: ...Action Step Click File Browser in the left pane 5 Click Storage Card SD in the File Browser pane 6 Xcellerex XDUO 2500 Mixer Operating Instructions 29146667 AH 303 C Download audit and data logs...

Page 304: ...rted time data verify that the computer region and language settings in Control Panel are set to English United States This makes sure that your time data format is compatible with Excel Tip Download...

Page 305: ...file 6 The audit trail file is located in the StorageCardSD folder The data log file is located in the Logs subfolder On the Edit menu click Copy 7 Browse to My Computer Storage Card USB 8 On the Edi...

Page 306: ...5 Agitator Detail Synced Mo tors screen 107 Agitator motor illustration 67 Agitators illustration 66 Agitator speed measuring units 281 Alarm configuration screen 100 illustration 101 Alarm overview s...

Page 307: ...audit logs 301 data logs 301 Counterclockwise agitation 68 D Data access 77 Data export 301 Data logging start or stop 210 Data logs download 301 Deadband pH control 270 Delete user account 299 Dimen...

Page 308: ...me screen 90 I I O Cabinet check connection 274 cleaning 258 connection to TCU 78 description 62 disposal 43 emergency stop 47 illustration 63 supply voltage 126 279 280 Illustration system 51 Importa...

Page 309: ...ufacturing information 9 Maximal power consump tion 279 280 Mixer automation 74 basic equipment 52 control 74 75 FlexFactory component 75 FlexFactory control 75 local control 74 75 optional functions...

Page 310: ...prepare installation 186 Probe sheath assembly autoclave 183 compatibility 85 compressed 196 description 85 holder 185 insert probe 184 with probe 86 Probe support install 130 remove 130 Process vari...

Page 311: ...ndards 14 Start stand alone mixer 207 Start mixer 207 Step ladder 61 illustration 61 install 132 Sterilization disposable bag verify 158 Supervisor 41 System dimensions 279 280 illustration 51 label 2...

Page 312: ...nload logs 304 export data 304 User add account 297 change account proper ties 298 change password 298 delete account 299 unlock account 299 User account add 297 change properties 298 delete 299 unloc...

Page 313: ...t is available on re quest Any use of the Xcellerex configuration of the Wonderware software is subject to a valid Software Licence Agreement with Schneider Electric The purchase of the product from G...

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