Pall Palltronic Flow Check II User manual

USD 2642
Instructions For Use
Palltronic®Flow Check II Unit
Part numbers: FC02, FC02M and FC02H

2
Contents
Saf ty and Information Symbols ...........................................................................................3
1. Saf ty Instructions .............................................................................................................3
1.1 Personal Safety ..............................................................................................................3
1.2 Safe Use of the Palltronic Flow Check II Unit..................................................................3
2. Introduction ........................................................................................................................4
2.1 Key Features and Benefits ............................................................................................4
2.2 Standard Functions........................................................................................................4
3. Using th Palltronic Flow Ch ck II Unit ............................................................................5
3.1 Features ........................................................................................................................5
3.3 Display Function ............................................................................................................6
3.3 Test Preparation ............................................................................................................6
3.4 Performing a ‘Flow Check’ Test......................................................................................7
3.5 Understanding the Test Results......................................................................................7
4. Maint nanc .......................................................................................................................8
4.1 Changing the Battery ....................................................................................................8
5. Troubl shooting..................................................................................................................8
5.1 Preliminary Troubleshooting............................................................................................8
5.2 Continued Difficulties......................................................................................................9
App ndix A – Atmosph ric Pr ssur Corr ction Tabl ......................................................10

Safety and Information Sym ols
Safety and information is identified in this instruction manual with the following symbols:
W rning! Identifies d ngerous situ tion where there is s fety risk nd person l injury m y follow.
Import nt: Identifies potenti lly d ngerous situ tion, risk to the equipment or other import nt
inform tion.
Note: Identifies user tips nd other useful inform tion.
1. Safety Instructions
W rning! Ple se re d the following instructions c refully nd completely before using the
P lltronic Flow Check II unit.
Ple se lso re d the Oper ting Instructions for the pplic ble integrity test instrument which will
be used with the P lltronic Flow Check II unit to ensure s fe use. The list of liter ture is s follows:
Tabl 1
Liter ture
Document Title Number
Palltronic Flowstar IV Integrity Test Instrument: Instructions for Use USD2594
Palltronic Flowstar C Integrity Test Instrument: Operating Instructions USD2005
Palltronic Flowmod Filter Integrity Test Instrument: Operating Instructions USD2223
Palltronic Flowstar MU Integrity Test System: Operating Instructions USD2292
Palltronic AquaWIT C Automatic Integrity Test System: Operating Instructions USD2363
Ple se cont ct your loc l P ll office or distributor if you require copy of the l test revision of
ny of these documents.
1.1 Personal Safety
• Appropriate protective clothing should be worn by operators (e.g., gloves and safety goggles)
when working with chemicals and compressed gas supplies during filter integrity testing.
• All pneumatic tubing used for integrity testing and with the Palltronic Flow Check II unit should
be rated to withstand the gas pressure used (up to 8 bar or 116 psi).
• The operator should check the tubing and connectors for damage before each use.
1.2 Safe Use of the Palltronic Flow Check II Unit
• The Palltronic integrity test instrument uses compressed air when in use and, therefore, caution
is necessary when disconnecting pneumatic connections from the Palltronic Flow Check II unit.
It is the user’s responsibility to ensure that an oil-free regulated gas supply is used during
operation of the Palltronic integrity test instrument and Palltronic Flow Check II unit.
• The maximum operating pressure of the Palltronic Flow Check II unit is 3.0 bar (43.5 psi) at a
maximum operating temperature of 40 °C.
• Do not exceed the maximum operating pressure.
• Compressed gas exits the Palltronic Flow Check II unit at low velocity through the ‘VENT’
port. To ensure correct and safe operation, the ‘VENT’ port must be open to atmosphere.
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2. Introduction
The Palltronic Flow Check II unit contains a capillary with a certified flow rate, protected against oil and
fluid contamination by an integral Gaskleen®filter on the ‘IN’ port.
The Palltronic Flow Check II unit can be used to perform a fast and simple check to verify the operation
and the calibration status of a Palltronic integrity test instrument. The Palltronic integrity test instruments
feature a ‘Flow Check’ test that will measure the flow rate through the Palltronic Flow Check II unit and
compare the measured value with the calibrated value supplied for the Palltronic Flow Check II unit.
If the deviation in flow measurement is less than 5% then the Palltronic integrity test instrument is
functioning and measuring correctly. This ‘Flow Check’ test should be performed regularly to show that
the flow measurement function of the Palltronic integrity test instrument is working correctly.
The Palltronic Flow Check II unit is used in place of a filter for the purposes of the ‘Flow Check’ test and
is available in three flow ranges:
Tabl 2
Flow R nges
Part Number Flow Rate Range Upstream Volume Requirements
FC02 8 ± 1 mL/min 0.5 to 2 meter hose
FC02M 90 ± 10 mL/min 0.5 to 2 liter vessel
FC02H 900 ± 50 mL/min 2.5 to 6 liter vessel
2.1 Key Features and Benefits
Within the pharmaceutical industry there is a regulatory requirement to integrity test filters both
before and after use in a production environment. Therefore, a fully functional integrity test
instrument is required to provide documentary evidence of filter integrity. The main benefit of the
Palltronic Flow Check II unit is to provide the operator with the ability to verify that a Palltronic
integrity test instrument is functioning and measuring correctly before using it to verify the
integrity of a critical filter.
2.2 Standard Functions
The Palltronic Flow Check II unit can be used to verify the operation and the calibration status
of a Palltronic integrity test instrument.
Import nt: The P lltronic Flow Check II unit c n be used to verify the oper tion of P lltronic
integrity test instrument th t displ ys ‘SERVICE!!!’ mess ge on screen, but it c nnot be used
to repl ce regul r c libr tion.
We recommend th t integrity test instruments undergo full service every 3 ye rs by P ll,
during which ll components re cle ned nd checked nd rec libr tion is c rried out.
A c libr tion is recommended t le st every 12 months. This c n be performed loc lly on site
or t n pproved P ll service centre. For more inform tion reg rding this, ple se cont ct your
loc l P ll office or distributor.
If the P lltronic integrity test instrument is displ ying ‘SERVICE!!!’, ple se consult the Oper ting
Instructions for th t instrument for further inform tion nd troubleshooting steps.

3. Using the Palltronic Flow Check II Unit
3.1 Features
The Palltronic Flow Check II unit provides two pneumatic ports, as follows:
Figur 1
The specification label attached to the enclosure displays the certified flow rate using air at an
atmospheric pressure of 1000 mbar (14.5 psi), the associated test pressure and the unit serial
number.
The display is switched on by pressing the button on the right hand side:
Figur 2
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1 = ‘Start’ Button
2 = Display
1 = Sp cification lab l
2 = ‘IN’ port
3 = ‘V nt’ port
2
2
3
1
1

6
On the rear side there is a serial port and the compartment for the battery:
Figur 3
3.3 Display Function
Pressing the ‘Start’ button activates the following display sequence
Tabl 3
Typic l Displ y Functions
Step Display Meaning
1 Device type
Serial number/Version number
2 Atmospheric pressure (Reference value)
Flow in mL/min (Reference value using air)
3 Actual temperature
Expected flow in mL/min (Corrected for ambient pressure)
4 Actual atmospheric pressure
Expected flow in mL/min (Corrected for ambient pressure)
5 Test pressure
Expected flow in mL/min (Corrected for ambient pressure)
The display changes from 3 – 5 until a timeout switches the display off after 10 minutes to
conserve battery power.
The display can be switched off manually by pressing the start button for more than 5 seconds.
This is recommended to extend the battery life.
The unit displays the pressure in mbar only.
The test pressure is normally 2000 mbar (29 psi, 200 kPa, 2.039 kp/cm2).
3.3 Test Preparation
The integrity test assembly (comprising the Palltronic Flow Check II unit and the integrity test
instrument) should be brought to room temperature (between 18 °C and 25 °C) before
conducting a ‘Flow Check’ test.
Import nt: Oper ting the P lltronic Flow Check II unit brought from cold environment to
w rm environment c n c use condens tion to form within the c pill ry. The c pill ry is
extremely sensitive to w ter nd will ce se to function if w ter is llowed to form within or enter
the P lltronic Flow Check II unit.
• Connect the ‘OUT’ port of the integrity test instrument to the male Stäubliu‘IN’ connection on
the Palltronic Flow Check II unit. If an upstream volume is required (see Section 2) then this
should be connected between the integrity test instrument and the Palltronic Flow Check II unit.
1 = Batt ry compartm nt
2 = S rial port (S rvic us only)
2
1

Note: The remote vent v lve m y be ddition lly inst lled between the integrity test instrument
nd the P lltronic Flow Check II unit (or between the integrity test instrument nd the upstre m
volume, if required) so th t le ks within the remote v lve m y be detected. Therefore, should
the Flow Check test f il, ple se repe t the Flow Check test without the remote vent v lve
tt ched to determine whether the remote vent v lve is the c use of the f ilure or not.
• Ensure that the ‘VENT’ connection on the Palltronic Flow Check II unit is open to atmosphere.
• It is recommended that the red pneumatic tubing supplied with the Palltronic Flow Check II
unit be used exclusively for this purpose. It is also highly recommended that this tubing is
kept clean and dry. In this way accidental contamination of the internal capillary within the unit
can be mitigated.
Import nt: Although the P lltronic Flow Check II unit h s n integr l G skleen filter in order to
limit the possibility of cont min ting the intern l c pill ry, the oper tor should still t ke gre t
c re to void cont min tion. Should either the integr l filter or the c pill ry become
cont min ted, d m ged or blocked, the oper tion of the P lltronic Flow Check II unit will be
severely compromised.
3.4 Performing a ‘Flow Check’ Test
Note: The following test procedure ssumes th t the integrity test instrument provides
dedic ted ‘Flow Check’ test (see your integrity test instrument Oper ting Instructions for the
instrument c p bilities). If the dedic ted ‘Flow Check’ test is not v il ble, ‘Forw rd Flow’ test
m y be used inste d. In this situ tion, the ‘Expected Flow’ becomes the ‘M ximum Flow’ test
p r meter nd the p ss/f il result t the end of the test should be ignored: refer inste d to
Section 3.5 for the interpret tion of the result.
• Select a ‘Flow Check’ test on the Palltronic integrity test instrument (for more information, see
the relevant Operating Instructions for your integrity test instrument).
• Enter the following test parameters (and where indicated by 1below, using the relevant values
displayed by the Palltronic Flow Check II unit in use, see also Section 3.2.
Test Pressure1: 2000 mbar (29 psi)
Test Time: 600 seconds
Ref. Unit Serial No.1: 1234567
Expected Flow:1X.XX m /min
• Press the ‘Start’ button on the Palltronic integrity test instrument to activate the
‘Flow Check’ test.
• On completion of the test (i.e. after the test time has elapsed), the measured value will be
given with a percent deviation value between the measured and the expected values (if the
dedicated ‘Flow Check’ test has been used).
Note: After use, the P lltronic Flow Check II unit should be c refully disconnected from the
P lltronic integrity test instrument, the protective c ps should be repl ced on the inlet nd vent
ports nd the unit stored in dry pl ce t room temper ture.
3.5 Understanding the Test Results
The test result will be reported as a flow rate value. Under stable test conditions, the Palltronic
integrity test instrument should be within ± 5% of the expected flow value displayed by the
Flow Check II unit.
The expected flow value is calculated from the reference value (as shown on the side of the
Palltronic Flow Check II unit and on the calibration certificate provided with the Palltronic Flow
Check II unit) by compensating for any variation in atmospheric pressure.
If the dedicated ‘Flow Check’ test has been used, the percent deviation value will be calculated
and presented by the integrity test instrument. If, however, the integrity test instrument does not
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provide a dedicated ‘Flow Check’ test, the following calculation may be used to determine the
deviation value from the ‘Forward Flow’ test result:
Equation 1
Devi tion V lue from Forw rd Flow Test Result
Note: A low me sured flow v lue m y indic te the presence of moisture in the intern l c pill ry.
In this c se, it is recommended to blow cle n, dry ir t 2 b r (29 psi) pressure for 2 hours
through the P lltronic Flow Check II unit.
If test results are consistently outside the 5% limit, please contact your local Pall office or
distributor as either the Palltronic Flow Check II unit or Palltronic integrity test instrument may
require service and/or calibration.
4. Maintenance
The Palltronic Flow Check II unit requires no maintenance except that the battery should be
changed when required.
4.1 Changing the Battery
Open the black cover of the battery compartment by using a coin or a screwdriver.
Remove the old battery and replace it by a new 1.5 V battery type AA ( R06/AM-3)
The negative (–) terminal of the battery should be inserted into the unit.
Close the battery compartment.
After changing the battery the ‘Battery failed’ message can be erased by pressing the ‘Start’
button for more than 5 seconds to switch the unit off.
Used batteries should be discarded in accordance with relevant local and national regulations.
The battery will be replaced as part of a standard service and calibration at a Pall facility.
5. Trou leshooting
5.1 Preliminary Trou leshooting
If any difficulties are experienced with the value measured through the Palltronic Flow Check II
unit, please try the following:
• If the display cannot be activated by pressing the button on the right side, then replace the
battery
• It is possible to operate the Flow Check II unit without the display switched on or
with no battery installed. In this case the atmospheric pressure should be
measured using an independent method of measurement. The reference value of
flow shown on the label should then be corrected by multiplying by the correction
factor given in Appendix A.
• Check that the Palltronic Flow Check II unit is correctly connected to the integrity test
instrument
• Check if the environmental temperature is out of the recommended range between 18 °C
and 25 °C.
• Check that the integrity test instrument is correctly supplied with the appropriate air supply
and that the air supply is oil and water free
Deviation (%) = Measured flow – Expected flow
Expected flow x 100

Note: The Flow Check II instrument is c libr ted with ir. If it is intended to use Nitrogen or
other g ses the expected flow v lue will not be correct. Ple se cont ct your loc l P ll office or
distributor if it is intended to use g s other th n ir.
• Ensure that the Palltronic Flow Check II unit is dry – if you suspect that the moisture is
present in the internal capillary, it is recommended to blow clean, dry air at 2 bar (29 psi)
pressure for 2 hours through the Palltronic Flow Check II unit
Note: If the intern l c pill ry h s moisture present or is cont min ted, the flow me sured by the
integrity test instrument will be low comp red to the expected v lue. The displ y on the Flow
Check II unit will still show the expected v lue, corrected for the mbient pressure.
• Check that the test parameters (especially test pressure) are set correctly – these details are
available with the Palltronic Flow Check II unit, see Section 3.4 for more information.
• If the remote vent valve is installed, repeat the Flow Check test without the remote vent valve
to determine whether the remote vent valve is the cause of the failure or not.
If test results are consistently outside the 5% limit, please contact your local Pall office or
distributor as either the Palltronic Flow Check II unit or Palltronic integrity test instrument may
require service and/or calibration.
5.2 Continued Difficulties
If following the steps in Section 5.1 has not solved the problem or additional technical support
is required (available as a charged service), please contact your local Pall office or distributor.
Supplying a detailed written description of the problem will facilitate a quick response.
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Appendix A – Atmospheric Pressure Correction Ta le
The flow value measured with the Palltronic Flow Check II unit is dependent on atmospheric pressure and is
given as a reference value normalized for an atmospheric pressure of 1000 mbar (absolute), using air. The unit
measures the actual atmospheric pressure which is influenced by the altitude and the actual atmospheric
conditions and displays a corrected “expected” value. Table 4 shows the influence of the atmospheric pressure
on the capillary flow value.
Tabl 4
Atmospheric Pressure Correction V lues
(mbar)
Atmospheric Pressure
(kPa) (psi)
Approx. Altitude
Above Sea Level
‘Expected Flow’
Deviation (%)
Correction
Factor
1070
1060
1050
1040
1030
1020
1010
1000
990
980
970
960
950
940
930
920
910
900
890
880
870
860
850
840
830
820
810
800
790
780
770
760
750
740
730
720
710
700
107.0
106.0
105.0
104.0
103.0
102.0
101.0
100.0
99.0
98.0
97.0
96.0
95.0
94.0
93.0
92.0
91.0
90.0
89.0
88.0
87.0
86.0
85.0
84.0
83.0
82.0
81.0
80.0
79.0
78.0
77.0
76.0
75.0
74.0
73.0
72.0
71.0
70.0
15.52
15.37
15.23
15.08
14.94
14.79
14.65
14.50
14.36
14.21
14.07
13.92
13.78
13.63
13.49
13.34
13.20
13.05
12.91
12.76
12.62
12.47
12.33
12.18
12.04
11.89
11.75
11.60
11.46
11.31
11.17
11.02
10.88
10.73
10.59
10.44
10.30
10.15
+3.5
+3.0
+2.5
+2.0
+1.5
+1.0
+0.5
0.0
-0.5
-1.0
-1.5
-2.0
-2.5
-3.0
-3.5
-4.0
-4.5
-5.0
-5.5
-6.0
-6.5
-7.0
-7.5
-8.0
-8.5
-9.0
-9.5
-10.0
-10.5
-11.0
-11.5
-12.0
-12.5
-13.0
-13.5
-14.0
-14.5
-15.0
1.035
1.030
1.025
1.020
1.015
1.010
1.005
1.000
0.995
0.990
0.985
0.980
0.975
0.970
0.965
0.960
0.955
0.950
0.945
0.940
0.935
0.930
0.925
0.920
0.915
0.910
0.905
0.900
0.895
0.890
0.885
0.880
0.875
0.870
0.865
0.860
0.855
0.850
0 m
250 m
500 m
750 m
1000 m
1250 m
1500 m
1750 m
2000 m
2250 m
2500 m
2750 m
3000 m
0 ft
750 ft
1500 ft
2250 ft
3000 ft
3750 ft
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6750 ft
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