Ametek mocon AQUATRAN 3/38 User manual

Revision G
Part Number 143-216
AQUATRAN®
3/38
Operator’s Manual
Gas-Detection
Lauper Instruments AG
Irisweg 16B
CH-3280 Murten
Tel. [phone]
[email protected]
www.lauper-instruments.ch

Trademarks & Patents
MOCON and AQUATRAN are registered trademarks of MOCON, Inc.
For information on applicable patents see:
https://www.ametekmocon.com/aboutus/legal/intellectualproperty
Copyright© 2021 MOCON, Inc. All rights reserved.

AQUATRAN 3/38 Operator’s Manual About This Manual
MOCON, Inc. Revision G iii
About This Manual
This manual explains how to set up and use the AQUATRAN 3/38 Water Vapor Transmission Rate System.
This manual is designed for viewing electronically. Most references to other sections or chapters in this
document are hyperlinks which can be used to navigate to the referenced section.
Please use the following guide to get started with the system.
If You Want to Set Up the AQUATRAN 3/38
1. Prepare your test site.
See Appendix A “Site Preparation Instructions” starting on page A-1 in this manual.
2. Install the AQUATRAN components.
See Chapter 2 “Setting Up” starting on page 2-1 in this manual.
If You Want Some Background on How the System Works:
1. Get an overview of the system.
See Chapter 1 “Introduction” on page 1-1 in this manual.
2. Learn how the AQUATRAN measures water vapor transmission.
See Appendix D “Theory of Operation” on page D-1 in this manual.
3. Learn about the software.
See Chapter 4 “Using the Instrument Software” starting on page 4-1 in this manual.
If You Want to Get Started Measuring Water Vapor Transmission Rate:
See Chapter 3 “Preparing for a Test” beginning on page 3-1, Chapter 6 “Testing Film
Samples” on page 6-1.
If You Have Problems Operating the System:
1. If an error message appears on the instrument screen see Chapter 8 “Troubleshooting”
beginning on page 8-1 in this manual.
2. If no error message appears but you have other problems, see Chapter 8 “Troubleshooting”
beginning on page 8-1 in this manual.
SERVICE NOTE:
Please do not hesitate to call MOCON in the USA at [phone]. We want you to receive the
best in product support services.

Safety Information AQUATRAN 3/38 Operator’s Manual
iv Revision G MOCON, Inc.
Safety Information
Be sure to read and understand this section and all other applicable chapters of the Operator's Manual and all
on-product safety signs before setting up, operating, and maintaining this analyzer.
Safety signs appear in this manual and on the analyzer. All safety signs are identified by the words WARNING and
CAUTION. These words signify the following:
•WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
serious personal injury.
•CAUTION indicates a potentially hazardous situation which, if not avoided, may result in moderate
personal injury and/or possible damage to the analyzer and its components.
To avoid personal injury and equipment damage, observe the following precautions:
Installation Precautions
•Use appropriate precautions when lifting or moving the instrument. A two-person lift is recommended.
•The maximum pressure applied to the instrument from the Carrier Gas tank must not exceed 29 psi (2
bar), or damage to the instrument will occur.
Operating Precautions
•To avoid plumbing contamination use only specified gas type at recommended operating pressure.
•Use only HPLC-grade water in the humidity generator.
•Use care to avoid splashing the RH sensor with any salt solution. The RH sensor can be irreparably
damaged by direct contact with salt solutions.
•Handle the RH probe carefully. The sensor housed in the probe is easily damaged.
•Do not expose the RH probe to an environment with RH greater than 90% RH.
Maintenance and Service Precautions
WARNING! HAZARDOUS VOLTAGES ARE PRESENT INSIDE THIS INSTRUMENT. SERVICE
SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY.
AVERTISSMENT: CET INSTRUMENT PRESENTE DES NIVEAUX DANGEREUX DE TENSION.
L'ENTRETIEN DOIT ETRE EFFECTUE PAR UN PERSONNEL QUALIFIE
UNIQUEMENT.
WARNING! Protection may be impaired if this device is not used in the manner specified.
•Maintenance and service should only be performed by qualified personnel.
•Make sure the instrument is powered OFF and unplugged from the power source before removing the
covers to perform any internal maintenance or service. Failure to do so can result in electrical shock,
which can cause injury or death.
•Failure to use proper safety equipment when mixing salt solution can result in frostbite or burn injuries.
Salt solutions should be prepared only by qualified people with proper safety equipment.

AQUATRAN 3/38 Operator’s Manual Table of Contents
MOCON, Inc. Revision G v
Table of Contents
About This Manual ........................................................................................................................................iii
Safety Information........................................................................................................................................ iv
Chapter 1: Introduction..............................................................................................................................1-1
Features...............................................................................................................................................1-2
Permeation Test Overview ...................................................................................................................1-3
Individual Zero Phase.....................................................................................................................1-3
Conditioning the Sample ................................................................................................................1-3
ReZero State..................................................................................................................................1-3
Cell Examination State ...................................................................................................................1-3
Bypass State ..................................................................................................................................1-3
Test Completion .............................................................................................................................1-3
Report Generation..........................................................................................................................1-4
Measuring Water Vapor Transmission Rate .........................................................................................1-5
Testing Samples ..................................................................................................................................1-6
Chapter 2: Setting Up ...............................................................................................................................2-1
Unpacking the System .........................................................................................................................2-1
Preparing for Installation ......................................................................................................................2-1
Front Panel Parts and Controls ............................................................................................................2-2
Back Panel Parts and Controls.............................................................................................................2-5
Carrier Gas (Nitrogen)..........................................................................................................................2-7
Gas Distribution System.......................................................................................................................2-7
Connecting the Gas Lines ....................................................................................................................2-8
Setting the Gas Supply Pressure .........................................................................................................2-9
System Outgassing ..............................................................................................................................2-9
Chapter 3: Preparing for a Test.................................................................................................................3-1
Testing Basics......................................................................................................................................3-1
How Barrier Properties Affect Testing ..................................................................................................3-1
Testing Mixed Barriers .........................................................................................................................3-1
Testing Moisture Sensitive Barriers ......................................................................................................3-2
Developing Test Methods for your Films and Packages .......................................................................3-2
The Examination Time....................................................................................................................3-2
The ReZero Frequency ..................................................................................................................3-2
The Sample Conditioning Time ......................................................................................................3-3
Individual Zero Processing .............................................................................................................3-3
Determining When to Stop a Test...................................................................................................3-4
Choosing a Test Method ......................................................................................................................3-4
The Advanced Test Method............................................................................................................3-4
Saved Test Methods ......................................................................................................................3-4
QC Mode........................................................................................................................................3-4
Chapter 4: Using the Instrument Software.................................................................................................4-1
Software Features................................................................................................................................4-1
Instrument Software Structure and Organization ..................................................................................4-2
Chapter 5: Permeant Sensor Calibration...................................................................................................5-1
Permeant Sensor Accuracy Check.......................................................................................................5-1
Performing a Permeant Sensor Calibration ..........................................................................................5-1
Permeant Sensor Calibration Test Setup .............................................................................................5-3

Table of Contents AQUATRAN 3/38 Operator’s Manual
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Chapter 6: Testing Film Samples ..............................................................................................................6-1
Testing Suggestions.............................................................................................................................6-1
Preparing for a Film Test......................................................................................................................6-2
Sample Size.........................................................................................................................................6-2
Special Cartridge for Thick Samples ....................................................................................................6-2
Using Masks ........................................................................................................................................6-2
Orienting the Sample ...........................................................................................................................6-4
Using a 100% RH Test Gas .................................................................................................................6-4
Using Saturated Sponges for testing at 100% RH ..........................................................................6-4
Using a Generated RH Test Gas..........................................................................................................6-5
Filling the Humidifier.......................................................................................................................6-5
Filling the Humidifier during a Test .................................................................................................6-5
Humidifier Ports and Controls.........................................................................................................6-6
Mounting Samples in the Test Cartridge ..............................................................................................6-7
Mounting a Sample in the bottom Test Cartridge position...............................................................6-7
Mounting a Sample in the top Test Cartridge position ....................................................................6-9
Loading and Unloading the Test Cartridge ...........................................................................................6-9
Setting Up and Starting a Film Test....................................................................................................6-11
Monitoring and Controlling a Film Test ...............................................................................................6-12
Chapter 7: Maintenance............................................................................................................................7-1
Cleaning the Instrument .......................................................................................................................7-1
Cleaning the Air Filters.........................................................................................................................7-2
Cleaning the Test Cells ........................................................................................................................7-3
Maintaining the Test Cells ....................................................................................................................7-3
Drying Out the Humidifier .....................................................................................................................7-3
Test Cartridge Components and Part Numbers....................................................................................7-4
Changing the Desiccant .......................................................................................................................7-6
System Standby...................................................................................................................................7-8
System Shutdown for Storage or Repair ..............................................................................................7-8
Chapter 8: Troubleshooting.......................................................................................................................8-1
Error Messages and Warnings .............................................................................................................8-1
Troubleshooting Testing Problems .......................................................................................................8-1
Recovering from a Sensor Over-Range Condition................................................................................8-2
Recovering from a Power Failure .........................................................................................................8-2
Chapter 9: Specifications ..........................................................................................................................9-1
Physical Specifications.........................................................................................................................9-1
Environmental Requirements ...............................................................................................................9-1
Electrical Requirements .......................................................................................................................9-2
Gas Supply Requirements ...................................................................................................................9-3
Operational Capabilities .......................................................................................................................9-3
Transmission Rate Range and Repeatability Capabilities ....................................................................9-4
Appendix A: Site Preparation Instructions ................................................................................................ A-1
Appendix B: Spare Parts.......................................................................................................................... B-1
Appendix C: Warranty and Service Policies ............................................................................................. C-1
Appendix C: Warranty and Service Policies .................................................................................................... C-1
Appendix D: Theory of Operation............................................................................................................. D-1
How the Water Vapor Transmission Rate is measured ....................................................................... D-1

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How the Water Vapor Sensor Works................................................................................................... D-1
Water Vapor Sensor Calibration Theory.............................................................................................. D-1
Barrier Temperature ...................................................................................................................... D-2
Test Gas Driving Force.................................................................................................................. D-3
Barometric Pressure...................................................................................................................... D-3
Relative Humidity .......................................................................................................................... D-3
How a Humidified Test Gas is Generated............................................................................................ D-4
How the ReZero Cell Works................................................................................................................ D-4
Appendix E: Electrical and Plumbing Diagrams ....................................................................................... E-1
Appendix F: Preparing RH Calibration Standards .....................................................................................F-1
RH Calibration Equipment....................................................................................................................F-1
Choosing a Salt Solution ......................................................................................................................F-1
Preparing a High-Level Calibration Standard .......................................................................................F-2
Preparing a Low Level Calibration Standard ........................................................................................F-2
Preparing a Saturated Salt Solution .....................................................................................................F-2
Appendix G: Compliance ......................................................................................................................... G-1

Table of Contents AQUATRAN 3/38 Operator’s Manual
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Figures
Figure 1-1: AQUATRAN 3/38 System .......................................................................................................1-1
Figure 1-2: The AQUATRAN 3/38 - 100% RH Test Cell............................................................................1-5
Figure 2-1: Front Panel Parts and Controls ...............................................................................................2-2
Figure 2-2: Front Panel Parts and Controls ...............................................................................................2-4
Figure 2-3: Back Panel Parts and Controls ...............................................................................................2-5
Figure 2-4: System Plumbing Connection Diagram...................................................................................2-7
Figure 6-1: Humidifier Fill Ports.................................................................................................................6-6
Figure 6-2: Mounting a Film Sample (Bottom Position) .............................................................................6-8
Figure 6-3: Mounting a Film Sample (Top Position) ..................................................................................6-9
Figure 6-4: Loading the Test Cartridge....................................................................................................6-10
Figure 6-5: Press Load/Unload Button While Holding the Tray................................................................6-11
Figure 7-1: The Air Filters .........................................................................................................................7-2
Figure 7-2: Test Cartridge Components ....................................................................................................7-4
Figure 7-3: The Desiccant Chamber .........................................................................................................7-7
Figure 9-1: Plumbing Diagram Page 1 ................................................................................................... E-2
Figure 9-2: Plumbing Diagram Page 2 ................................................................................................... E-3
Figure 9-3: Electrical Diagram Page 1.................................................................................................... E-4
Figure 9-4: Electrical Diagram Page 2.................................................................................................... E-5
Figure 9-5: Electrical Diagram Page 3.................................................................................................... E-6
Tables
Table 2-1: Front Panel Parts and Controls ................................................................................................2-4
Table 2-2: Back Panel Parts and Controls.................................................................................................2-6
Table 6-1: Humidifier Ports and Controls ..................................................................................................6-6
Table 7-1: Test Cartridge Part Numbers ...................................................................................................7-5
Table 9-1: Physical Specifications.............................................................................................................9-1
Table 9-2: Environmental Requirements ...................................................................................................9-1
Table 9-3: Electrical Specifications............................................................................................................9-2
Table 9-4: Gas Supply Specifications........................................................................................................9-3
Table 9-5: Operational Capabilities ...........................................................................................................9-3
Table 9-6: Range and Repeatability Capability ..........................................................................................9-4
Table 9-7: Salt Solution Humidity Standards in Percent RH ......................................................................F-1

AQUATRAN 3/38 Operator’s Manual Introduction
MOCON, Inc. Revision G 1-1
Chapter 1:Introduction
This chapter provides a brief overview of the AQUATRAN 3/38 Water Vapor Transmission Rate System.
Read this chapter to get an overview of:
•The features of the AQUATRAN 3/38 system
•A summary of basic steps in a permeation test
•A summary of how a Water Vapor Transmission Rate measurement is performed
•A summary of how Film and Package testing is performed
Figure 1-1: AQUATRAN 3/38 System

Introduction AQUATRAN 3/38 Operator’s Manual
1-2 Revision G MOCON, Inc.
Features
The following features of the AQUATRAN 3/38 Water Vapor Transmission Rate System make it very
versatile and easy to use:
•Fully automatic (Hands Off) testing.
•Pneumatically clamped Test Cartridges.
•Removable Dual-Film Test Cartridges for faster film mounting.
•Test Cartridges with TruSeal™ for increased performance.
•Automatic control of Pressure, Flow and RH.
•Automatic control of the Test Cell Temperature.
•QC Mode
•Advanced Gas Saver function reduces gas consumption.
•Automatically save and print Test Results.
•Internal storage of at least 100 Test Results.
•Integrated and intuitive touch screen operator interface.
•Remote Access and Control (requires optional Perm-Net Light software).
•Standard Ethernet port (100T).
•Dual USB 2.0 ports (for connection of keyboard, mouse or memory devices).

AQUATRAN 3/38 Operator’s Manual Introduction
MOCON, Inc. Revision G 1-3
Permeation Test Overview
A “Permeation Test” consists of up to two phases that are performed using a Test Cell. The “Cell” contains
the film sample. The Test Phase (always present) is used to measure the transmission rate of the test
sample. The Individual Zero Phase is optional and may occur at the beginning or end of a Permeation Test.
Each phase in the test consists of a series of discrete states. A Permeation Test may utilize all or only a
subset of the possible test states. During a test the steps (or states) within each phase are executed in a
fixed order. This order is called the “Test Sequence”. A brief description of the phases and states within a
permeation test are given below:
Individual Zero Phase
An Individual Zero Phase is used to determine the amount of water vapor that is present in the carrier gas
from factors other than actual transmission through the sample. This amount is subtracted from the
transmission rate obtained for each sample during testing. For more information on when and how to use an
Individual Zero Phase see “Individual Zero Processing” in Chapter 3.
Conditioning the Sample
Almost every material requires a period of time to acclimate to the environment and reach equilibrium. A
time period can be specified to allow the barrier to “Condition” to the test environment. The Conditioning
Period when used will occur at the beginning of each test phase.
ReZero State
Periodically the instrument baseline must be measured so that any changes in the baseline will not affect
the accuracy of your transmission rate data. This is done during a “ReZero State” by measuring the
apparent water vapor transmission rate of the ReZero Cell.
Cell Examination State
The Cell Examination State is used to measure the transmission rate of the barrier sample. The carrier gas
leaving the Test Cell is sent to the water vapor sensor where the amount of water vapor contained in the
gas is measured to determine a transmission rate.
Bypass State
The Bypass State is used to minimize exposure of the water vapor sensor to excessive background levels
of water vapor. The water vapor sensor is automatically placed in the Bypass State during conditioning,
when tests are completed or when an excessively high level of water vapor is detected.
Test Completion

Introduction AQUATRAN 3/38 Operator’s Manual
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At some point sufficient measurements will have been made to accurately determine the transmission rate
of the samples. A Permeation Test can be terminated manually by the user, after a fixed number of test
cycles or using an automatic convergence process. When testing is complete, the cell is removed from the
test sequence and no further transmission rate examination of that sample is performed. For more
information on stopping a transmission rate test see “Determining When to Stop a Test” in Chapter 3.
Report Generation
You can request a report for one cell or any cell at any time until a new permeation test is started. See the
instrument Help System for information on printing reports.

AQUATRAN 3/38 Operator’s Manual Introduction
MOCON, Inc. Revision G 1-5
Measuring Water Vapor Transmission Rate
To make an accurate transmission rate measurement a known concentration Test Gas (usually 100%
Water vapor) is applied to one side of the barrier material to be tested and the other side is swept with a
water vapor free Carrier Gas (nitrogen). This is accomplished by mounting the sample in a device called a
Diffusion Cell. For convenience a diffusion cell is often referred to as a “test cell” or as a “cell”.
This process is illustrated in Figure 1-2 which is a simplified depiction of a film sample mounted in a
diffusion cell. The Test Cartridge used in the AQUATRAN 3/38 contains two diffusion cells.
As shown in the illustration the film is mounted between two parts of the cell. The o-rings and sealing
surfaces in the cell prevent outside air from affecting the measurement.
The Test Gas is continuously applied to bottom half of the cell. When performing a test using a 100% RH
test gas, the water vapor is supplied by a saturated sponge. To perform a test using a Generated RH the
sponge is removed and a gas at the specified RH is supplied to the Test Gas side of the cell.
The Carrier Gas (nitrogen) enters the top half of the cell. As water vapor permeates the sample barrier it
mixes with the Carrier Gas. The output side (exhaust) of the test cell is routed to the water vapor sensor.
The amount of water vapor in the carrier gas is measured using the water vapor sensor.
Seal leakage can be a significant source of error when measuring the transmission rate of a film sample.
The TruSeal™ flush ring at the perimeter of the cell minimizes the effect of ambient water vapor on the
measurement. During a test the TruSeal™ flush ring is purged with carrier gas minimizing the possibility of
leakage past (or permeation through) the seals.
Figure 1-2: The AQUATRAN 3/38 - 100% RH Test Cell

Introduction AQUATRAN 3/38 Operator’s Manual
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Testing Samples
The AQUATRAN 3/38 is designed measure the Water Vapor Transmission Rate of film samples. The
AQUATRAN 3/38 provides no capability for testing packages.
To test a film sample, it is prepared and mounted in a Test Cartridge. Both positions in the Test Cartridge
(referred to as the top and bottom) must contain a film or foil. The test cartridge is used to maintain the film
sample at the specified test conditions. For more information on testing Film Samples see Chapter 6.

AQUATRAN 3/38 Operator’s Manual Setting Up
MOCON, Inc. Revision G 2-1
Chapter 2: Setting Up
This chapter provides information on how to set up an AQUATRAN 3/38 and prepare it for use.
Read this chapter to learn about:
•Unpacking the System
•Preparing for System Installation
•Front Panel Parts and Controls
•Back Panel Parts and Controls
•Connecting the nitrogen gas line to the instrument
Unpacking the System
Each AQUATRAN 3/38 instrument is shipped in its own crate. Any optional kits or accessories may be
shipped in the instrument crate or in separate cartons. A checklist will be included for the instrument and
any of the optional kits you may have purchased.
If any components are missing or damaged, please call MOCON in the USA at [phone].
Preparing for Installation
The Site Preparation Instructions (Appendix A) contain important information about preparing a location for
the instrument and the facilities required for your new instrument. Please read Appendix A before
proceeding with the installation of the AQUATRAN 3/38.
The ambient environmental conditions in which the instrument will be used must meet those specified on
page 9-1 in Chapter 9.
The AQUATRAN 3/38 should be placed on a bench or table capable of supporting approximately 43 kg (95
lbs.). The work surface should be flat, clean and free of excessive vibration.
If installing a printer that will be directly connected to the AQUATRAN 3/38, place it next to the instrument.
Read the manual that came with the printer for installation procedures.
Do not plug the instrument or printer into a power source until all components have been set up and
connected.
Before proceeding with the setup or operation of the instrument familiarize yourself with the locations and
names of the parts and controls on the front and rear of the instrument.

Setting Up AQUATRAN 3/38 Operator’s Manual
2-2 Revision G MOCON, Inc.
Front Panel Parts and Controls
The names and locations of the parts and controls located on the front of the instrument are shown in
Figure 2-1, Figure 2-2 and Table 2.1.
Figure 2-1: Front Panel Parts and Controls
6
3
5
8
7
4
1
2

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15
9
10
14
13
11
12

Setting Up AQUATRAN 3/38 Operator’s Manual
2-4 Revision G MOCON, Inc.
Figure 2-2: Front Panel Parts and Controls
Item
Name
Description
1
Cartridge B Load/Unload button
This button is used to Load and Unload the Test Cartridge
2
Cartridge B Status Indicator
This indicator is used to show the Status of Cartridge B
3
Cartridge A Load/Unload button
This button is used to Load and Unload the Test Cartridge
4
Cartridge A Status Indicator
This indicator is used to show the Status of Cartridge A
5
Cover
The cover that is used to access the Humidifier and gas vents
6
Instrument Display
The color touch-screen display used for instrument control
7 Cartridge Drawer - Cartridge A The drawer which contains Test Cartridge A
8
Cartridge Drawer - Cartridge B
The drawer which contains Test Cartridge B
9
ReZero Cell Vent
The carrier gas vent for the ReZero cell
10
Cartridge A Vent
The carrier gas vent for Test Cartridge A
11
Cartridge B Vent
The carrier gas vent for Test Cartridge B
12
Thermometer Well
A thermometer well for use with an external thermometer
13
Reservoir Fill/Drain Valve
The screw used to open & close the Reservoir drain
14
Reservoir Drain/Fill Port
The drain port for the Reservoir
15
Water Reservoir
Window showing the Reservoir water level
Table 2-1: Front Panel Parts and Controls

AQUATRAN 3/38 Operator’s Manual Setting Up
MOCON, Inc. Revision G 2-5
Back Panel Parts and Controls
The names and locations of the parts and controls located on the back of the instrument are shown in
Figure 2-3 and Table 2.2.
Figure 2-3: Back Panel Parts and Controls
4
3
2
1
5
6
7
8

Setting Up AQUATRAN 3/38 Operator’s Manual
2-6 Revision G MOCON, Inc.
Item Name Description
1 Power In The connector the power cord attaches to.
2 Fuse Holder The fuse holder contains the fuses used to protect the instrument.
3 Power Switch
The switch that is used to turn the instrument on and off.
l is ON
О is OFF
4 Carrier Gas Inlet Port The fitting that connects the carrier gas supply to the instrument.
5 Cooling Fan The fan that supplies cooling air to the sample heating/cooling system.
6 Network Port A 10/100T Ethernet port for connection to a network.
7 USB Ports USB 2.0 Ports for connection of USB devices (keyboard, mouse).
8 Enclosure Fans The fans that supply cooling air to the instrument enclosure.
Table 2-2: Back Panel Parts and Controls