Pall Palltronic AquaWIT IV User manual

Palltronic
®
AquaWIT IV
Filter Integrity Test System
Also

Operating Instructions for the Palltronic AquaWIT IV test system Page 2
© Pall Corporation 2013 Version2.0-2
Contents
1. Safety instructions ..........................................................................6
1.1 Safe Use of the Palltronic AquaWIT IV Test System................................................... 6
1.2 Sources of Danger...................................................................................................... 6
1.3 Authorized Users ........................................................................................................ 6
1.4 Filter Assembly ...........................................................................................................7
1.5 Personal Safety ..........................................................................................................7
1.6 Use of Compressed Gas............................................................................................. 7
1.7 Electrical..................................................................................................................... 7
1.8 Transport ....................................................................................................................7
2. Introduction ....................................................................................9
2.1 Standard Functions.....................................................................................................9
3. Set-up Procedure .........................................................................10
3.1 Connections.............................................................................................................. 10
3.1.1 Power Supply ...........................................................................................................................................14
3.1.2 Pressure Supply .......................................................................................................................................14
3.1.3 AIR OUT ...................................................................................................................................................15
3.1.4 Valve V10 – V15.......................................................................................................................................15
3.1.5 External Vent Valve ..................................................................................................................................15
3.1.6 External Pressure Transducer ..................................................................................................................15
3.1.7 USB connection........................................................................................................................................15
3.1.8 Network Connection .................................................................................................................................16
3.1.9 BUS ..........................................................................................................................................................16
4. Start-Up Procedure ......................................................................17
4.1 Self Test and Warm-up Period.................................................................................. 17
4.2 Screen Navigation .................................................................................................... 18
4.3 Use of the Touch Screen .......................................................................................... 18
4.4 Help Function ........................................................................................................... 19
5. Configuration of the Palltronic AquaWIT System ..........................20
5.1 Basic configuration of the Palltronic Flowstar Instrument .......................................... 20
5.1.1 Date/Time .................................................................................................................................................20
5.1.2 Language..................................................................................................................................................20
5.1.3 Pressure Units ..........................................................................................................................................20
5.1.4 Keyboard Beep.........................................................................................................................................21
5.1.5 Enable AquaWIT base unit .......................................................................................................................21
5.1.6 Pre-stabilization ........................................................................................................................................21
5.1.7 Minimum Flow field...................................................................................................................................21
5.1.8 External Vent Valve ..................................................................................................................................21
5.1.9 External Pressure Transducer ..................................................................................................................22
5.1.10 Ne t w or k S e tt i n g .......................................................................................................................................22
5.1.11 Automation settings ..................................................................................................................................23
5.1.12 Main Menu Configuration..........................................................................................................................23
5.1.13 Customized test data fields.......................................................................................................................23
5.1.14 Keyboard layout........................................................................................................................................23
5.2 Printer setting ........................................................................................................... 23
5.2.1 Internal printer ..........................................................................................................................................23
5.2.2 External printer .........................................................................................................................................24
5.3 Access Management ................................................................................................ 26
5.3.1 Standard Access Control ..........................................................................................................................26
5.3.2 High Level Access Control........................................................................................................................26
5.3.3 Create/Edit user........................................................................................................................................27
5.3.4 Password management ............................................................................................................................27
5.3.5 Audit Trail .................................................................................................................................................28

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5.3.6 Electronic Signature..................................................................................................................................29
5.4 Configuration of the Palltronic AquaWIT System....................................................... 29
5.4.1 Fill Filter settings.......................................................................................................................................29
5.4.2 Drain Filter settings (WIT only) .................................................................................................................30
5.4.3 Soak Filter settings (FF and BP only) .......................................................................................................30
5.4.4 Flush Filter Settings (FF and BP only)......................................................................................................30
5.4.5 Dry Filter Settings (WIT only)....................................................................................................................31
5.4.6 Cool Filter Settings ...................................................................................................................................31
5.4.7 Fill Tank Settings ......................................................................................................................................31
5.4.8 Drain Tank Settings ..................................................................................................................................32
5.4.9 Dry System Settings .................................................................................................................................32
5.4.10 Sanitization ...............................................................................................................................................32
5.4.11 Clean System Settings .............................................................................................................................33
6. System preparation ......................................................................34
6.1 Manual Filling ........................................................................................................... 34
6.2 Automatic Filling ....................................................................................................... 34
7. System Operation.........................................................................35
7.1 Test Set-Up for Testing Hydrophobic Filter ............................................................... 35
7.1.1 Connection of External Valves..................................................................................................................35
7.2 The Water Intrusion Test (WIT)................................................................................. 37
7.2.1 Introduction...............................................................................................................................................37
7.2.2 Input for the Water Intrusion Test .............................................................................................................37
7.2.3 Procedure of the Water Intrusion Test......................................................................................................39
7.3 Test Set-Up for testing hydrophilic filter .................................................................... 41
7.3.1 Connection of External Valves..................................................................................................................42
7.4 The Forward Flow Test (FF) ..................................................................................... 43
7.4.1 Introduction...............................................................................................................................................43
7.4.2 Input for the Forward Flow Test................................................................................................................43
7.4.3 Procedure of the Forward Flow Test.........................................................................................................45
7.5 The Bubble Point Test .............................................................................................. 46
7.5.1 Introduction...............................................................................................................................................46
7.5.2 Input for the Bubble Point Test .................................................................................................................46
7.6 The Combined Forward Flow and Bubble Point Test ................................................ 49
7.6.1 Input for the Combined Forward Flow and Bubble Point Test ..................................................................49
8. Test Programs..............................................................................50
8.1 Creating Test Programs............................................................................................ 50
8.2 Editing Test Programs .............................................................................................. 50
8.3 Deactivating Test Programs...................................................................................... 50
8.4 Printing Test Programs ............................................................................................. 51
9. Recall of Stored Test Results .......................................................52
9.1 Searching a test result .............................................................................................. 52
9.2 Sorting test results .................................................................................................... 52
9.3 Reprint of a test result............................................................................................... 52
9.4 Electronic signature .................................................................................................. 52
10. Maintenance of the Palltronic AquaWIT System...........................53
10.1 Maintenance of the Palltronic Flowstar ..................................................................... 53
10.1.1 Self Test ...................................................................................................................................................53
10.1.2 Flow Check Test.......................................................................................................................................53
10.1.3 Printer Test ...............................................................................................................................................54
10.1.4 Network Test ............................................................................................................................................54
10.1.5 Cleaning (Palltronic Flowstar instrument) .................................................................................................54
10.1.6 Status Log ................................................................................................................................................54
10.1.7 Screen Adjustment ...................................................................................................................................54
10.1.8 Changing the Printer Paper ......................................................................................................................55
10.1.9 Cleaning the external Vent Valve..............................................................................................................55
10.1.10 Cleaning the Instrument............................................................................................................................56
10.1.11 Dismantling of the Palltronic Flowstar instrument from the base unit........................................................56

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10.2 Maintenance of the Palltronic AquaWIT Base Unit.................................................... 58
10.2.1 Cleaning of the System.............................................................................................................................58
10.2.2 Manual cleaning of the water tank ............................................................................................................59
10.2.3 Sanitization ...............................................................................................................................................60
10.2.4 Steam sanitization ....................................................................................................................................60
10.2.5 Hot water sanitization ...............................................................................................................................61
10.2.6 Drying the Palltronic AquaWIT System.....................................................................................................61
10.3 Dismantling of the tank ............................................................................................. 62
11. Additional functions ......................................................................65
11.1 Fill tank ..................................................................................................................... 65
11.2 Drain Tank................................................................................................................ 65
11.3 Cool filter .................................................................................................................. 65
11.4 Drain filter ................................................................................................................. 66
11.5 Manual Operation ..................................................................................................... 66
12. Palltronic AquaWIT MUX extension..............................................67
12.1 System preparation................................................................................................... 67
12.1.1 Valve control.............................................................................................................................................67
12.1.2 Filter test fluid supply ................................................................................................................................67
12.1.3 Enabling the MUX control on the Palltronic AquaWIT system ..................................................................68
12.2 Programming the filter test........................................................................................ 68
13. Data Transfer ...............................................................................69
13.1 Backup ..................................................................................................................... 69
13.2 Export Test Results .................................................................................................. 70
13.3 Export Configuration ................................................................................................. 71
13.4 Import Configuration ................................................................................................. 71
13.5 Export Access Management Configuration ............................................................... 72
13.6 Import Access Management Configuration ............................................................... 72
13.7 Export Test Programs............................................................................................... 72
13.8 Import Test Programs ............................................................................................... 73
13.9 Export User Lists ...................................................................................................... 73
13.10 Import User Lists....................................................................................................... 73
13.11 Deletion of Records .................................................................................................. 74
14. Remote control and data logging..................................................75
14.1 OPC Server .............................................................................................................. 75
14.2 Fieldbus.................................................................................................................... 75
15. Error Messages............................................................................76
16. System Retirement.......................................................................80
17. Technical Data .............................................................................81

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© Pall Corporation 2013 Version2.0-2
Safety and information symbols
Safety and information is identified in this instruction manual with the following symbols:
Warning! identifies a dangerous situation where there is a safety risk and personal injury
may follow.
Important: identifies a potentially dangerous situation, a risk to the equipment or other important
information.
Please note: identifies user tips and other useful information.

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© Pall Corporation 2013 Version2.0-2
1. Safety instructions
Warning! Please read the Operating Instructions carefully and completely before using
the product.
1.1..Safe Use of the Palltronic AquaWIT IV Test System
The Palltronic AquaWIT system is designed for the testing hydrophobic sterilizing filters using the Water
Intrusion Test (WIT) including the preparation of the filter before and after the test. The Palltronic
AquaWIT system has also been designed to test hydrophilic membrane filters with the Forward Flow (FF)
and Bubble Point (BP) tests including the required wetting of the filter before the test.
Unauthorized modifications and changes to the system are not recommended for safety and warranty
reasons.
Misuse may lead to the following risks:
•Injury or death to user
•Damage to the system, filter or other systems
•Inefficient working of the system
Everybody who uses or maintains the Palltronic AquaWIT system must read and follow the instructions in
this operating manual. It is for your safety!
1.2..Sources of Danger
Water, electrical current, compressed air, cleaning agents, steam and hot water may all be connected to
the system.
If the filter system is opened when pressurized, connections and components may be propelled by the air
pressure and cause injury.
Steam, hot water and condensate can cause burns when exiting the system, for example when the test
system is moved during a steaming cycle, or by touching pipework when it is at elevated temperatures.
Electrical components may cause shock.
Before service or repair the system should be fully drained and disconnected from the electrical power
supply.
Warning! Only Pall trained service personnel should access the system inside the
stainless steel housing lid or cabinet of the Palltronic AquaWIT system or open the
integrated Palltronic Flowstar instrument!
1.3..Authorized Users
Warning! The Palltronic AquaWIT system should only be used by authorized and
trained users
Users of the test instrument must make sure that they have read and understood the instruction manual
before use.

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The responsibility for the different activities on the test instrument should be clearly established. The
User Rights function allows different access levels for users to be set.
1.4..Filter Assembly
The test pressure must be less than the maximum operating pressure rating of the filter housing or
filter capsule. If the test pressure exceeds the pressure rating of the filter housing or filter capsule
contact the filter manufacturer before starting the test.
1.5..Personal Safety
•Appropriate protective clothing should be worn by operators (e.g. gloves and safety goggles)
when working with chemicals and compressed air supplies during filter integrity testing.
•After test, check that the pressure in the filter housing has been vented and has reached
atmospheric pressure before attempting to use or dismantle the filter assembly.
•Care should be taken when disconnecting pneumatic tubing from pressurized assemblies.
1.6..Use of Compressed Gas
Warning! The maximum inlet pressure of 8 bar (116 psi) must not be exceeded.
•It is the user’s responsibility to ensure that an oil-free regulated gas supply is used during
operation of the instrument.
•All pneumatic tubing used for integrity testing must be rated to withstand the gas pressures used
(up to 8 bar / 116 psi).
•The operator should check the tubing and connectors for damage before each use.
•To prevent the possibility of danger from cross-connection of the pneumatic connections, do not
use a male-to-male pneumatic tube on the air outlet connection.
1.7..Electrical
•The power supply plug must be disconnected from the power source before changing the fuse.
•Repairs must only be carried out by Pall authorized service personnel. Faulty unqualified repair
work may cause accidents or injury to the user.
•Do not open the instrument enclosure under any circumstance, but especially not with the power
on.
•When connecting the instrument, check the electrical cable for damage. If the cable is
undamaged then connect the cable to the power source. The power source should be grounded.
Due to developments in technology, data or procedures may be subject to change. Consequently, we
advise users to review their continuing validity annually.
1.8..Transport
When moving the Palltronic AquaWIT system the weight of at least 120 kg should be regarded.
Warning! Move the system slowly and take special care at edges or if moving on
ramps to avoid tilting.
Warning! During use the Palltronic AquaWIT system should be secured by the brakes.

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The Palltronic AquaWIT system should be shipped in the original shipping case if possible.
For shipping the tank should be empty and if cleaned with chemicals as last activity the cleaning agent
should be flushed out.
The appropriate tools for lifting 120 kg are required for loading the Palltronic AquaWIT system for
transport.
During transport the Palltronic AquaWIT system must be secured by appropriate fixings.
Packing, loading and transport should be performed by personal trained for this task.

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2. Introduction
2.1..Standard Functions
The instrument features the following standard functions:
•Forward Flow Test (FF)
•Bubble Point Test (BP)
•Combined Forward Flow and Bubble Point Test (FF/BP)
•Water Intrusion Test (WIT)
•Leak Test (LT)
•Pressure Decay Test (PD)
•Printout via internal printer
•Storage of test results
•Time and date display
•Automatic Self Test
•Test preparation
oWIT: Filling with water/Draining after test/Drying
oFF/BP/FF+BP Wetting with water
•Automatic control of stabilization and test times
•Maintenance functions: Sanitization, System cleaning and drying
•Language options: US English, English, French, Italian, Spanish and German, other languages in
preparation
•Units of pressure in mbar, psi, kPa or kp/cm
2
•Password-protected storage of at least 500 test programs

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3. Set-up Procedure
3.1..Connections
The set up is described in the following figures and schematic drawings
Figure 1: Front view :
.

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Figure 2: Rear view:

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Figure 3: Schematic Diagram during Filter Test:
The steaming and cleaning manifold is not installed during integrity testing.

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Figure 4: Schematic Diagram During System Steaming:
The manifold for the maintenance functions is installed.

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3.1.1 Power Supply
The system is designed for input voltages of 100-240 V AC and input frequencies of 50 or 60 Hz.
3.1.2 Pressure Supply
Connect the pressurized air supply to the male Stäubli* (AIR IN) connector on the left side of the
instrument. In order to avoid contamination of the internal components of the Instrument with test liquid
that has entered the pneumatic tubing, the red pneumatic tubing should always be used to connect the
Instrument to the compressed air line. The inlet pressure of the compressed air supply should be > 5000
mbar (72.5 psi). It is recommended that the instrument is operated with an inlet pressure between 6000 –
8000 mbar (87 – 116 psi)
Please note: throughout this document pressure values given are relative to atmospheric
pressure.
Warning! The operating pressure of the filter housing or filter capsule assembly must not
be exceeded.
The maximum inlet pressure of the Instrument (8000 mbar/116 psi) must not be exceeded.
The maximum inlet pressure of the Instrument (8000 mbar/116 psi) must not be exceeded.
Figure 5: Connectors on the left side of the instrument

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3.1.3 AIR OUT
This connector allows the performance of tests without the base unit being involved in the filter tests.
This connector should be used for filter tests where the filter is prepared for testing without using the
AquaWIT system, for Flow Check tests and leak tests.
3.1.4 Valve V10 – V15
These connectors allow controlling pneumatic valves outside the AquaWIT system during a filter test or
during maintenance activities.
3.1.5 External Vent Valve
The external valve should only be used when filter tests are performed without the
filter preparation by the base unit!
Insert the External Vent Valve plug into the socket at left the side of the Palltronic AquaWIT base unit.
The External Vent Valve connector should not be inserted or removed while the measurement instrument
is switched on, in order to prevent the possibility of damaging the instrument due to electrical transient
conditions. The External Vent Valve should be used if a filter is prepared manually and the filter is
connected to the ‘AIR OUT’ port- Then the External Vent Valve should be connected in-line between the
measurement instrument outlet hose and the filter housing with Stäubli connectors. The female Stäubli
connection of the vent valve is connected to the housing.
3.1.6 External Pressure Transducer
If the use of an external pressure transducer is required, insert the plug from the transducer into the
socket at left the side of the Palltronic AquaWIT base unit. The external pressure transducer connector
should not be inserted or removed while the instrument is switched on, in order to prevent damage to the
instrument due to electrical transient conditions.
3.1.7 USB connection
The USB port can be used for the connection of a USB printer, a barcode reader or a USB flash drive.
There is one USB (Universal Serial Bus) connection in front of the internal printer and one USB
connection on the left side of the Palltronic AquaWIT base unit.
The instrument is supplied with a USB flash drive installed in the connection in front of the printer.
The external pressure transducer should only be used when the downstream side is
not open to atmosphere or the filter is not connected to a large volume on the
downstream side.

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1 – USB flash drive 2 – Touch screen pen
Figure 6: USB flash drive, touch screen pen and the internal printer
3.1.8 Network Connection
The network connection (RJ45) allows connection of the Palltronic AquaWIT system to a Ethernet
network. The system is also equipped with a WLAN connection.
3.1.9 BUS
The BUS connection is only active if the type of connection (ProfiBUS or Device Net) has been specified
and ordered.

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4. Start-Up Procedure
The system is turned on using the power switch on the right side beside the Palltronic Flowstar
instrument.
4.1..Self Test and Warm-up Period
When turned on, the screen displays the software version and then switches automatically into the Self
Test mode after a few seconds.
In order to carry out the Self Test, the pressure of the compressed air supply must be between
3000 mbar (43.5 psi, 3.06 kp/cm
2
) and 8000 mbar (116 psi, 8.16 kp/cm
2
).
The Self Test will start automatically only once per calendar day when first switched on.
On completion of the Self Test and the warm-up time the system displays the Main Menu.
After the primary electronic checks it is possible to leave the Self Test screen and move to the Main Menu
and subsequent screens while the Self Test is running. It is not possible to start another test or to change
the system configuration until either the Self Test is completed or the Self Test is aborted.
The Self Test can be aborted, although this procedure is not recommended if the equipment has been
switched off for a long period between operations. Abort the Self Test by touching ‘Abort’ on the screen.
The ‘Abort’ button does not appear on the screen until the pressure transducer test is complete.

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4.2..Screen Navigation
After the Self Test has been completed the Main Menu screen is displayed.
1 = Screen Title 2 = Main Navigation
3 = Status Screen
Figure 7: Main Menu and screen structure
At the top of the screen, the screen title, the serial number and software version of the instrument are
displayed.
If the Login function is active the name of the user logged in is displayed.
At the left side of the screen the main navigation buttons are displayed. Functions which are not active on
the screen are grayed out.
At the bottom of the screen there is a status section which displays the number of stored test results, the
number of test programs and the number of users. Other background activities, for example - a test in
progress - are also displayed in the status section.
4.3..Use of the Touch Screen
The Palltronic Flowstar instrument has an easy-to-use touch screen and liquid crystal display for data
input and display. Selecting test programs and other functions via buttons on the screen is very simple
and the large screen allows the display of real time graphs and other test data.
Avoid touching the screen unless selecting a function, otherwise inadvertent selection of the wrong
function may occur.
Avoid using sharp tools when operating the touch screen.
A pen to operate the touch screen can be found beside the internal printer. There are magnets in the face
of the instrument on either side of the touch screen to hold the pen temporarily when not in use.

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4.4..Help Function
To access the help function touch the ‘?’ button on the left side of the screen. During parameter entry the
help function can be accessed using the ‘?’ button beside the parameter field.

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5. Configuration of the Palltronic AquaWIT System
Prior to first use the following actions are recommended:-
•set the date and time, if required
•set up the system configuration (language, pressure unit etc.)
•configure the access management
•configure the Palltronic AquaWIT system settings
To access these functions touch the TOOLS button on the left side.
Level 3 access is required for these activities. The initial password is ‘Pall’ For details see
Section 5.3.
It is not possible to change the configuration of the system when a test is running.
Level 3 access is required to change the date/time and the system configuration and to configure the
access management. The default password for access is <pall>.
5.1..Basic configuration of the Palltronic Flowstar Instrument
5.1.1 Date/Time
The date and time settings can be accessed from the TOOLS Screen.
The following points can be defined under TOOLS and CONFIGURATION.
5.1.2 Language
The following languages are available:
English
English (US)
German
French
Spanish
Italian
Portuguese
Japanese
Chinese
The full list of available languages installed on an individual instrument can be seen in the
system configuration.
If the English (US) language option is selected the date display will automatically be in the format
MMM/DD/YYYY. In all other languages the date is displayed as DD/MMM/YYYY. The program will react
to a change in language as soon as the System Menu screen is exited.
5.1.3 Pressure Units
This button determines the unit for the input and output of pressure values. Pressure units may be shown
in mbar, psi, kp/cm
2
or kPa.