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Laboratory Instruments

SERVICE MANUAL

VAPODEST 10sn

Introduction

Special Remark

Identify Parts

Theory of Operation

Troubleshooting

Maintenance

V1.30.2 11/12
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Special Remark

The novoprene tubing may stick in the closed position - although the solenoid pinch valve
for STEAM is activated. This would lead to an excess pressure error message.

To protect against this risk the functionality of the system has been changed.

When the instrument is switched ON, the solenoid pinch valve for STEAM is initialized 3
times.
When a distillation is started, the heating power is switched on and the steam generator is
heated up until the temperature of 115C is reached.
Now the heating power is reduced to 30% and the system is pre-filled with steam for
some seconds.
Now the distillation process is started and the solenoid pinch valves are activated.

If there is an excess pressure signal during the distillation, first the ventilation valve will be
switched for 2 seconds. If there is still an excess pressure signal coming from the excess
pressure switch, then the appropriate error message will be generated.

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Table of contents Service Manual Vapodest 10sn

1. Introduction for users of the Service Manual Vapodest 10sn

2. Identification of parts


2.1 Front View Vapodest 10sn

2.1.1 Screw caps and seals

2.1.2 Condenser and distribution head

2.1.3 Ventilation valve

2.1.4 Inlet tubing STEAM

2.1.5 Others


2.2 Rear View Vapodest 10sn

2.2.1 Tubing NaOH and non-return valve

2.2.2 Tubing connection module



2.2.3 Pump-holding module

2.2.4 Clamping device

2.2.4.1 Micro switch

2.2.5 2nd condenser and tubings

2.2.6 Solenoid pinch valves

2.2.7 Steam generator

2.2.7.1 Steam generator bottom

2.2.7.2 Pressure switch

2.2.8 PCB Module

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3. Theory of operation

4. Troubleshooting

4.1 Service menu

4.2 Maintenance menu

4.3 Connecting Control PCB

5. Maintenance

6. Firmware Update

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1. Introduction

This manual was written exclusive for the service staff of C. Gerhardt GmbH & Co. KG and for the service
staffs of our international agencies.

This service manual shall help to get a deeper knowledge of how the instrument is constructed and how it
works. It is an important tool to service and repair the instrument in a safe, competent and specific way. The
transparent structure will enable to order and to store the most useful spare parts. This manual will make
servicing easier, in particular for our international agencies.

To provide yourself against risks during operation or service, the following safety instructions should be
obeyed:

Make sure that no liquid gets into contact with cable conntections or the interior of the
electrical parts of the unit! Danger of electrical shock!

Repairs on electrical, electronic or mechanical parts must only be done by authorized


personnel.

Always switch off the apparatus at the mains and pull the plug before opening! Danger of
electrical shock!

The apparatus must be used according to the instruction manual. It is not allowed to make changes to the
apparatus in order to modify its application.

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2.1 Front View VAP 10sn
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2.1.1 Screw caps and seals
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1004322 Screw cap GL45, open


1000357 Silicone seal GL 45

1004321 Screw cap GL18, open 1000356 Silicone seal GL18

1004320 Screw cap GL14, open


1000358 Silicone seal GL14, with tubing
connection

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2.1.2 Condenser and distribution head
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b d

a) 12-0363 Distribution Head c) 1000058 Condenser


b) 12-0351 Vitone Cone d) 1000496 Silicone tubing, 8/12, 20cm

e) 1000536 Clamp for 12-0363 and 1000058


f) 1001079 Screw

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2.1.3 Ventilation valve
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a) 1000036 Ventilation valve for condenser


b) 1000484 Silicone tubing, 6/10, 12cm

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2.1.4 Inlet tubing STEAM
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a) 1002178 PTFE-Inlet tubing, STEAM


b) 1000630 PTFE-sieve
c) 1000250 PP tube joint

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2.1.5 Others
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1000399 Drip Tray 1000391 Hinge (pair)

1003487 Magnetic door switch

This is the mounting hole for the


magnetic door switch.
It is located behind the bottom hinge.

1001263 Front Door

1000392 Handle for front door

1001875 Magnet for Door switch

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2.2 Rear view VAP 10sn
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2.2.1 Tubing NaOH and non-return valve
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1003401 PTFE - tubing, NaOH

1003396 Clamp

1000493 Tubing, Isoversinic

1000081 Non - return valve

1000659 Clamp

1000495 Tubing, Viton

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2.2.2 Tubing connection module
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1000363 Cooling water inlet valve


(with pressure switch, > 0,5 bars)

b d

a: Inlet for H2O Steam generator

b: Outlet for condensed steam from 2nd condenser

c: Inlet for NaOH

d: Outlet for cooling water

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2.2.3 Pump holding module
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1005988 Pump H2O steam generator

1000070 Tubing connector, 6mm 1000071 Tubing connector, 8mm

1004794 Dosing pump NaOH

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2.2.4 Clamping device

1000537 Clamping device for sample tube, complete


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1000390 Spring

1000290 Micro switch

1001303 Wedge, complete with axis

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2.2.4.1 Micro switch
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with sample tube inserted:

closed

without sample tube:

open

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2.2.5 2nd Condenser and tubings
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1000497 Silicone tubing

1003904 Silicone tubing

1000484 Silicone tubing

1000496 Silicone tubing

1003904 Silicone tubing

1003274 2nd condenser 1000497 Silicone tubing

1000359 Tubing connector, angle

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2.2.6 Solenoid pinch valves
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1002289 Novoprene tubing 1000141 Plug with rectifier and seal

1006039 4-way connector

1000048 Ventilation glass 1000090 Pinch valve

1000091 Tubing holder (guidance)

1003705 angle connector

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2.2.7 Steam generator

1005987 Steam generator, complete


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Inlet for H2O for steam generator Outlet for steam

1005989 Pressure switch (for excess pressure)

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2.2.7.1 Steam generator bottom

1003482 Excess-temperature switch, 190C


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1005128 Thermoelement
2.2.7.2 Pressure switch

Switch connectors:
1+3

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2.2.8 PCB module

1000233 Semiconductor Relais


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(Solid State Relais / SSR)

1005985 Control PCB 1005986 Noise filter PCB

1000229 Mains switch


1004842 Mains socket
1001358 Excess current switch, 10A

1004888 Adhesive foil, front


View from front:
1004325 Knob

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3. Theory of operation

When the instrument is switched ON, the main menu is shown and the illumination of the
display is green.
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If the instrument detects an error condition, the illumination of the display will change to red
and an error message will be generated. Any error will stop the distillation.

There is a difference between non-critical errors and critical errors:

Non-critical errors are written on the display and can be solved by the customer. As soon
as a non-critical error is solved, the display will change to green and the system is operatio-
nal again. (door open, cooling water, sample tube, etc.)

Critical errors can not be solved by the customer. There is no written error message, but a
calculated error number which should be noted.
The error number is in decimal format and must be converted back to a binary format (8-bit).
Each bit represents an specified error condition and it is possible that more than one error is
shown at the same time.

Under normal conditions there is already water inside the steam generator. If now START is
pressed, the display illumination will change to yellow and the message Heating is shown.
Also [Abort] is available now. Heating phasis is ready as soon as the steam generator has
reached 115C. Distillation has started now and the remaining distillation time is shown in
the display. Now also [Add NaOH] is available.

If during the distillation the door is opened ( for example), the display will change to red and
the error message is written in the display. Also the remaining distillation time is written.
When the door is closed again, the display will change to green and the distiilation can be
continued with [Continue] or can be stopped with [Abort].

If the VAP10sn can not suck water for the steam generator when the distillation is started,
the temperatur of the steam generator will increase too strong and heating will be stopped.
There will be a message System filling. Now, the pump will run for a couple of seconds
continuously and is trying to cool down the steam generator. If the temperature was able to
decrease, the instrument can operate normally again.
If the temperature can not decrease enough, the cooling process is stopped, the unit returns
to the main menu and shows the water tap pictogram.

It is mandatory to use the instrument only with a connected level sensor for the distilled
water reservoir. If the level sensor is connected, the system will recognize low water level
and is able to adjust the whole filling process.
If the level sensor is not connected and low water will happen, the steam generator will over-
heat, the display will change to red and the message System overheated will be shown.
The message will disappear when the steam generator has cooled down again, but the
water tap pictogram will remain in the display.

OVERHEATING WILL DESTROY THE STEAM GENERATOR!

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If the pressure of the cooling water is lower than 0,5 bars for more than 10 seconds, then
the distillation is paused, the display will change to red and the message Low water pres-
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sure will appear. If the pressure is back again, the display will change to green again and
the distillation can be continued.

Water tap pictogram:

This sign will indicate that there is no water inside the steam generator. The display still will
stay green and the system is operational. The user should check that there is enough of
distilled water and that the tubing is fitted properly.
As long as the water tap pictogram is shown, previous to a distillation the system will try to
fill water for 6 seconds. Heating power is reduced to 60%. As soon as the system allows to
start the distillation the water tap pictogram will disappear.

New systems will manually be set into this water tap pictogram condition. This will allow an
initial filling of the steam generator.

It is possible to set the system manually into the initial filling mode (water tap pictogram):

- While the instrument is switched OFF, set the service jumper into the MAINTENANCE-
Position.
- Now, press the knob at the front of the unit and at the same time
- While the knob is pressed switch ON the unit.
- Now you can release the knob.
- Switch OFF the unit
- Disconnect the service jumper and put it into PARKING-POSITION
- Switch the unit ON again

Now the water tap pictogram should be indicated in the upper right corner of the display.

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4. Troubleshooting

Critical errors can not be solved by the customer. There is no written error message, but a
calculated error number which should be noted.
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The error number is in decimal format and must be converted back to a binary format (8-bit).
Each bit represents an specified error condition and it is possible, that more than one error
is shown at the same time.

Bit Error Description


1 Heating element defective or power interrupted (excess temperature switch)
2 Steam generator not heating up or heating too slow
3 Temperature sensor defective or not detected
4 Excess pressure switch activated
5 Watchdog-Reset: internal software error or processor defective
6 Door switch or mikroswitch for sample tube
7 Low pressure cooling water
8 External tank for H2O empty or level sensor not connected

Example: On the display is shown error number 6

In binary format the 6 is 0000 0110. Here Bit2 and Bit3 are active which means, in our
example there is a problem with the steam generator and the temperature sensor.

Steam generator:

A defective steam generator can be recognized indirectly.

If the system is not able to reach the operating temperature within a certain time, it is
presumed that there is a defect and an error number will appear. An error number will also
appear if during distillation the temperature is decreasing too much.

If there is a very strong overheating, the system is protected by an mechanical excess


temperature switch (bimetal) and the power circuit is cut.
After cooling down, this excess temperature switch will reset automatically and the power
circuit is closed again. If the system is started but it is not cooled down, an error number will
be generated again.

Temperature sensor:

The electronics is communicating with the temperature sensor continuously. If the tempera-
ture value is not valid, or if the communication is lost, after 1 second an error number will be
generated.
It is very important that the temperature sensor is tightened correctly!

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Excess pressure switch:

The pressure is checked continuously. If the pressure increases too much the appropriate
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error number will appear.


There may be different reasons for an excess pressure. First of all the system presumes
that the tubing in the pinch valve for steam is sticky so that it can not release the steam.
This is why both solenoid pinch valves are activated again for 2 seconds - trying to release
the tubing.
If there is still an excess pressure then the eror message will be shown.

It will only disappear if the temperature is lower than 80C when the system is started again.

EXCESS PRESSURE WILL DECREASE THE LIFETIME OF THE STEAM GENERATOR!

4.1 Service menu

To enter the service menu, switch on the instrument while the knob is pressed.

Rinsing steam generator:

Make sure that there is enough of water in the reservoir for distilled water. When the rinsing
process has been started, the message Cleaning process running is written in the display.
The water pump is running continuously and the heating power is about 60%. The water is
heated up and since the pump is running all the time, the steam generator is rinsed.

There are two ways to stop the rinsing process:

a)
When [Abort] is selected, the message Process ending will be shown and the water pump
will be switched off. Now all the water inside the steam generator will be steamed out and
as soon as the temperature begins to increase up to 100C the process is stopped. The
system is ready for use again now.

b)
Since it is mandatory to use the VAP10sn only when the level sensor is connected, the
system will detect when the reservoir is empty. Then the rinsing process will be stopped
automatically and the system will return to the main menu.

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Attention:
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During the rinsing process the cooling water may reach a temperature of
about 40C!

During the rinsing process the rinsing water may reach a temperature of
about 60C!

Pump calibration:

During the pump calibration, the pump for NaOH will run for 10 seconds. Using a measuring
beaker, the delivered volume can be determined and the value can be entered using the
wheel knob. Press the knob to save the value

During the pump calibration, the pump for water will run for 30 seconds. Using a measuring
beaker, the delivered volume can be determined and the value can be entered using the
wheel knob. Press the knob to save the value.

The pumps and tubings must be prefilled and free of air bubbles to guarantee a successful
calibration.

Language:

Using the wheel knob, the desired langue can be selected and saved by pressing the knob.

Contrast:

Using the wheel knob, the desired contrast can be adjusted and saved by pressing the
knob.

Altitude data:

The boiling point of water decreases when the altidude is increasing. This is the reason why
the altitude data must be adjusted.
At 0 meters above sea level the boiling point is approx. 100C.
At 2500 meters above sea level the boiling point is approx. 93C.

The altitude data can be adjusted in steps of 500 meters.

Wrong altitude data may result in malfunctions and may destroy the steam generator.

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4.2 Maintenance menu

The maintenance menu must only be used by qualified and trained


service engineers.
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C. Gerhardt does not take any responsibility for mishandling!

The maintenance menu allows to check the status of all sensors and it allows to test the
function of all connected actuators.
When using the maintenance menu, all temperature control is deactivated!

How to enter the maintenance menu?

Switch OFF the instrument and open the rear cover. Set the jumper from Parking position
to Service position and switch ON the unit.
The display will change its colours and then service mode is active.

Jumper in parking position

Jumper in

Service position

Do not forget to put the jumper back to parking position when service is
done!
Instrument must be switched OFF while resetting the jumper!

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Sensors:
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This sub-menu allows to read out the available sensors. The values are shown on the
display.

Temp Temperature of the steam generator in C. There is a X if there is no


connection to the temperature sensor
Drck X if the steam generator has excess pressure, else 0
Tr X if the door is closed, else 0
Glas X if a sample tube is inserted, else 0
KW X if preesure of cooling water is OK, else 0
Tank X if external reservoir H2O is full enough, else 0

Actuators:

This sub-menu allows to activate and test all available actuators. The actuator in question
can be selected by using the wheel knob. Pressing the knob will switch ON, pressing again
will switch OFF.
0 = OFF, X = ON

When in maintenance mode, the heating power is limited to 65%. As long as the steam
generator is heating there is a X
When the steam generator is not heating due to the limitation, there is
When the steam generator is switched OFF there is 0.

There is no protection for the steam generator when in maintenance


mode. When the steam generator has been activated manually, the
temperature value in the display must always be observed. As soon as
the temperature reaches 110C the steam generator must be switched
OFF and cooled down.

The emergency cool down for the steam generator at 115C is


deactivated when you are in maintenance mode!

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Operating Voltage:
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The VAP10sn allows to adjust the electronics to the local voltage in the lab. This is to
ensure a constant steam power at any location.
The steam generator has a power of 1,7 kilowatts when used with 230V. If the voltage in
the lab is significant lower or higher, the voltage setting in the maintenance menu should be
used. The voltage can be selected by using the wheel knob and can be saved by pressing
the knob. If the adjustment was successful the display will change to green for a short time.
Otherwise it will change to red and the voltage adjustment must be repeated.

The voltage must also be adjusted when the steam generator has been replaced and
during the regularly preventative maintenance.

System:

Here is shown

- the type of instrument


- the serial number of the electrinics module/instrument
- the number over overheatings
- the number of excess pressure

These numbers C. Gerhardt will ask for whenever there are service issues and/or warranty
issues with VAP10sn.

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4.3 Connecting Control PCB
Since momentarly a wiring diagram is not available, the following list will help you to re-
connect all plugs and wires.
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P 6 Thermoelement


P 5 Door switch

P 7 Microswitch for sample tube

P 9 Pressure switch cooling water

P10 Level sensor external tank

P11 Pump H2O

P12 Heating element

P13 Pressure sensor steam


P16 Pinch valve 1 (right)


P 3 free

P 4 Valve cooling water

P 1 Pump NaOH

P14 free

P15 Pinch valve 2 (left)

J 3 Mains

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5. Maintenance

At least every 12 months a preventative maintenance should be performed for VAP10sn.


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Also for VAP10sn a Preventative Maintenance Kit is available with the minimum of required
parts.
The maintenance must be performed by following the Preventative Maintenance Form for
VAP10sn. This will keep the instrument in a good and reliable condition - in the best case
without failures or downtimes.

The actual Preventaive Maintenance Kit xxxxxxxxx for VAP10sn consists of:

1,5 meter 1002289 Novoprene tubing

0,5 meters 1003904 Silicone tubing

0,25 meter 1000496 Silicone tubing

1 piece 1000081 Non-return valve

1 piece 12-0351 Vitone cone

2 pieces 1000356 Seal GL18

1 piece 1000357 Seal GL32

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6. Firmware Update
VAP10sn allows the user to perform a firmware update.
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The D-SUB connector at th erear of the instrument must be connected with a free COM-
Port of the PC. For this connection a 1:1 cable must be used.

Update:

The instrument must be switched OFF.

- Take your PC and create a new folder >> FIRMWARE


- Open folder FIRMWARE and create a subfolder>> exe
- Copy the files FBOOT.EXE and Vapodest.hex into this subfolder
- Copy the file Vapodest.exe into FIRMWARE
- When VAP10sn is switched off, connect your PC and the VAP10sn via RS232
- Start Vapodest.exe and select 1-Firmware-Update
- Select COM port
- Switch ON the VAP10sn
- When update is finished, switch VAP10sn OFF and ON again.
- Enter all configuration data and program, recalibrate.

The above mentioned files FBOOT.EXE, Vapodest.hex and Vapodest.exe will be provided
by C. Gerhardt if there is a firmware update available.

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