Malvern Instruments Limited

Grovewood Road, Malvern

Worcestershire, WR14 1XZ, UK

Tel +44 1684 892456

Fax +44 1684 892789

www.malvern.com

PARTICLE SIZE
MASTERSIZER 3000
AERO SERIES
DRY DISPERSION UNITS
MAN0481
MRK1956-01

MRK1956-01_AERO_dry_disp_units_cover_58pp.indd 1 28/08/2013 12:48:11

Aero series dry
dispersion units
MAN0481-04-EN-00 March 2015
Copyright © 2011, 2014, 2015 Malvern Instruments Ltd.

Malvern Instruments pursues a policy of continual improvement due to technical development. We

therefore reserve the right to deviate from information, descriptions, and specifications in this
publication without notice. Malvern Instruments shall not be liable for errors contained herein or
for incidental or consequential damages in connection with the furnishing, performance or use of
this material. No reproduction or transmission of any part of this publication is allowed without the
express written permission of Malvern Instruments Ltd.

Head office:

Malvern Instruments Ltd.

Enigma Business Park,
Grovewood Road,
Malvern,
Worcestershire WR14 1XZ
United Kingdom.

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 Table of contents
Introduction and hardware
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Aero dispersion units - overview . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Aero dispersion units - description . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Aero dry cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Connecting the Aero dispersion units . . . . . . . . . . . . . . . . . . . . . . 1-23

Software and Control

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Making a measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control of a Dispersion unit via an SOP . . . . . . . . . . . . . . . . . . . . . 2-2
Manually controlling the dispersion unit . . . . . . . . . . . . . . . . . . . . . 2-6

Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Consumable kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Appendix
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Chemical compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Regulatory Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Aero Series Dispersion Units Page i

 Table of Contents Aero Series Dispersion Units

Page ii MAN 0481

 1

Introduction
and hardware
Introduction
This manual details the important features of the Mastersizer 3000 Aero series dry
sampling dispersion units.

Dispersion unit Description Model number

Aero S Automatic dry dispersion unit MAZ3500
- Options include stainless steel and
ceramic venturi dispersers
Aero M Manual dry dispersion unit MAZ3550
- Options include stainless steel and
ceramic venturi dispersers

The Aero S dispersion unit is designed for use with the Mastersizer 3000. It
cannot be used with the Mastersizer 3000E.
The Aero M dispersion unit is designed for use with the Mastersizer 3000E
only. It cannot be used with the Mastersizer 3000.

This manual is a supplement to the following manuals:

 Mastersizer 3000 User Manual
 Mastersizer 3000 Basic Guide

Warning!
The dispersion units or the samples to be measured may be hazardous if
misused. Users must read the Health and Safety information in the
Mastersizer 3000 Basic Guide before operating the system.

This manual focuses on specific issues of the Aero series dry dispersion units that
are not covered by the above manuals. Within the following chapters the manual
will detail:

Aero series dry dispersion units Page 1-1

1 Chapter 1 Introduction and hardware

Introduction and Hardware

This chapter serves as the introduction to the dispersion units and describes what
the Aero dispersion units are and explains in simple terms how they work. It also
identifies the physical features of each model of the dispersion units and how to
connect each one to the Mastersizer optical unit.

Software and Control

This chapter describes the Aero software controls identified in the Mastersizer
3000 user manual and explains how to use the dispersion units to make measure-
ments on the system.

Maintenance
This chapter covers all the user maintenance procedures for the dispersion units.
This includes a maintenance schedule and associated maintenance procedures for
inspecting and cleaning each dispersion unit and its respective components. Spe-
cific procedures for inspecting and cleaning the flowcell windows are described.

Appendices
This chapter details the useful specifications of each dispersion unit and identifies
the chemical compatibility of the dispersion unit components that may come into
contact with the sample. Additionally it provides the important regulatory informa-
tion to which the dispersion units are compliant.

Page 1-2 MAN 0481

Introduction and hardware Chapter 1

Aero dispersion units - overview

What do the Aero dispersion units do
The sole purpose of any sample dispersion unit is to prepare the sample and then
deliver it to the optical unit so that it can be measured.
The Aero dispersion units allow the Mastersizer to be used for particle-in-gas parti-
cle sizing; in the majority of cases the gas will be air.
The materials used in the manufacture of the dispersion units maximise the range
of materials that can subsequently be handled. Direct software control over the feed
rate and air pressure is provided, which enables flexible control of both the sample
throughput and dispersion. This allows a wide range of particle sizes and densities
to be suspended and delivered to the optical bench, enabling adequate dispersion
and representative sampling prior to a measurement being performed.

Aero dispersion units

The Aero units are fitted with a venturi disperser. The disperser is stainless steel for
standard sample measurements, and ceramic when measuring more abrasive sam-
ples. The software will automatically recognise which disperser is in use.

4 5 2 3 1

ill 8867

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Chapter 1 Introduction and hardware

Note
For clarity the Aero images in this manual are shown with the (right-
angled) high energy disperser fitted. When the (straight) standard disperser
is fitted the Aero unit will be positioned facing to the right along the bench.

Control of the Aero dispersion units

The Aero dispersion units can be controlled by two methods - both via the Master-
sizer application software.
 Automatically as part of measurement protocol when controlled through a
Standard Operating Procedure (SOP). The software will tell the user what
interaction they will need to do as the measurement progresses.
 Alternatively the dispersion unit can be controlled by a separate manual acces-
sory control dialogue. This will enable simple control of the dispersion unit,
allowing individual selection and operation of the units functionality. This is
useful for performing evaluation methodology before constructing a SOP.

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Introduction and hardware Chapter 1

Aero dispersion units - description

The following section explains the important aspects of the Aero dispersion units:
 How the sample dispersion is performed.
 The main features of the dispersion units.
 How to connect the dispersion unit to the Mastersizer optical unit and other
accessories.

How is the dispersion performed

The dry powder sample is manually placed in the sample hopper (Aero S only)
fitted to the top of the sample feed tray of the dispersion unit . Additionally an
optional mesh basket, and added ball bearing, can be used to help smooth the flow
of sample and break up any loose agglomerates within the sample before it falls into
the disperser.

1 2

ill 8868

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Chapter 1 Introduction and hardware

The air supply and vacuum extraction system is then connected and the sample tray
vibrated.
With the sample feed tray vibrating the sample exits the hopper and travels down
the tray until it eventually falls into the main feed mechanism - the venturi dis-
perser.
The rate at which the sample is fed into the venturi disperser is governed by the
amplitude of vibration on the feed tray, (controlled from the software) and also by
the gap set between the feed tray and hopper (Aero S) or tray gate (Aero M) on the
sample tray.
As the sample falls through into the funnel of the venturi disperser, it is accelerated
by compressed air within the centre of the venturi disperser where agglomerates are
dispersed. The sample is then directed through the dry cell  fitted to the Master-
sizer optical unit, where it is measured and then collected by the vacuum extracting
system at the rear of the dry cell.

Features of the Aero dispersion units.

This section identifies the main features of the Aero dispersion units.

9 9 6 7 8

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Introduction and hardware Chapter 1

 Sample area lid  CAN connection

 Air intake / noise reduction fitting  Auxiliary connection
 Sampling area  Feet
 Status indicator  Lifting holds
 Air in connector

Sample area lid

The sample area unit lid is primarily a safety feature that protects the user from the
sample being measured and also reduces the sound emissions from the dispersion
unit. The lid must be firmly closed to ensure that sound emissions are reduced to
an adequate level. A magnetic catch is incorporated in the cover assembly to ensure
the lid is securely closed before any measurement is begun.
The lid is interlocked so the dispersion unit automatically returns to standby
mode if it is opened during a measurement. It is therefore important that the sam-
ple is added to the sample tray before the measurement is started.
Air intake filter / noise reduction fitting

Warning!
Do not run the dispersion unit without the air filter fitted, otherwise
acceptable sound emissions will be surpassed.

The fitting on the lid allows clean filtered air to be drawn into the sample area.
Using the dispersion unit without the filter will affect the measurement perfor-
mance and create excessive noise levels.

Sampling area
The sampling area is where the sample is added into the dispersion unit prior to
being measured. There are five primary parts to the sample area; these are described
below in the order the sample would progress through the sampling area.

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Chapter 1 Introduction and hardware

D
A

ill 8783

 Sample hopper  Sample tray lock

 Sample flow control  Venturi disperser
 Sample tray

 The Aero M is the same but uses a different flow control / tray arrangement.
There is no sample hopper on the Aero M.

Sample hopper and flow control (Aero S)

The sample hopper and sample tray (described below) are supplied together as a
complete paired assembly.
 Different sample tray types are available that can be used for sampling different
grades and sizes of sample. Encoding in the sample tray and hopper will auto-
matically identify the hopper/tray pair when it is attached to the dispersion
unit, with it automatically detected and reported in the sample measurement
and records.

Note
If a tray is used that requires a hopper, then the hopper must be fitted, or
the unit will not work and will stay in standby mode until the hopper is
inserted.

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Introduction and hardware Chapter 1

The hopper attached to the sample tray is used as a method of controlling the flow
rate of the sample into the tray and subsequently also into the venturi disperser.
This is done by rotating the top of the hopper, therefore varying the aperture gap
between them. The hopper has markings positioned around the hopper to indicate
the setting of the aperture gap.
To attach the hopper to the sample tray:
1. Slide the hopper lock lever towards the front of the unit.
2. Insert the hopper assembly into the location holes on the sample tray - it can
only be inserted one way.
3. Secure the hopper by sliding the lever fully back.

ill 8780
Removal is the reverse of the procedure.
 Mesh baskets and ball bearing (Aero S only)
Prior to the measurement, sample can be placed into one of the supplied mesh
baskets (1mm or 2mm), which in turn is pushed onto the top of the sample
hopper.
The mesh baskets, and the added ball bearing, help smooth the flow of sample
as they effectively store the sample within the assembly for a short period.

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Chapter 1 Introduction and hardware

Additionally the ball bearing helps break up any loose agglomerates within the
sample before it falls into the hopper.
It is not necessary for the mesh basket or ball bearing to be used; the sample can
be placed directly into the sample hopper if desired. This will depend upon the
characteristics of the sample to be measured.
Sample tray (Aero S)
The sample tray receives the sample to be measured from the hopper assembly; the
sample feeds down the sample tray as it is vibrated. The tray is channelled so that
the sample is deposited into the centre of the funnel of the Venturi disperser.
The rate at which the sample is fed into the venturi disperser is governed by the
amplitude of vibration of the sample tray, this is controlled from the software.
Three sample trays are available:

Standard tray The standard sample hopper and tray pair provided with
(General purpose) the Aero dispersion units is the General purpose hopper/
tray pair. This is most suitable for free-flowing materials
and materials having broad size distributions (between 1 to
3500 microns where larger samples need to be measured
to obtain statistical significance.
Micro tray The micro tray is designed for samples where either very
little material is available for sampling, or the material is
prohibitive expensive for repeated measurements.
No hopper is included with the micro tray; the sample is
placed directly onto the tray
Macro tray The macro tray is designed to hold more sample than the
micro tray insert, but much less than the standard tray. It is
intended for use for larger samples where the small size of
the micro tray may prove a problem in terms of reliable
measurements, but where it is critical that as little sample
as possible is used. The macro tray is a good compromise
between the standard and micro options.
No hopper is included with the macro tray; the sample is
placed directly onto the tray

Sample tray (Aero M)

The sample tray for the Aero M does not contain a hopper attachment; instead the
sample is placed directly onto the tray and the sample feeds down the sample tray as
it is vibrated. The tray is channelled so that the sample is deposited into the centre
of the funnel of the Venturi disperser.
The rate at which the sample is fed into the venturi disperser is governed by the
amplitude of vibration of the sample tray, this is controlled from the software.

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Introduction and hardware Chapter 1

A tray gate assembly at the end of the sample tray additionally controls the flow.
This is done by altering the height of the gate above the sample tray.
 To adjust, loosen the knurled thumb screws on either side of the gate, move
the gate up or down to the desired position, then secure the thumbscrews.

ill 8894

Sample tray lock (Aero S / M)

The sample tray is locked in position onto the lower vibration plate, by using the
sample tray lock at the back of the dispersion unit.
To attach the sample hopper/tray:
1. Turn the sample tray lock anti-clockwise to the un-locked position.
2. With the tray angled slightly, locate the location pins at the front of the sample
tray are onto the front of the vibration plate.
3. Lower the rear of the sample tray down until it sits flush on the vibration plate.
4. Turn the sample tray lock fully clockwise to secure.

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Chapter 1 Introduction and hardware

ill 8781
Removal is the reverse of the procedure.

Note
If the sample hopper/tray is not attached and locked onto the vibration
plate correctly, then the unit will not work and will stay in standby mode
until the hopper is inserted.

Venturi disperser (Aero S / M)

The sample from the tray falls into the venturi disperser, where a combination of
incoming air pressure and the vacuum connected to the air cell, disperses and helps
break up any agglomerates in the sample. This is delivered via the attached sam-
pling tube to the measurement flow cell.
The sampling tube, connected to the outlet of the venturi disperser, is used to
deliver the sample from the venturi funnel and sample area to the measurement air
cell.

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Introduction and hardware Chapter 1

Venturi dispersers available for the Aero S and Aero M:

Standard This has a straight-through connection to the dry measure-

disperser ment cell. This venturi provides good dispersion capabilities
(Aero S / M) for a wide range of samples, including fragile particles. When
this venturi is used, the dispersion unit should be positioned
parallel to the optical unit.
Available in both stainless and ceramic materials.
High energy Used for the dispersion of more robust particles which are
disperser strongly agglomerated. This disperser has a right-angled
(Aero S only) connection for the sampling tube, therefore when using this
venturi the dispersion unit will be positioned facing away
from the optical unit.
Available in both stainless and ceramic materials.

The ceramic option dispersers are designed for abrasive materials such as cement.
They can be identified by a couple of matching rings on the venturi body and
receiver tube, as shown below.
The stainless steel variant has no rings present.

ill 8827
Connection of the sampling tubes to the air cell is simply push on and twist to
secure the connection lock.
Over time different venturi dispersers may be developed that can be used for sam-
pling different grades and sizes of sample and other applications. Encoding in the
venturi disperser will automatically identify the dispersers when they are attached
to the dispersion unit, with the disperser type being reported in the sample meas-
urement and records.

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Chapter 1 Introduction and hardware

Venturi disperser removal and cleaning

The venturi disperser can be removed for cleaning:

Warning!
Take care when removing the venturi not to trap fingers between the tray
holder (vibration plate) and the venturi.

1. Open the dispersion unit cover.

2. Remove the sample tray.
3. Aero S - Rotate the disperser a 1/6th turn clockwise, then lift off the mount.
Aero M - Rotate the disperser a 1/4th turn clockwise, then lift off the mount.

Note
The Aero S disperser will only fit on the Aero S.
The Aero M disperser will only fit on the Aero M.

For more information of cleaning the venturi disperser refer to the Maintenance
chapter.

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Introduction and hardware Chapter 1

Status indicator
A status indicator illuminates to indicate the operating condition when the disper-
sion unit is powered up:
 Blue - full intensity
The dispersion unit is functioning correctly and the cell has been loaded into
the optical bench. (i.e. the dispersion unit is “active”).
 Blue - pulsing
The dispersion unit is functioning correctly but its cell has not been loaded
into the optical bench. (i.e. the dispersion unit is at “standby”)
If communication has failed with the optical unit the status indicator will also
be on standby, but the optical unit indicator will be off.

Air in connector
The compressed air line is connected here. The compressed air is used to disperse
the sample. The input range is from 5.5 to 8 bar g, but should nominally be set to 6
bar g.
 Refer to the Mastersizer 3000 User Manual and Basic Guide for the site
requirement details of the compressed air supply.
The outlet from the compressor must be fitted with a push-fit adapter capable of
taking a 6mm o/d polyurethane pneumatic tube.

Warning!
The air pressure regulator fitted to the Aero has a maximum input pressure
limit of 10 Bar. If there is a possibility that the air supply could exceed this,
then a protection device ensuring this limit is not exceeded must be fitted.

Caution!
The air line supply must be dry, free from oil and filtered to less than
0.01mm. Failure to meet this specification will permanently damage the
dispersion unit and invalidate the warranty.

CAN connection
The CAN connection provides both the communications and power to operate the
dispersion unit.
The CAN cable is connected from the CAN connection to one of the CAN con-
nections on the side of the optical unit.

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Chapter 1 Introduction and hardware

Auxiliary connector
The Auxiliary connector (AUX) is used to connect to the Ancillary switching unit,
described below, and any additional accessories that can be used with the dispersion
unit.

Feet
The feet are used to level the dispersion unit horizontally so that an accurate feed of
the sample is delivered into the venturi disperser. The sample should feed centrally
along the sample tray and not move to the side.
To level the dispersion unit
The sample tray must be level in both horizontal axes. Rotate the two feet at the
back of the unit to level the unit on the bench as required.
1. Remove the sample hopper from the sample tray.
2. In one axis, place a spirit level on to the sample tray and adjust the feet until
level.
3. Place the spirit level in the other axis, and again adjust the feet until level.
4. Repeat both adjustments until sample tray is level in both axes.

Lifting holds
Recesses on either side of the dispersion unit body can be used for lifting and trans-
porting the unit.

Additional components
Ancillary switching unit
The Ancillary switching unit is an external control accessory that is used to switch
on the vacuum unit required for the sample extraction during each measurement.
Power into the switching unit
Connect mains supply to this port. Input supply: 100-240V / 50-60Hz.
Power to the vacuum unit
Connect the vacuum unit to this port.
Reset button.
The unit uses an internal resettable fuse, press this button if the unit requires reset-
ting.

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Introduction and hardware Chapter 1

1 3 4 2

ill 8656

 Power into the switching unit  Reset button

 Power to the vacuum cleaner  Control

Control.
Connects to the dispersion unit AUX connection. Communication to the switch-
ing unit is done via the dispersion unit. The software will request the dispersion
unit to switch on the vacuum unit when required.

Note
The on/off switch of the vacuum unit must be set to On to allow the ancil-
lary switching unit to work.

Note
An adaptor cable is required to connect an IEC 60320 C13 power cable (as
used by the Nilfisk GM80 vacuum cleaner) to the higher-rated IEC 60320
C20 connector on the ancillary switching unit. Contact Malvern Instru-
ments for more information.

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Chapter 1 Introduction and hardware

Vacuum extraction unit

The vacuum extraction unit removes the sample from the Aero dry cell exhaust
once it has been measured. Never let the exhaust discharge directly into an
enclosed room.
Control of the vacuum extraction unit can be done via the software and the ancil-
lary switching box, or manually.
Refer to the Mastersizer 3000 User Manual and Basic Guide for the site
requirement details of the Vacuum extraction unit.

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Introduction and hardware Chapter 1

Aero dry cell

Caution!
The dry cell is an optical device. Scratches to the surfaces of the cell win-
dows may affect performance.

Each Aero dispersion unit will be connected to a matching Aero series dry cell.
The dispersion unit continually delivers the sample from the dispersion unit to the
Aero dry cell and through the analyser beam of the optical unit so that a measure-
ment can be performed.
The cell windows in the dry cell are critical parts of the measurement optical path
of the system and should be kept clean and free from scratches at all times. Refer to
the Maintenance chapter for details on cleaning/maintaining the cell.

Features of the dry cell

1
6
2
7

3
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Chapter 1 Introduction and hardware

 Cell shroud  Sample inlet

 Shutter activation arm  Air intake and filter assembly
 Sampling dry cell, cell windows  Vacuum port
and seals
 Cell handle and unlocking button

Cell shroud
The cell shroud prevents stray light entering the measurement area that may affect
a measurement. More importantly, the cell shroud stops human access to laser
radiation. The cell shroud on the dry cell also reduces noise emissions
The cell shroud incorporates an arm that will open a mechanical shutter when
inserted into the optical unit. With the shutter open laser light is allowed into the
sample area. When the cell is withdrawn the shutter will move back into position to
prevent the emission of any laser light.
The system should never be used if the cell shroud or shutter arm is damaged.

Sampling dry cell, cell windows and seals

The Sampling dry cell is where the measurement of the sample is performed.The
cell windows allow the analyser beam of the optical unit to pass through the cell
and hence the particle field. For optimum measurement analysis it is vital that the
cell and cell windows are kept clean of all residue. The cell windows can be
removed to allow cleaning - the cell lock handle is rotated and the front plate of
the cell, containing the one window and seal pair, removed. The cell windows are
delicate and should be treated with caution; refer to the Maintenance chapter for
details on removing the front plate and cleaning and inspecting the cell windows
and seals.

Cell handle and unlocking button

Warning!
Never attempt to lift the optical unit by the locking handle of the cell. Read
the Health and Safety section in the Mastersizer 3000 Basic Guide for
details of correct moving techniques.

When the cell is inserted into the sample area of the optical unit, a locking motor
will pull the cell down and lock it into a defined measurement position. This
ensures that the cell is always optimally located before any measurements are per-
formed.
To remove the cell, press the button on the cell handle. This will release the lock-
ing motor and raise the cell slightly ready to be withdrawn from the optical unit.

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Introduction and hardware Chapter 1

Sample inlet
The sampling tube from the dispersion unit is connected to this inlet.
Connecting the sampling tube.
To connect the sampling tube:
1. On the sampling tube, line up the catches on the collar to the pins on the dry
cell connection.
2. Holding the collar, push the sampling tube onto the connection, then rotate
the collar to lock the tube on.
 Removal is the reverse of the procedure.

Air intake and filter assembly

The U-shaped air intake assembly provides an additional conditioning on the sam-
ple that will aid its dispersion and subsequent measurement.
The air intake connects in front of the air intake filters on the rear of the optical
unit (see below illustration). When required the air intake filters can be cleaned or
replaced; refer to the maintenance chapter.

Vacuum port
This connects up to the vacuum connection on the rear of the optical unit. A vac-
uum unit must be used to prevent samples being discharged into the laboratory.

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Chapter 1 Introduction and hardware

Inspect the seal at the rear of the dry cell before each use. If the seal is damaged the
operation of the dry cell and measurement will be reduced.
To connect the vacuum hose, an extraction elbow needs to be fitted to the back of
the unit; this will replace the blanking plate normally used when any Hydro wet
cell is fitted. The elbow can be positioned in any position suitable for the vacuum
unit connection.

Note
The on/off switch of the vacuum unit must be set to On to allow the
Ancillary switching unit to work.

The air intake filters must be fitted at all times; though providing the vacuum unit
and hose are attached, the blanking plate does not require fitting when measure-
ments with the Hydro dispersions units and wet cell are performed.
If the vacuum unit and hose are not available the blanking plate must be fitted.

Note
The vacuum hose, used to connect to the vacuum port, requires an inter-
nal diameter (i.d.) of 38mm

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Introduction and hardware Chapter 1

Connecting the Aero dispersion units

11
9
12

AERO
10

3
2

1
8

ill 8659

 Power cable from External PSU  Auxiliary Control cable

 CAN cable
 Computer connection (USB)
 Sample tubing to cell
 Air supply input
 Ancillary switching unit
 Power cable to switching unit
 Vacuum unit
 Power cable to vacuum unit
 Vacuum elbow/pipe to optical unit
 Vacuum pipe to vacuum unit

The Mastersizer 3000 User Manual details specific connections to the optical
unit.
 Depending on the vacuum cleaner attached, an additional power cable  may
be required. Refer to the Mastersizer 3000 Basic Guide.

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Chapter 1 Introduction and hardware

Page 1-24 MAN 0481

 2

Software and Control

Introduction
This chapter describes the features of the software which are specific to the disper-
sion unit. It covers:
 Making a measurement – the basics of making a measurement using the dis-
persion unit.
 Controlling the dispersion unit via a Standard Operating Procedure (SOP).
 Manually controlling the dispersion unit.

Making a measurement
Making a measurement using the Aero dispersion units is fully documented in the
Mastersizer 3000 User Manual. Refer to that manual for details.
The dispersion units can be controlled in several ways;
 Manually or automatically by running an SOP. The system automatically
detects which dispersion unit and cell is connected. If more than one disper-
sion unit is connected, the system detects all dispersion units connected, but
only the dispersion unit that has its cell installed on the optical bench will be
“active”.
 Alternatively the dispersion unit can be controlled by a separate manual acces-
sory control window. This enables simple control of the dispersion unit, allow-
ing individual selection and operation of the unit’s functionality.
These are described in the following pages.

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2 Chapter 2 Software and Control

Control of a Dispersion unit via an SOP

An SOP can be configured to control all settings for the dispersion unit automati-
cally. When an SOP is run, the software will (depending on how the SOP has been
set up) automatically set the air pressure and feed rates to a pre-defined setting and
then run through a measurement sequence.
The SOP Editor setup is described in full in the Mastersizer 3000 User Man-
ual. Most of the SOP sections are common to all dispersion units, and these are
described in the above manual. Other SOP sections are specific to the Aero disper-
sion unit and are described below.

Creating or editing an SOP - Dispersant unit

selection
SOPs need to be specified and saved before they can be run. To create a new SOP:
1. On the Home ribbon, select New-SOP from within the Documents group.
ribbon. (To edit an existing SOP, choose Open-SOP instead.)

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Software and Control Chapter 2

Note
The software will automatically recognise which disperser is in use (stand-
ard or high energy) and the material type used to make the venturi (stain-
less steel or ceramic).

2. Select an SOP template from the list in the New SOP window or click the
From existing SOP... button to locate an SOP in the file system that fulfils
(or is close to) your required criteria.
3. The SOP Editor window is now displayed. This will be configured to apply to
the dispersion unit selected.
4. Complete the SOP Editor as described in the Mastersizer 3000 user manual.

Sample Dispersion - Accessory

This section describes the Aero S accessory control settings. There are no Acces-
sory control settings for the Aero M.
The Accessory control settings allows you to set up the behaviour of the currently
connected accessory during a manual or SOP measurement. Depending on the
accessory that is connected, the settings presented differ accordingly.

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Chapter 2 Software and Control

Section Description
Air pressure Use this slider bar to set the air pressure at which the sample
is circulated (from 0-4 bar, in 0.1 bar increments). Lower air
pressures tend to be better for fragile particles, higher air
pressures for agglomerates or metallic particle samples
Feed rate Use the slider bar to set the rate at which the sample is fed
into the system - effectively this controls the vibration speed
of the feed tray. The correct feed rate is one at which the
sample is vibrated evenly along the feed tray and gives the
required obscuration - this rate is best established as part of
a method development process.
Configuration Use the pull down menus to select both the Venturi and Tray
types to be used in the measurement.
Input the hopper gap that has been manually set for the
sample measurement.

Sample Dispersion - Cleaning

This section describes the Aero S Cleaning control settings. There are no Cleaning
control settings for the Aero M.

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Software and Control Chapter 2

The Cleaning options allow you to specify a clean sequence for the dispersion
unit. This ensures that all traces of the sample just measured are removed so that no
contamination of the next sample occurs. Cleaning following a measurement is
essential to ensure that background noise, consisting of particles agglomerating
within the system and forming accumulations, is minimized.

Section/option Description
Clean Sequence Each Clean type specifies a set number of cycles (nothing
further is changed in the cleaning method). Select a Clean
type of either Quick, Normal, Extensive or Custom. If Cus-
tom is selected the user must also manually specify the
number of Clean cycles.
If measuring the same sample type in succession a Quick
clean may be sufficient.
If making the last measurement of the session, it is prudent
to perform an Extensive clean to ensure that the system is as
free as possible from contamination in readiness for the next
measurement session.
Air pressure Use the slider bar to set the air pressure at which any
remaining sample is removed (from 0-4 bar, in 0.1 bar incre-
ments).
Feed rate Use the slider bar to set the rate at which the remaining sam-
ple is removed - effectively this controls the vibration speed
of the feed tray.

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Chapter 2 Software and Control

Manually controlling the dispersion unit

When performing a Manual measurement, an accessory controls panel is available
on the right of the active measurement window to manually control the dispersion
unit. This can be used to initiate and control the currently attached accessory.

Normally, an SOP or Manual measurement controls the accessory's operation

within the context of a measurement. Alternatively, the Accessory controls panel
allows you initiate the current accessory before the measurement is actually made.
This is essential when observing the effects of variation to the accessory's settings
on the live Laser and Light Scattering panels, in order to optimise the sample's
concentration and circulation prior to making a measurement. This option could
also be used as part of a manual cleaning process.
 To access the Accessory control panel: the instrument must be in Manual
Measurement mode, then select the Accessory controls tab on the right of
the Manual Measurement window.

Tip
The same controls are also available from the Active accessory control
feature (choose Tools-Accessories from the control ribbon).

The accessory controls panel for the Aero S is shown as follows (in this example the
Air pressure/Feed rate have been set):

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Software and Control Chapter 2

Each section can be collapsed to save space on the Measurement window.

Section/option Description
Disperser / Tray Displays the configuration of the dispersion unit.
(Aero S only) I.e. Standard venturi disperser and General purpose trays
are fitted
Standby / Air Standby - By default the Aero is in standby mode when the
flow / Feed but- accessory is connected and powered up, but not active. In
tons this mode the front LED is pulsating.
Flow - Activate the air flow.
Feed - Starts the vibrating feed tray. Selecting this option
also automatically turns on the Air Flow.
Air pressure Use this slider bar to set the air pressure at which the sample
is circulated (from 0-4 bar, in 0.1 bar increments). Lower air
pressures tend to be better for fine or fragile particles, higher
air pressures for agglomerates or metallic particle samples.
Feed rate Use the slider bar to set the rate at which the sample is fed
into the system - effectively this controls the vibration speed
of the feed tray. The correct feed rate is one at which the
sample is vibrated evenly along the feed tray and gives the
required obscuration - this rate is best established as part of
a method development process.
Clean Select the cleaning sequence required: Quick (1 cleaning
(Aero S only) cycle), Normal (3 cycles), Extensive (5 cycles). The disper-
sion unit will perform a clean sequence, for the selected
duration, that will remove any remaining sample from tray
and the disperser.

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Chapter 2 Software and Control

Section/option Description
Clean Select the cleaning sequence required: Quick (1 cleaning
(continued) cycle), Normal (3 cycles), Extensive (5 cycles). The disper-
(Aero S only) sion unit will perform a clean sequence, for the selected
duration, that will remove any remaining sample from tray
and the disperser.
A Custom vacuum sequence can be configured. Clean
duration, air pressure and feed rate set as appropriate for the
sample and application.

To start the cleaning sequence select the Clean system but-

ton .
Note: In the Active accessory control window (Tools-
Accessories) pressing Clean will start the cleaning
sequence
To help cleaning the unit - when the unit is in standby and
with the air supply turned off - the Vacuum can be manually
turned on independently of the air and feed. The
lid can then be opened and any remaining sample brushed
into the vacuum for extraction from the system.
Abort Stops all operations and close all valves. The accessory is
returned to the Standby status.

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 3

Maintenance
Introduction
This chapter covers all the user maintenance procedures for the dispersion unit. Do
not attempt any maintenance procedure not specified here. This chapter covers:
Maintenance schedule
This section suggests a maintenance schedule for inspecting and cleaning the dis-
persion unit and its respective components.
Maintenance procedures
This section describes how to perform various maintenance procedures and actions
identified in the schedule to help ensure the dispersion unit is kept working opti-
mally. Maintenance procedures described are:
Cell window inspection and cleaning procedures
This section includes topics on:
 How to inspect the cell windows, in case of poor background results.
 Cell windows removal and inspection.
 How to inspect the quality and cleanliness of the windows.
 Appropriate cleaning techniques.
Dispersion unit cleaning
This section describes how to clean the various components of the dispersion unit
that have been identified in the maintenance schedule. This section includes topics
on:
 Cleaning of covers.
 Sample tray cleaning.
 Cleaning after a measurement.
 Checking and replacing of sample tubing, vacuum cleaner bags and air vac-
uum.

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3 Chapter 3 Maintenance

Performing a Quality Audit Standard measurement

Malvern supplies a Quality Audit standard (QAS) specifically designed to test the
performance of the dispersion unit. It is recommended this is performed at least
once a week or as internal quality procedures dictate.
Power connections, lead and fuses
Checking of the power input to the dispersion unit.

Warnings
General

Warning!
The dispersion unit contains no internal serviceable parts. Never attempt
to remove the covers of the optical bench or dispersion unit. Removal of
the covers invalidates the warranty and may expose the user to dangerous
laser radiation.

Warning!
Failure to follow these guidelines could result in the emission of laser radi-
ation or exposure to hazardous voltages. Laser radiation can be harmful to
the body and can cause permanent eye damage.

Aero dispersion units do not contain a laser but are connected to the optical
bench that does.

Maintenance and cleaning

Warning!
Before carrying out any maintenance operation, read and observe the safety
warnings listed in the Mastersizer 3000 Basic Guide.

Warning!
Before cleaning, always disconnect the unit from the power supply and
computer and disconnect all electrical cables.

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Maintenance Chapter 3

Maintenance schedule
Follow the maintenance schedule below to keep the dispersion unit working well.
This list is only a guide; the exact frequency at which to perform tasks depends on
many factors, including:
 The samples being measured.
 The environmental conditions.
 The number of measurements made (frequency of use).
The procedures indicated below are described in the following pages of this chap-
ter.

Procedure Period/situation
Inspect cell windows The cell windows should be checked for general
for dirt and scratches cleanliness every day, or if during a background
measurement either of these is seen:
 One of the first few detectors displays a value
above 100 light energy units.
 Background signal over 20 light energy units
recorded by one of the detectors above detector
20.
Either of these situations would indicate a poor
background; this will effect the quality of any meas-
urements.
Clean the unit Check/clean sampling area (sample tray and hopper
assembly, venturi disperser) at least daily
Check/clean air intake filters monthly
Check/clean vacuum cleaner bag weekly
Check/clean compressed air supply filters monthly
Clean the covers Once a month.
Replace the venturi At least quarterly dependent upon sample type used.
disperser tubing
Perform a Quality Audit At least once a week or as internal quality procedures
Standard measurement specify.

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Chapter 3 Maintenance

Maintenance procedures
Inspection of cell windows - Poor background
The cell windows should be inspected for cleanliness every day and after each
measurement session. Problems which indicate the need for cleaning or mainte-
nance are the following. These expand on the situations in the first row of the
maintenance schedule table.

Material stuck to windows

Significant scattering on the detector channels, as shown below , often indicates
that fine material is stuck to the cell windows:

ill 8830
 If your system displays high detector channels, refer to the Cleaning the cell
windows section as described later in this chapter and remove and clean the
cell windows.

Cell windows removal and inspection

The cell windows should be inspected for cleanliness every day and after each
measurement session, as described in the previous section.

Note
The cell window faces must not be touched directly during the removal
and replacement procedure. Lens tissues should be placed over the win-
dow faces where necessary.

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Maintenance Chapter 3

Removing the cell window and cover plate (frame) assembly:

Remove all sample from the system, then remove the dry cell from the system.
Rotate the cell lock lever  to release the cell front cover plate. Once unlocked,
remove the cover plate from the cell holder assembly .

ill 8784

Inspecting and cleaning a cell window

1. Inspect both sides of the cell window. If there are traces of scratches replace the
windows - as described in the Removing the cell window section below.
Spare windows can be obtained from Malvern Instruments.
2. Remove any dust on the window surfaces using a compressed gas duster can.
Keep the can upright in use to prevent liquid propellant emerging. Do not
shake the can immediately before use or it will emit liquid propellant.

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Chapter 3 Maintenance

Caution!
Do not wipe the windows with an ordinary dry cloth as this will cause
scratches. Always use the procedure below to clean the surfaces.

3. Inspect the window by reflected light for smears or prints.

4. Clean the windows as described in the Cell window cleaning procedures
section below. For general cleaning, the cell window can remain in the cover
plate (frame), but may need to be removed if more in-depth cleaning is
required.

Note
The cell windows are part of the optical system and removing them for
cleaning will change their position. Remember to add an Align stage to the
next measurement sequence or click the Align button.

Removing the cell window

Whilst holding the cover plate slightly above a clean lens tissue, place another lens
tissue over the cell window area and using light pressure push the cell window and
seal out from the cover plate onto the bottom lens tissue.
Using a clean lens tissue, remove the window from the o-ring seal. Be careful not
to mark the window.

ill 8661
Repeat the procedure for removing the remaining cell window and seal from the
other side of the cell.

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Maintenance Chapter 3

Caution!
The outer faces of the cell window are optically coated; treat them with the
same care as a camera lens.

Re-assemble the cell windows

The following procedure details how to fit a new cell window and cell seal and
reinsert it into the dry cell window plate/holder. Take the same precautions if reus-
ing the existing cell window after cleaning it; protect the cleaned window with lens
tissue where necessary.
Place the dry cell cover plate on to a flat surface with the seal cavity facing upward.

ill 8662
Without touching the window faces (use a lens tissue to hold), remove a cell
window from its protective paper wrapping.
Hold by the ground edges of window. Ensure that the face with the larger diameter
must be facing down (outwards) when inserted into the dry cell cover plate.
Once inserted, move the window so it is central in the plate.

ill 8663
Take a dry cell seal and carefully place it on the gap around the outside of the cell
window and cover plate.

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Chapter 3 Maintenance

ill 8664
Using a clean lens tissue carefully push the seal into the gap. Continue until the
seal is securely inserted. The seal must be of equal height all way round the win-
dow, with no bulges in the seal.

ill 8665

Cell window cleaning procedures

Follow these guidelines for cleaning the windows.

General guidelines
Laser light scattering systems rely on the cleanliness of the optical components (e.g.
cell windows). Dust on the optics causes light scattering; the system will respond to
particles on the optics in a similar way to particles presented in the flow cell. The
signal from dirty optics will contribute to the background signal, so it is good prac-
tice to keep the optical components as clean as possible.
When optical components have been used for a long period, even in the cleanest
laboratories, assume that they have traces of fine grit on them as well as the obvious
dust. Fingerprints usually contain grease and grit so need careful cleaning.

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Maintenance Chapter 3

As optical components are very expensive, take a cautious approach to cleaning,

assuming that the contamination is worse than it appears. As grit is usually as hard,
if not harder, than the glass used to make optical components, it is important to lift
it away from the surface before wipes are used. Use minimal pressure to clean the
surface. Repeat this if it doesn’t work first time, but remember that scratching the
optical surface ruins the component.
When cleaning a window, hold it with the fingertips and try to prevent them pro-
truding above the surface. This prevents any grease from fingers being picked up by
the tissue and deposited on the surface. To further limit problems of grease pick-up
from the fingers, hold the window with the fingers at the top and bottom and wipe
from side to side so that if any grease is picked up, it is not deposited on the surface.
Do not use rubber gloves to hold the window. Gloves invariably have oils and short
chain polymers in the surface; some of these oils, especially silicone components,
are more difficult to remove than finger smears. Never bring silicone products
into close contact with glass optical components. Clean hands are best.

Caution!
If any silicone oils are deposited on the glass surface they adhere so
strongly that it is impossible to clean them off, ruining the component.

Cleaning steps
Depending upon the quality and cleanliness of the windows, use the appropriate
cleaning technique as described. Read through the below steps to determine the
correct techniques required; these are described in order of severity and contami-
nation.
It is recommended to inspect the cell window in reflected light from a fluorescent
tube or other light source.
Gritty surface particles / Smeared surface - with grit
If the surface has fingerprints on it or has not been cleaned for a long time, assume
there is grit present. First wash the surface then wipe it as described; refer to the
Washing cell windows and Wiping cell windows sections below.
Dusty surface:
If the surface is just dusty use a clean air aerosol duster or soft brush; refer to the
“Clean air” aerosol dusters and Brushing optical surfaces sections below. If
marks are present afterwards wipe the surface as described in Wiping cell win-
dows.
Smeared surface - no grit
If the surface is smeared and you are sure there is no grit on it, wipe the surface as
described below in Wiping cell windows.

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Chapter 3 Maintenance

Caution!
The outer faces of the windows have an anti-reflective coating and are
more prone to scratching than the inner surfaces. Be careful not to touch
the faces of the windows or put them down on dirty surfaces.

Washing cell windows

Wash the cell windows if there are particles deposited on the surface.
1. Remove the window from the cell.
2. Pour a small amount of dilute detergent solution into a flat container such as a
petri dish. For heavily soiled windows, or when contamination with grit is sus-
pected, use a very dilute detergent solution. A neutral detergent like Decon75 is
best, although most detergents sold for cleaning glassware can be used if suffi-
ciently dilute.
3. Hold the window above the dish with the surface to be cleaned facing down-
wards. Using a very soft brush, such as sable, run the detergent solution across
the surface. The window may need angling slightly to allow the liquid to run
across it. Use the brush to lift the liquid, allowing it to run across the surface,
but not to rub.
4. Once the surface has been flooded a few times, adopt a gently flicking action as
described above. Wet the brush and try to flick away the dirt on the window. As
before, avoid applying any pressure to the surface and work across the whole
area, flicking the grit away.
5. Do not expect to remove all the greasy smears or o-ring marks at this stage;
they will be removed by wiping later. The aim is to weaken the bond between
the grit/grease and the glass surface, allowing it to be lifted away by the water.
6. After carefully cleaning both sides of the surface, wash away the dilute deter-
gent solution by flooding the surface with ethanol from a wash bottle.
Wipe the cell windows as described in Wiping cell windows below to produce the
final clean surface.

“Clean air” aerosol dusters

If used appropriately, aerosol dusters can quickly clean the worst dust off a compo-
nent. These cans use liquefied butane which boils off when the valve is pressed
down, producing a blast of gas to blow dust off the optical surface. Do not use these
in a dusty environment as they can stir up settled dust, which then settles on the
surface being cleaned.
The aerosols only remove the largest and most loosely attached dust particles, but
can often deposit droplets of liquid butane on the optical surface. These droplets

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Maintenance Chapter 3

boil away leaving a drying mark on the surface. This effect can be limited by keep-
ing the aerosol perfectly upright, and testing the aerosol first by squirting it in a safe
direction to ensure that the nozzle is clean.
Once the dust is removed, wipe the cell windows as described in Wiping cell win-
dows below to produce the final clean surface.

Brushing optical surfaces

Camera suppliers sell large soft brushes for brushing dust off camera lenses. These
often have a bulb attachment to blow gently on the lens to assist in removing dust.
Use the brush with a light flicking action to knock dust off without applying pres-
sure to the surface.
Avoid a typical “brushing” action; as the brush is moved sideways grit trapped in
the brush is dragged across the surface, scratching it. These scratches accumulate
with subsequent cleaning, causing early failure of the component.
Avoid touching the brush itself as grease from fingers will stick to the brush and be
transferred to the window when the brush is used.
Once the dust is removed, wipe as described in Wiping cell windows below to
produce the final clean surface.

Wiping cell windows

Fold a piece of lint free cloth (a good quality proprietary lens tissue is best) into
quarters. The edge that wipes the surface should be large enough to span the whole
width of the window. If the tissue is too small a corner of the wipe will be drawn
across the surface, leaving a smear.
Do not touch the window with fingers during the cleaning wipe.
The procedure is:
1. Gripping the tissue about half way down, dampen the edge of the tissue with a
small quantity of ethanol (too much will flood the tissue). Allow the ethanol to
soak in.
2. To note any marks and smears, inspect the window in reflected light from a
fluorescent tube or other light source. Next, breathe gently on the window,
allowing warm moist air to condense on the optical surface, producing an even
fogging without wet spots. Immediately wipe the whole surface in a single pos-
itive action before the condensed water vapour disappears. Do not put fingers
behind the tissue to press it down; use the stiffness of the tissue to hold itself
against the surface, curving the tissue to increase the pressure if necessary. This
not only limits the pressure that can be applied to the surface but prevents
grease being dissolved off the fingers and passing through the tissue and onto
the surface.

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Chapter 3 Maintenance

3. Use each tissue for one pass only. This is the only way to ensure a clean
undamaged surface. If a wipe has done its job it will be loaded with grease from
the surface. Wiping the surface again will just deposit the grease back on the
surface. Worse, if the wipe has lifted off some remaining grit this could scratch
the clean surface.
4. Marks from the o-rings usually form an oily line around the outer part of the
optical surface. With surfaces contaminated in this way, wiping from the centre
outwards prevents the oily mark from being spread from an unimportant area
across the window centre. If there are smears associated with starting the pass
in the centre of the surface, once the o-ring marks have been completely
removed give the surface a single wipe from side to side.
5. Re-inspect the window; if it’s still marked, repeat the procedure with a new
clean tissue.

Note
If marks remain, use a liquid cleaner such as Ethanol or Propan-2-ol. This
can be soaked on a cotton wool bud and wiped across the window gently.
After one pass over the window discard the bud to avoid scratching. Re-
inspect the window and repeat until clean.

Cleaning the covers

Caution!
The surfaces of the system may be permanently damaged if samples or dis-
persants are spilt on them. If a spillage occurs, disconnect the system from
the power supply before carefully cleaning it up.

Periodically clean the covers thoroughly using a mild soap solution.

Never use excessive liquid for cleaning and always avoid electrical components
(connectors, etc.) and the cell windows.
Never use a solvent based solution for cleaning; it may damage the surface.

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Maintenance Chapter 3

Cleaning the sampling area

Warning!
If the dispersion unit has been used to measure hazardous materials (see
the notes in the Health and Safety information), the vacuum used must
have an efficient filter that stops particles being ejected into the atmos-
phere.

Warning!
Refer to the Material Safety Data Sheets supplied with the material
before beginning any cleaning routine.

We recommend cleaning the dispersion unit periodically using the vacuum nozzle
a soft brush.
Disconnect the dispersion unit from the CAN connection before proceeding with
any cleaning.

Replacing the lid air intake filter

During use of the dispersion unit, the air filter on the sample area lid will accumu-
late particles; the filter material used with the lid air intake should therefore be
replaced periodically.
To replace the filter:
Pinch the filter and pull out, then replace with a new filter. New filters can be
obtained from Malvern Instruments.

Cleaning the mesh basket

If the mesh basket clogs with powder, a simple way to clear it is to detach the tray,
remove the hopper and mesh and empty its contents into the tray, then gently tilt
the tray. The ball bearing will roll and separate from the powder. To clean more
thoroughly use a brush.
Note that if the ball bearing has entered the venturi dispenser, remove the dis-
penser and tip upside down to remove.
If required, dip the mesh tool into a beaker of water. Brisk agitation will rinse the
basket and balls that can then be dried. The mesh basket, sample tray and other
sampling components must be completely dry before reusing.

Cleaning the sample hopper and tray assembly

Remove the sample tray by releasing the sample tray lock. Clean any spillage seen.
Clean the covers with a damp cloth but do not use solvents here: it may cause per-
manent damage.

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Chapter 3 Maintenance

With the accessory controls, the vacuum can be manually turned on

independently of the air and feed; the lid opened and any access sample then
brushed off the tray into the venturi and vacuum.

Cleaning the venturi disperser

General cleaning
On a system in regular use, some powder build up will occur in the venturi cone,
nozzle, sampling tube and exhaust throat. The speed at which this develops
depends on the materials measured and their adhesion properties. This build up is
not a problem unless it starts to restrict the airflow significantly and then affect the
measurement accuracy.
We recommend periodically running coarse glass beads through the dispersion unit
to help remove any attached powder. Alternatively, clean the cone more frequently
using a bottle brush. This is easiest with the mesh and sample tray removed.
Advanced cleaning
To aid removal of any sample build-up over time, the venturi disperser can be
removed, disassembled and all parts then cleaned separately with a liquid.

2 1

ill 8810

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Maintenance Chapter 3

 Remove the Venturi dispenser from the dispersion unit.

 Pull the sampling tube off the disperser body , then unscrew and separate the
individual venturi disperser components . Clean with brush or vacuum, and
water or solvent as required.
 Ensure when reassembled that all parts are securely reconnected.

Note
Ensure the venturi disperser is fully dry inside and out before reusing. It is
recommended to flush the dispenser with ethanol or isopropanol after first
cleaning with water.

Cleaning the cell air intake filters

During use of the dispersion unit and dry cell, the air filter at the rear of the cell
area will accumulate particles; eventually this may impair of the air flow through to
the sample and its subsequent measurement. The filter material used with the dry
cell air intake should therefore be periodically cleaned.
To clean the filter:
Pinch the filter through the centre of the filter holder and pull out, wash the filter,
leave to dry, and then replace back into the assembly.

Cleaning after measurements

Cleaning must match the intensity of usage and the adhesion properties of materi-
als. Generally, the advice is as follows:

Every 20 measurements:
 Inspect and, if necessary, clean the cone area under and around the mesh.
 Inspect the contents of the mesh basket to see if large sample agglomerates are
gathering. If so, remove the ball bearing (if used) and clean the mesh basket.
 Brush the tray/hopper and surrounding area clear of sample, taking care not to
introduce dust onto any optical components.

Every 100 measurements:

 Repeat the above, but also run some glass beads through the instrument for
approximately 30 seconds. If necessary, repeat until clean. Use about one
heaped desert/table spoon of grit with maximum feed rate and a pressure of 3
bar g.

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Chapter 3 Maintenance

Checking and replacing tubing

The sampling tube may need replacing.

Sampling tube
The bore of the sample tube will eventually become coated with a layer of powder.
This can be removed by running a cleaning sample such as glass beads through the
feeder on a regular basis. Once this fails to clean the tubing, replace it.

Checking the compressed air supply filter

If an air filter is fitted to the dispersion unit’s compressed air supply, clean or
replace this as necessary. Drain any condensation from the filter bowl regularly.

Checking the air exhaust vacuum

If the air exhaust is a vacuum filter system, ensure the filters are changed regu-
larly as recommended by the manufacturer.
If the air exhaust is provided by a vacuum unit, regularly clean and empty this as
recommended by the manufacturer. Refer to the vacuum units user manual for
details for servicing and filter replacement.
Ensure that any hazardous waste collected is disposed of according to the Material
Safety Data Sheets supplied with the material.

Note on cyclone vacuum units

Cyclone vacuum units will use a bag to contain the sample, which will need empty-
ing, though this will not reduce air flow when full.
Any filters will need cleaning or replacing as required.

Note on non-cyclone vacuum units

Vacuum cleaner bags lose their efficiency when choked by fine particles. This grad-
ually destabilizes optimum airflows within the unit, causing inconsistent results.
The fullness of the vacuum cleaner bag is not a reliable indicator of a need to
replace the bag, particularly if the materials measured are very fine:
 Fine particles (1 to 10 microns) will quickly clog the pores in the bag without
filling it.
 Coarse particles can half fill the bag before any destabilizing effect is observed.
We recommend noting the interval between bag changes and always measuring a
sample just before a bag is changed. Measuring the same sample after changing the
bag will show how smooth the transition between bags was. If a noticeable differ-
ence is observed, change bags more frequently.

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Maintenance Chapter 3

Any filters will need cleaning or replacing as required.

Note
It is recommended that any vacuum unit used with the dispersion unit is
equipped with HEPA filters, or can have HEPA filters fitted.

Performing a Quality Audit Standard

measurement
Malvern supplies a Quality Audit standard (QAS) specifically designed to test the
performance of the dispersion unit. It is recommended this is performed at least
once a week or as internal quality procedures.
The Quality audit standard is supplied with instructions to enable the measure-
ment to be easily followed and performed.
Contact Malvern Instruments for more information.

Power connections, lead and fuses

Power is supplied to the Aero dispersion units via the CAN cable from the Master-
sizer optical unit. This cable will supply both power and communications for the
dispersion unit.
Consult the Mastersizer 3000 User Manual and Basic Guide for maintenance
information on the optical unit and power connections.

Consumable kits
Consumable kits and additional spares for maintaining the Aero series dry sampling
dispersion units are available from your Malvern representative. Please contact
them for full details and requirements.
The consumable kit include the following components:
Aero consumable kit

Standard dry cell

1/2” paint brush for cleaning
Quality Audit Standard (QAS)
- pack of 10 2.5g vials
10mm steel ball bearing
Mesh basket (1mm)
Lens tissues
Standard dry cell windows and seals
pack (FKM)
Sample lid air intake filter element

Aero series dry dispersion units Page 3-17

Chapter 3 Maintenance

Page 3-18 MAN 0481

 4

Appendix
Specification
The following table details the specification of the Aero dispersion unit and Aero
series dry cell. Full specifications of the optical unit and the Mastersizer as a com-
plete system can be found in the Mastersizer 3000 User Manual and Basic
Guide.
All specifications correct at time of publication, but may be subject to alteration.

Dispersion type Dry, with controllable airflow, controllable feed rate,

Typical applications
Modes of operation
Weight
-- Aero dispersion unit
-- Aero cell
Dimensions
-- Aero dispersion unit
-- Aero dry cell
Power
Power consumption
and interchangeable feed trays automatically
sensed by the unit.
Dry powders, pharmaceutical excipients, fillers,
cements, flour, powder coatings.
Automatic via SOPs.
Manual via software control panel.
10.5 kg
2.0 kg
Width: 180mm / Height: 380mm / Depth: 260mm
Width: 106mm / Height: 273mm / Depth: 253mm
Supplied via CAN cable from the Optical unit
5W - Standby / 10W - Nominal*
96W - Maximum operating power**
* The power recorded on a typical unit using maximum vibration.
** The maximum power available through the CAN ports.

Size range
-- Aero S 0.1 to 3500 μm*
-- Aero M 0.1 to 1000 μm*†
* Sample dependent.
† When used with the Mastersizer 3000E

Aero series dry dispersion units Page 4-1

4 Chapter 4 Appendix

Chemical compatibility
Components of the Dispersion unit that may come into contact with the sample
are manufactured from materials that are considered to give the widest protection
from chemical attack. However, it is important to check that any sample or titrant
used is chemically compatible with the materials mentioned. The table below indi-
cates the components that may come into contact with either sample or dispersant.

Warning!
It is advisable that the chemical compatibility is checked against the materi-
als identified below before inserting a sample. It is also recommended that
a test is performed on the material with the sample before more permanent
usage is undertaken.

Any cleaning and maintenance procedures necessary are described in the Mainte-
nance chapter of this manual.

Component Materials
Sample tray assembly Stainless steel 316
Venturi disperser
- Stainless steel Stainless steel 303/410 hardened
- Ceramic Stainless steel 303/410 hardened/High purity alumina
Mesh basket Stainless steel 316
Ball bearings Stainless steel 316
Sample pipes to cell Carbon impregnated polyurethane
Cell Borosilicate Glass / Stainless steel 316
Vacuum extraction elbow Carbon filled acetal

Note
For chemical compatibility of the Mastersizer 3000 optical unit, refer to
the Mastersizer 3000 basic guide.

Regulatory Information
Regulatory information for all Mastersizer 3000 instruments and dispersion units,
can be found in the Mastersizer 3000 basic guide.

Page 4-2 MAN 0481

 Malvern Instruments Limited
Grovewood Road, Malvern
Worcestershire, WR14 1XZ, UK

Tel +44 1684 892456

Fax +44 1684 892789

www.malvern.com

PARTICLE SIZE
MASTERSIZER 3000
AERO SERIES
DRY DISPERSION UNITS
MAN0481
MRK1956-01

MRK1956-01_AERO_dry_disp_units_cover_58pp.indd 1 28/08/2013 12:48:11