Pall PadMixer 1000 Premium User manual

020-17467-00 Instructions For Use PadMixer 1000 Premium RevD
Filtration. Separation. Solution.SM
Instructions For Use
PadMixerTM 1000 Premium Mixer
USD 3188

020-17467-00 Instructions For Use PadMixer 1000 Premium RevD
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Contents
1. Introduction.................................................................................................................. 4
2. Safety warnings ........................................................................................................... 4
3. Assembly and commissioning.................................................................................... 4
4. Touch screen operation .............................................................................................. 5
General................................................................................................................... 5
Start-up screen....................................................................................................... 5
Main screen –main menu....................................................................................... 5
4.3.1. Select recipe.................................................................................................... 7
4.3.2. Test Mode........................................................................................................ 7
4.3.3. Settings............................................................................................................ 9
4.3.4. Inflate............................................................................................................. 17
4.3.5. Print............................................................................................................... 17
4.3.6. Reset............................................................................................................. 17
4.4 Troubleshooting.................................................................................................... 18
4.5 Error Messages .................................................................................................... 19
4.6 Information............................................................................................................ 19
5Installation and use of mixing biocontainer............................................................. 21
5.1 Installing the mixing biocontainer.......................................................................... 21
5.2 Filling the mixing biocontainer............................................................................... 23
5.3 Setting the mixing angle on the drive unit.............................................................. 26
5.4 Connecting the mixing biocontainer to the drive unit............................................. 27
5.5 Adding powders.................................................................................................... 31
5.6 Creating a recipe .................................................................................................. 32
5.6.1 Guidelines to define the correct connection height......................................... 32
5.6.2 Mixing speed and mixing angle limitations..................................................... 32
5.6.3 Acceleration and deceleration limitations....................................................... 33
5.7 Height adjustment................................................................................................. 33
5.8 Inflating the mixing biocontainer............................................................................ 34
5.9 Starting the mixing cycle....................................................................................... 35
5.10 Emptying the mixing biocontainer ......................................................................... 35
5.11 Emergency stops.................................................................................................. 37
6Cleaning, maintenance and inspection activities.................................................... 38
6.1 Cleaning ............................................................................................................... 38
6.2 Maintenance and inspection ................................................................................. 38
6.3 Retrieving a lost password.................................................................................... 38

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6.4 Replacing the printer roll....................................................................................... 38
6.5 Adjusting the inflation pressure............................................................................. 39
6.6 Replacing the motor.............................................................................................. 40
6.7 Uploading a new PLC code................................................................................... 41
7General machine specifications ............................................................................... 47
7.1 Materials............................................................................................................... 47
7.2 Capacity................................................................................................................ 47
7.3 Noise level............................................................................................................ 47
7.4 Operating temperature.......................................................................................... 47
8Service........................................................................................................................ 47
9Warranty..................................................................................................................... 48

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1. Introduction
The purpose of this manual is to inform the users about the safe and correct use of the
PadMixer 1000 Premium. This includes all persons who have the task of installing,
commissioning, adjusting, maintaining, cleaning, repairing, transporting or scrapping the
machine. Before using this machine all persons involved should thoroughly read and
understand the user manual. All safety precautions and safety provisions in use in the
company must be known and respected.
This user manual must always be available near the machine. It is very important that all
instructions are carefully followed and, where appropriate, they should be incorporated into
the user’s standard operating procedures. If some of the procedures do not suit your needs,
please consult your Pall distributor before finalizing your system. Use of this product in a
manner other than in accordance with Pall’s current recommendations may lead to injury or
product loss. Pall cannot accept liability for such injury or loss.
2. Safety warnings
Operation outside the specifications defined in this manual may cause personal injury
and result in damage to the equipment.
No operations (cleaning, maintenance, ...) may be performed on the machine if the
machine is not switched off. Protections around moving parts may not be removed.
3. Assembly and commissioning
It is not permitted to move the machine when a tank and/or mixing biocontainer is connected
to it. To move the machine push it from the backside.
Do not attempt to move the machine by pushing/pulling the mixing head.
Requiredfacilities:
Electricity:
The system 701024 can be used on a single phase net of 220V.
The system 701039 can be used on a single phase net of 110V.
The fuse present in the local power supply cabinet has to be minimum
16Ampère, with a curve C or curve D.
In case a differential switch is present in the local power supply
cabinet, it has to be type A or type B.
Compressed air:
Min. 3 bar, max. 8 bar.
Use of nitrogen is permitted.
The connection of the system to the compressed air system is effected
by connecting a 6 mm ID compressed air hose to the compressed air
coupling closest to the rear of the machine.
A compressed air cable is provided on the coupling closest to the front
of the machine with a fast coupling to be connected to the mixing
biocontainer.
The outgoing pressure (to the mixing biocontainer) can be adjusted by
means of the manometer underneath the mixing head cover plate. This
pressure is preset to a maximum of 500 mbar.

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The machine is ready for use as soon as the electricity is connected. Connection of the air
supply is not necessary for the functioning of the machine, only for the inflation.
Voltage is applied to the machine by means of the main switch fitted on the door of the
electrical cabinet. All other controls are effected using the Touch Screen.
4. Touch screen operation
General
All items (text & symbols) with a light blue background fulfil a certain function and can
be touched to perform the underlying function or to change the underlying adjustment.
Also the start, pause and stop symbols can be touched to perform their function.
The following symbol appears in the top left corner on different screens and can be used to
return to the previous screen and finally to the main menu:
Start-up screen
A screen saver appears when the main power switch is switched on. The main screen is
shown when the screen is touched.
Main screen –main menu
Figure 1: Main Menu
The main screen consists of the following fields:
Control buttons: Start - Pause - Stop
Table with Set and Actual process parameters
oRPM: Mixing speed expressed in revolutions per minute
oMixing time: expressed in hours : minutes : seconds
oAlternation time: expressed in hours : minutes : seconds

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Function buttons
oSelect recipe
oTest mode
oSettings
oInflate
oPrint
o Reset
The operation of the machine is controlled by this main menu only. The active recipe is
executed by pushing the Start button. This starts the mixer (see the set acceleration &
deceleration times) until it reaches the set rpm and the mixing and alternation time start
running. As soon as the alternation time is reached the mixer changes the direction of
revolution. The mixer stops when the mixing time has elapsed. If so set, the data are printed
out on the printer.
If during mixing the Pause button is pushed the mixer decelerates in accordance with the set
deceleration time. The actual data remain valid so that the recipe can be continued with
the remaining actual values when the Start button is pushed again.
If the Stop button is pushed the mixer decelerates and the actual values are deleted.
In both cases the mixer always returns to the zero position. This is the position where
connecting the mixing biocontainer to or disconnecting the mixing biocontainer from the
system is effected most easily (with the paddle pointing towards the back of the mixing
tank).
If the mixing cycle is interrupted by an emergency stop the mixer will immediately stop and
the actual data will be deleted. The mixer will not stop in the zero position, but in this case
the mixing head can easily be manually turned to the zero position in order to disconnect the
mixing biocontainer.

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4.3.1. Select recipe
Pressing Select recipe shows a screen on which a (different) recipe may be selected. No
password is required.
Figure 2: Menu “Select recipe”
The operator can call this screen only if the active recipe is completed (or has been
interrupted). The following message will appear if another recipe is in progress or paused.
Figure 3: Message “stop current recipe”
The number of the recipe that is ready for activation appears on top. It may be changed
by keying the number. A small numeric keypad appears with which a number may be
entered. To enter a number via the numerical keypad first push CLR (clear) to delete the
old value, then enter the new value. Alternatively the recipe number can be increased or
decreased by 1 using the up and down arrows. The data of the selected recipe are shown
under the recipe number.
Pushing the “Confirm” button activates this recipe number and the main screen appears
again. This recipe number then appears on the main screen as active recipe number.
4.3.2. Test Mode
In the Test Mode screen the setting values of the active recipe can be changed during
mixing. This requires a password.

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Figure 4: Screen to enter password
If the password you entered is incorrect the following screen appears with an error message.
Figure 5: Message when incorrect password entered
By pushing the “Main menu” button the main menu appears again. When the “Test
mode” button is pushed, a new password can be entered. If the password is correct the Test
Mode menu appears.

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Figure 6: Menu “Test mode”
On this screen all current settings can be changed during mixing. Pushing the “Confirm”
button copies all the values of this screen to the setting values of the active recipe and
the new values are immediately executed. The executed changes will only apply during this
“test mode”. The initial values of the recipe will not be changed.
4.3.3. Settings
This shows the menu in which the different mixing parameters can be changed.
Here again a password is required. The following screen with the adjustable parameters
appears upon correct entry of the password.
Figure 7: Menu “ Settings”
Pushing a button shows the corresponding settings.

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4.3.3.1 Change recipe
The setting values of all recipes (from number 1 to 999) can be changed on this screen.
Figure 8: Screen to change the recipe settings
The recipe number can be changed by keying the number. A small numerical keypad
appears with which a number can be entered. Alternatively the recipe number can be
increased or decreased using the up and down arrows.
The recipe settings can be changed by pressing them, calling up a numerical keypad
with which the setting value may be entered.
The desired height of the connection mixing biocontainer-to-system (distance to the
floor) depends on the type of mixing tank and mixing biocontainer used. This height
should be determined when a recipe is created. The mixing system will not be able to start
unless the system is installed at its correct height (to avoid a too high or too low position).
The “min. Height” value can be entered in 2 ways: either by entering the value in mm, or
by placing physically installing the mixing system at the desired height, followed by pressing
the “current” key. In this way the recipe will take the current height as value.
After all values of the recipe have been entered they can be saved using the “Save”button.
At the same time this recipe number from the “Select recipe” menu (see above) is set to
match this recipe number.
4.3.3.2 Change password
The password requested when choosing the “Test mode” and “Settings”options can be
changed here.

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Figure 9: Screen to change the password
First the existing (or old) password is requested, then the new password and the
confirmation thereof. If the old password is incorrect the following screen appears with the
error message:
Figure 10: Message when incorrect password
By pushing the “Settings”button the settings menu appears again. The following screen
appears with an error message if the new password does not correspond with its
confirmation:

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Figure 11: Message when incorrect password confirmation
Pushing the “Settings”button returns to the settings menu. The following screen appears if
both the entries for the existing password and the new password are correct:
Figure 12: Message when new password is activated
If this screen appears the new password is activated. Pushing the “Settings” button returns
the user to the settings menu.
The default password that is installed on new systems is 0000 or 1234.
The „master‟ password to enter all menus, including the Factory settings is a 5 digit
password. Contact your Pall distributor for more information.

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4.3.3.3 Language setting
The language of all words and texts appearing anywhere on the screen can be changed
here. Pushing the button for a language immediately activates that language on all screens.
Figure 13: Screen to select language
4.3.3.4 Working hours
The machine working hours are given here for information. The indication of the total
working hours (top row) cannot be reset, in other words the total counter from the first
moment that the machine was started. The indication of the working hours since the last
reset (bottom row) can be reset by pushing the button situated on the right.
Figure 14: Screen to view and reset the Working hours
The working hours indicate the period of time during which the mixer is working, in other
words the period of time during which the start button on the main screen is active.

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4.3.3.5 Time settings
As mentioned for the main screen it is possible to show the current time values of the
active menu in increasing or decreasing order. The choice between the two can be made on
this screen.
Also the time and date can be set.
Figure 15: Screen to change the Time settings
4.3.3.6 Printer setting
The data for the completed recipe can be printed out on the printer. On the following
screen the choice can be made to print out the data on completion of each recipe
automatically or not. Note that the data for the last completed recipe remain available for
reprinting, if necessary, by pushing the “Printer” button on the main screen.
Figure 16: Screen to change the Printer settings

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4.3.3.7 Spindle settings
The system contains 2 pairs of spindles. One pair that has a 300mm stroke and one pair
with a 500mm stroke. In this menu one can view the height of the pairs of spindles and the
total height, being the distance of the mixing head to the floor.
After a number of up-and-down movements, the system will automatically give a warning
message that the height measurement through the spindles need to be calibrated.
By pressing the “calibrate spindles” button, the system will go to its lowest possible position
(typically 675mm) and will reset itself.
It is at any time possible to perform an additional calibration in case the system height
mentioned on the display does not match with the actual height.
Figure 17: Screen to view the spindle location, settings and to calibrate
Note: as the system will automatically move down, no object should be present. The display
will mention following warning message. Press OK to carry out the calibration.
Figure 18: Warning message for calibration

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4.3.3.8 Factory settings
Certain settings are set by the manufacturer in accordance with the type of machine.
These data are intended solely for the technician who commissions the machine and
are thus not applicable for the operator. Entering the menu of the Factory settings is not
possible with the first level password. A master password is required (5 digits). Contact
your Pall distributor for more information. Figure 19: Screen to change the Factory settings
shows these factorysettings.
In the lower right hand corner of the screen one can see the current active password.
Figure 19: Screen to change the Factory settings
When pressing the „right‟ arrow one can modify some additional parameters related to an
alarm that the system can give when during mixing the actual RPM deviates from the set
value.
One can define the time before checking the actual versus set RPM. This is set default at
60 seconds to avoid false alarms during the acceleration phase.
One can define the delay time for actually displaying the „out of range‟ message. This is set
default at 30 seconds.
One can define the maximum RPM deviation allowed. This is set default at 20 RPM.

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Figure 20: Screen to change additional Factory settings
4.3.4. Inflate
This function is used to inflate the mixing biocontainer with compressed air or nitrogen.
When activated the icon turns green and the compressed air valve is activated.
The compressed air remains active until one of the following points:
The function is cancelled by touching the INFLATE icon on the touch screen again
The mixing biocontainer is inflated to the point that it presses against the mixing
biocontainer detection. However, if the mixing biocontainer is emptied and the
detection is released the compressed air will reactivate after a delay of three
seconds
The emergency stop is pressed
The protective front cover is opened.
4.3.5. Print
This prints out the data for the last finished recipe. To print the last recipe, make sure the
mixing system has completely stopped rotating.
Note: the total mixing time stated on the label may be a few seconds shorter than the
difference between the start and finish times. The reason is that the last deceleration time is
not included in the calculation of the total mixing time, but the finish time is not
determined until the mixer has come to a complete standstill.
4.3.6. Reset
This resets all error messages, for example after using the emergency stop.

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4.4 Troubleshooting
When touching the top left corner of the main menu a screen appears with the status of all
digital inputs. In the event of a malfunction a quick and easy check can be run to see which
inputs are working and which may be defective. This function is intended solely for the
technician carrying out troubleshooting on the machine.
Figure 21: Screen to consult the status of the machine inputs
When pushing the “Outputs” button a menu appears that displays the status of the outputs
(inflation valve, fan, …).
If the technician has activated the “Manual operation” feature in the “factory settings”
screen, a “Manual” button will appear at the bottom of this menu. The following screen
appears if this button is pushed.
Figure 22: Screen to manually modify machine status

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All outputs can be controlled from this screen. This may be useful in order to detect a
malfunction in the event that a given function is not working at all or not working correctly.
4.5 Error Messages
At the very bottom of the main menu appears a bar showing the error messages (if active).
Pushing this bar shows the complete list of error messages.
Figure 23: Screen to consult and reset alarms
The error messages can be reset by pushing the reset button in the main menu or,
alternatively, by pushing the reset button in the list of error messages.
The following malfunctions & corresponding error messages may occur:
Protective front cover is open
Frequencyregulator error
Emergency stop module error
Emergency stop button is pressed
4.6 Information
As mentioned earlier, contact information about Pall can be consulted by touching the
information icon situated in the top right-hand corner of most screens.

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Figure 24: Supplier contact information