dymax Tridak 1001 User manual

Tridak® Model 1001 User Guide
Syringe Filling System
▪Instructions for Safe Use
▪Setup and Operation
▪Maintenance
▪Ordering Spare Parts and Accessories

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Tridak® Model 1001 Syringe Filling System User Guide
About Dymax
Light-curable materials as well as systems for light curing, fluid dispensing, and fluid packaging.
Dymax manufactures a wide variety of light-curable oligomers, adhesives, and coatings as well as a complete line of manual and
automatic fluid dispensing systems, light-curing systems, and fluid packaging equipment.
Our Tridak® brand fluid packaging systems are designed for use in numerous industries, including industrial, medical, dental,
pharmaceutical, and food preparation. These filling systems provide significant productivity gains over manual and other more
complicated and costly filling methods. The equipment is suited for all industry standard packaging as well as custom molded syringes and
cartridges. We also possess the capability to fabricate nozzles and multi-port dispensing manifolds that perfectly match the packages
being filled. Single- and dual-component materials can be packaged in seconds, one at a time, or in multiples for higher volume
throughput. The equipment accommodates various mix ratios. High-pressure filling equipment is available for packaging highly filled
materials in tiny syringes or compules.
Please note that most filling system applications are unique. Dymax does not warrant the fitness of the product for the intended
application. Any warranty applicable to the product, its application and use is strictly limited to that contained in the Dymax standard
Conditions of Sale. Dymax recommends that any intended application be evaluated and tested by the user to insure desired performance
criteria are satisfied. Dymax is willing to assist users in their performance testing and evaluation.

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Tridak® Model 1001 Syringe Filling System User Guide
Contents
Introduction....................................................................................................................................................4
Introduction to the User Guide ....................................................................................................................................... 4
Where to Get Help .......................................................................................................................................................... 4
Safety..............................................................................................................................................................4
General Safety Considerations ........................................................................................................................................ 4
Specific Safety Considerations......................................................................................................................................... 4
Personal Protective Equipment....................................................................................................................................... 5
Product Overview ...........................................................................................................................................5
Description of the Model 1001 Syringe Filling System .................................................................................................... 5
Special Features and Benefits of the Model 1001........................................................................................................... 5
Description of Main Components.................................................................................................................................... 6
Assembly and Setup........................................................................................................................................7
Unpacking and Inspecting Your Shipment....................................................................................................................... 8
Parts Included in the Model 1001 Syringe Filling System ................................................................................................ 8
Utilities Required............................................................................................................................................................. 8
Preparing the System for Use..........................................................................................................................9
Installing the Reservoir Support ...................................................................................................................................... 9
Installing the Material Reservoir ..................................................................................................................................... 9
Connecting the Material Reservoir Pressure Supply Tube ............................................................................................ 10
Operation ..................................................................................................................................................... 10
Preparing the Cartridge................................................................................................................................................. 11
Loading the System ....................................................................................................................................................... 12
Pressurizing the System................................................................................................................................................. 14
Depressurizing the System ............................................................................................................................................ 15
Adjusting the Syringe Rest............................................................................................................................................. 15
Setting the Fill Amount for the Syringe Size .................................................................................................................. 15
Priming the System........................................................................................................................................................ 16
Preparing the Syringes................................................................................................................................................... 16
Filling the Syringe .......................................................................................................................................................... 17
Model 830 Valve Adjustments ...................................................................................................................................... 17
Cleaning and Maintenance ........................................................................................................................... 18
System Cleaning ............................................................................................................................................................ 18
Spare Parts and Accessories.......................................................................................................................... 18
Replacement Parts/Accessories ........................................................................................Error! Bookmark not defined.
Specifications................................................................................................................................................19
System Specifications .................................................................................................................................................... 19
Index....................................................................................................................Error! Bookmark not defined.

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Tridak® Model 1001 Syringe Filling System User Guide
Introduction
Introduction to the User Guide
This guide describes how to assemble, use, and maintain the Model 1001 Syringe Filling System safely and
efficiently.
Intended Audience
We prepared this user guide for experienced process engineers, technicians, and manufacturing personnel. If
you are new to filling systems and do not understand the instructions, contact Dymax Application Engineering
to answer your questions before using the equipment.
Where to Get Help
Additional resources are available to ensure a trouble-free experience with our products:
■Detailed product information on www.tridak.com
■Customer Support and Engineering teams are available in the United States, Monday through Friday,
from 8:00 a.m. to 5:30 p.m. Eastern Standard Time. You can also email us at [email protected]. Please
see the back cover of this user guide for worldwide contact information.
Safety
WARNING! If you use this filling system without first reading and understanding the
information in this user guide, injury can result. To reduce the risk of injury, read and ensure you
understand the information in this user guide before assembling and operating a Tridak filling
system.
General Safety Considerations
All users of Tridak equipment should read and understand this user guide before assembling and using the
equipment.
Specific Safety Considerations
Using Safe Operating Pressures
Pressurizing the components in the dispensing system beyond the maximum recommended pressure can
result in the rupturing of components and serious personal injury. To minimize the risk of rupturing
components and injury, do not exceed the maximum operating pressure of the components in your filling
system.

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Tridak® Model 1001 Syringe Filling System User Guide
Preventing Injection Injury
Discharging fluids or compressed air with a dispensing tip against your skin can cause very serious injection
injury. To minimize the risk of injection injury, do not place the dispensing tip in contact with your skin.
Personal Protective Equipment
Operators are recommended to wear any personal protective equipment specified by their company’s safety
policy for the materials used during filling. Personal protective equipment should be in place and used at all
times before pressurizing the system and when handling any potentially hazardous materials.
Product Overview
Description of the Model 1001 Syringe Filling System
The Model 1001 Syringe Filling System is designed to quickly fill piston and/or plunger-style syringes, one at a
time, quickly and accurately from a material reservoir. The system can be used with several different material
reservoirs including cartridge reservoirs, bottle reservoirs, and pail reservoirs. The system utilizes a Model 830
Disposable Fluid Path Valve to make material changeover fast and easy, while eliminating most cross-
contamination. The disposable fluid path can be fitted with a series of adapters to fill Luer-Lock and Oral tip
syringe types.
Special Features and Benefits of the Model 1001
This machine features several design features to make filling simple, quick and clean, including:
▪Disposable fluid path valve with disposable wetted parts that eliminate material contamination and
minimize clean-up and maintenance
▪Disposable fluid path can be capped and remain attached to the material cartridge for storage
▪Adjustable suck-back feature allows for a clean dispense of stringy and tacky materials
▪Material reservoir pressure regulator to control the reservoir pressure used for filling
▪Fills various syringes including 0.5, 1, 3 and 5 ml (up to 60 ml) syringes with pre-inserted plunger;
tooling nozzles are available for both Luer-Lock or Oral tips.
▪Adjustable pneumatic stop assures accurate fills and provides automatic shut-off
▪Foot-switch for hands-free, one-touch, fill cycle activation
▪Quick clamp design for fast and easy material changeover
▪Small footprint; dimensions (L x W x H) –24 in x 12 in x 26 in (60.96 cm x 30.48 cm x 66.04 cm)

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Tridak® Model 1001 Syringe Filling System User Guide
Description of Main Components
The main components in the Model 1001 Syringe Filling System include:
1. Air Regulator –The air regulator enables precise control of the air pressure in the fluid reservoir. The
air precision regulator includes:
a. Pressure gauge that displays the pressure in the fluid reservoir. A 0- to 100-psi (0- to
6.9-bar) pressure gauge is installed on the air regulator.
b. Pressure control knob that enables adjustment of the pressure of the air entering the
reservoir. 5-60 psi recommended for most applications.
2. Compressed Air Line –The air line consists of blue polyurethane tubing designed for compressed air
use.
3. Model 830 Valve –A disposable fluid path valve used to dispense material from the material
reservoir. This valve features suck-back, allowing drip-free dispensing from fill-to-fill.
4. Disposable Fluid Path –The fill tube and fittings used to deliver fluid material from bulk cartridges
to syringes. It is constructed of black, light-blocking polyethylene tubing compatible with many types
of commercial and medical fluids.
5. Material Reservoir Retainer –The reservoir retainers and tanks hold fluid reservoirs. Reservoir
retainers accept cartridge reservoirs. Reservoir tanks accept bottle and pail reservoirs.
6. Material Reservoir Support –The adjustable vertical support is used to mount material reservoir
support.
7. Material Reservoir Pressure Supply –The air supply line that pressurizes the material in the
material reservoir retainer. The air regulator controls the pressure supplied to the material reservoir.
8. Foot Switch –Depression of the foot switch initiates the machine fill cycle. Once the foot switch is
depressed, the machine will automatically cycle and shut off once the fill switch is tripped.
9. Adjustable Syringe Support –The support is used to ensure the syringe is supported to remain in
line with the fill stop switch and the Luer or Oral tip fitting.
10. Fill Stop –The air-operated switch that controls the machine shut off once target fill volume is
achieved.
11. Cylinder Retract Switch –Manual retraction switch for fill stop cylinder. This switch can be used to
stop the machine operation at any time in the cycle.
12. Quick Clamp Release –The clamp mechanism is used to hold the material line in the Model 830
Valve. The clamp allows for quick and easy material line changeover.

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Tridak® Model 1001 Syringe Filling System User Guide
Figure 1. Main Components of the Model 1001 Syringe Filling System
Material Reservoir Retainer
Material Reservoir Support
Model 830 Valve
Quick Clamp Release
Fill Stop
Foot Switch
Compressed Air Line
Inlet (60-90 psi)
Air Regulator
Disposable Fluid Path
Cylinder Retract Switch
Adjustable Syringe Support
Material Reservoir Pressure Supply

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Tridak® Model 1001 Syringe Filling System User Guide
Assembly and Setup
Unpacking and Inspecting Your Shipment
When your system arrives, inspect the boxes for damage and notify the shipper of box damage immediately.
Open each box and check for equipment damage. If parts are damaged, notify the shipper and submit a claim
for the damaged parts. Contact Dymax so that new parts can be shipped to you immediately.
The parts listed below will be included in your shipment. If parts are missing, contact your local Dymax
representative or Dymax Customer Support to resolve the problem.
Parts Included in the Model 1001 Syringe Filling System
▪Model 1001 with Foot Switch [1]
▪Tube Assemblies –Luer Female [2]
▪Reservoir [3]
▪Rod Assembly [4]
▪Airline Kit for Reservoir and Model 1001 [5 & 6]
▪Allen Key Kit [7]
▪0.32" Bleed Wire with Pull Ring [8]
▪Model 1001 User Manual [9]
▪Stopper Pin (for use with plunger-less syringes) [Not Shown]
Figure 2. Unpacking Diagram
Utilities Required
AIR: Clean, dry, non-lubricated air operating pressure of 60 –90 psi

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Tridak® Model 1001 Syringe Filling System User Guide
Preparing the System for Use
Installing the Reservoir Support
1. Place the Reservoir Support on top of the screw hole in the left side of the system base.
2. Using the screw and washer provided, place screw with the washer through hole in base and attach
to Reservoir Support. Tighten the screw until the Reservoir Support is secure (Figure 3).
Figure 3. Reservoir Support Installation
Installing the Material Reservoir
1. Slide the Material Reservoir Retainer (Figure 4, D) over the top of the Reservoir Support (Figure 4, B).
2. Position the Material Reservoir Retainer on the Reservoir Support so that the bottom of the Retainer
is approximately 2 inches above the top of the Back Plate.
3. Using the Height Adjustment Handle (Figure 4, C) tighten the Set Screw until the Material Reservoir
Retainer does not move.

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Tridak® Model 1001 Syringe Filling System User Guide
Connecting the Material Reservoir Pressure Supply Tube
1. Connect the material reservoir’s Pressure Supply (Figure 4, F) to the Air Regulator (Figure 4, G).
2. Connect the opposite end of the Material Reservoir Pressure Supply to the Material Reservoir Air Inlet.
NOTE: DO NOT CONNECT AIR TO COMPRESSED AIR LINE INLET (FIGURE 4, H) AT THIS TIME.
Figure 4. Syringe Filler with 20 oz Cartridge Retainer (Rear View)
C –Height Adjustment Handle
A –Material Reservoir Air Inlet
D –Material Reservoir
Retainer
E –Disposable Fluid Path
F –Material Reservoir Pressure Supply
G –Air Regulator
H –Compressed Air Line Inlet
(60-90 psi)
B –Material Reservoir Support