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Distek ezfill 4500

OperationManual

Document: 3845-0001 Rev. B

Distek ezfill 4500

Operation Manual

Document 3845-0001 Rev. B

© Distek, Inc.121 North Center Dr. • North Brunswick, NJ 08902Phone 732.422.7585 • Fax 732.422.7310http://www.distekinc.com

All rights reserved. No parts of this work may be reproduced in any form or by any means - graphic, electronic, ormechanical, including photocopying, recording, taping, or information storage and retrieval systems - without thewritten permission of Distek, Inc.

Products that are referred to in this document may be either trademarks and/or registered trademarks of therespective owners. Distek, Inc. makes no claim to these trademarks.

The information contained in the document is subject to change without notice.

While every precaution has been taken in the preparation of this document, Distek, Inc. assumes no responsibility forerrors or omissions, or for damages resulting from the use of information contained in this document or from the use ofprograms and source code that may accompany it. In no event shall Distek, Inc. be liable for any loss of profit or anyother commercial damage caused or alleged to have been caused directly or indirectly by this document.

Distek ezfill 4500


DISTEK, INC.121 North Center DriveNorth Brunswick, NJ 08902Tel. 732.422.7585

Website: http://www.distekinc.com

4Distek ezfill 4500


Table of Contents

Part I About this Manual 7

................................................................................................................................... 81 Purpose

................................................................................................................................... 92 Audience

................................................................................................................................... 103 Contents

................................................................................................................................... 114 Prerequisites

................................................................................................................................... 125 Documentation

................................................................................................................................... 136 Conventions

................................................................................................................................... 147 Document Revision History

Part II Introduction 16

................................................................................................................................... 171 Overview

................................................................................................................................... 182 Specifications

................................................................................................................................... 193 Physical Site Considerations

................................................................................................................................... 204 Environmental Considerations

.......................................................................................................................................................... 20Distek & the WEEE Directive (Waste Electrical & Electronic Equipment)

.......................................................................................................................................................... 20Ambient Laboratory Temperatures

.......................................................................................................................................................... 21Ambient Laboratory Humidity

.......................................................................................................................................................... 22Air Quality Considerations

................................................................................................................................... 235 Operation Warnings and Notes

................................................................................................................................... 256 General Instrument Overview

Part III Installation 28

................................................................................................................................... 291 Unpacking

................................................................................................................................... 302 System Setup

................................................................................................................................... 323 Installing the Remote Handle and Holder (if applicable)

................................................................................................................................... 344 Installing the autofill (if applicable)

................................................................................................................................... 365 Installation Checkout

Part IV Operation 38

................................................................................................................................... 391 Main Control Keypad

................................................................................................................................... 412 Remote Handle Keypad (Optional)

................................................................................................................................... 423 Running a Flush Cycle

................................................................................................................................... 434 Running a Standard Cycle

................................................................................................................................... 445 Displaying Realtime System Pressure/Vacuum

................................................................................................................................... 456 Displaying Realtime System Temperature

................................................................................................................................... 467 Running a Multiple Dispensing Cycle

................................................................................................................................... 478 Washing the System

5ContentsDistek ezfill 4500


................................................................................................................................... 489 Emptying the System

................................................................................................................................... 4910 Automation Setup

.......................................................................................................................................................... 51autofill (Optional)

................................................................................................................................... 5211 Advanced Setup

.......................................................................................................................................................... 52SLS Setup

.......................................................................................................................................................... 53Setup Dispensing Principle

.......................................................................................................................................................... 54Activate autofill

.......................................................................................................................................................... 55Activate Remote Handle

Part V Maintenance 57

................................................................................................................................... 581 General Information

................................................................................................................................... 592 Piston and O-ring Maintenance

................................................................................................................................... 603 Tubing Replacement

................................................................................................................................... 614 Volume Calibration

................................................................................................................................... 635 Temperature Calibration

Part VI Troubleshooting 65

................................................................................................................................... 661 Troubleshooting

................................................................................................................................... 672 Error Codes

................................................................................................................................... 693 Service

Part VII Appendix A: Spare Parts and Accessories 71

Part VIII Appendix B: Pre-Installation Considerations -Electrical Power Supply 73

Part IX Appendix C: CE Declaration of Conformity 75

Index 76

About this Manual

Part

I

About this ManualDistek ezfill 4500 7


1 About this Manual

About This Manual includes information about what is contained in this manual and theconventions used.

Document Number: 3843-0001 Rev. B



1.1 Purpose

This manual covers the installation, routine operation, maintenance and repair of your Distekezfill 4500. It has information regarding the controls, indicators and functions of theinstrument. Please read Chapters 1, 2 and 3 before operating the instrument.



1.2 Audience

This manual is written for any person responsible for maintaining, operating ortroubleshooting the Distek ezfill 4500.



1.3 Contents

Chapter 1 - Introduction Provides a general overview of theinstrument.

Chapter 2 - Installation Describes how to unpack and properlyinstall and qualify the unit.

Chapter 3 - Operation Describes the operation of the unit.

Chapter 4 - Maintenance Explains the steps necessary to maintainthe unit.

Chapter 5 - Troubleshooting Provides a troubleshooting chart anddescription of error messages to assist theuser if a problem should arise.

Appendix A : Spare Parts and Accessories Provides a table of recommended andoptional spare parts.

Appendix B : Pre-InstallationConsiderations: Electrical Power Supply

Recommendation information pertaining toelectrical power supply.

Appendix C : CE Declaration of Conformity CE Declaration of Conformity certificate.



1.4 Prerequisites

This manual assumes that you have an understanding of the principles of dissolution testing,specifically the de-aeration of dissolution media.



1.5 Documentation

This manual contains important information regarding the safe operation and maintenanceof your Distek ezfill 4500.



1.6 Conventions

The following table contains Warnings, Cautions and Notes that are used throughout thedocument for your protection. Please read this section before using the instrument.

“WARNING” statements are used in this manual to preventinjury to personnel.

Electrical hazard warning. Use caution as high voltage mayexist.

y “CAUTION” statements are used to prevent damage toequipment.

“NOTES” contain helpful information.

REQUIRED

ACTION

“REQUIRED ACTION” is used where necessary todistinguish the action needed from Warnings, Cautions andNotes.



1.7 Document Revision History

Rev Date Notes

A December 2006 Original Release. See Distek CN #0567.

B October 2007Update for autofill, CE approval as well as various

Firmware changes. See Distek CN #0590

Document Number: 3845-0001

Introduction

Part

II

IntroductionDistek ezfill 4500 16


2 Introduction

The Distek ezfill 4500 is a very useful accessory in the dissolution lab, allowing a chemist tominimize time between dissolution tests. This chapter will provide an overview of the unitand system specifications.



2.1 Overview

The Distek ezfill 4500 is a compact, transportable and easy-to-use media dispensing unit. The system is capable of vacuum degassing, heating and accurately dispensing volumes aslarge as 1000 mls. The system is user programmable and volumes are adjustable between250 and 1000 mls in 5 ml increments. The temperature is adjustable from roomtemperature up to 45ºC.

The unit is capable of running as a bench top instrument, can be purchased with a DistekMobile Cart and Remote Handle to allow mobile access throughout the laboratory ormounted atop an autofill for automatic dispensing in up to eight vessels.

This manual contains important information regarding the safe operation, maintenance andrepair of your Distek ezfill 4500.



2.2 Specifications

Dispensing Volume 250 mls to 1000 mls

Dispensing Accuracy ± 1% of set volume, but not less than ± 5 mls

Heating Capacity + 20 C degrees temperature increase

Degassing Removal of 3.0 ppm to a level no less than 5.0 ppm

Input Filter 25mm in-line filter holder

Temperature Control Cartridge Heater

Temperature Accuracy ± 2 °C

PC Interface RS-232 (serial) & USB 2.0

ezfill Dimensions Height 27.50 in. (70 cm)Width 12.25 in. (31 cm)Depth 10.25 in. (26 cm)

Mobile Cart Dimensions Height 37.00 in. (94 cm)Width 21.00 in. (53 cm)Depth 27.50 in. (70 cm)

autofill Dimensions Height 10.50 in. (27 cm)Width 20.50 in. (52 cm)Depth 20.50 in. (52 cm)

Weight ezfill 42 lbs (19 kg)

Mobile Cart 32 lbs (15 kg)

autofill 26 lbs (12 kg)

Electrical Power 115V ± 15V 50/60Hz 15Aor 230V ± 15V 50/60Hz 8A(Operating voltage pre-set at factory)



2.3 Physical Site Considerations

The dimensional requirements specified below are adequate for the installation of the Distekezfill 4500 System:

1. The minimum bench depth needed (front edge of bench to the back splash or wall) is 12”(31 cm). However, the recommended bench depth is 16" (41 cm).

2. The minimum linear bench space requirement is 14.5" (37 cm). Distek recommends thatat least 18" (46 cm) be allocated whenever manual operations are required to beperformed adjacent to the system.

3. There must be no obstruction (cabinet, shelf, etc.) that intrudes into the minimum footprintof the unit up to a height of 30" (76 cm) above the bench surface where the unit is to beinstalled.

4. The bench must be capable of sustaining the weight of the unit and all of its accessoryparts without significant bending. Because the entire mass of the unit is transferred to thebench surface through padded feet, the bench surface should be strong enough towithstand the entire weight of the unit.

5. The bench slope should be less than 0.75” (1.9cm) from front to back or from side to sideover the unit’s foot print.



2.4 Environmental Considerations

2.4.1 Distek & the WEEE Directive (Waste Electrical & Electronic Equipment)

Distek, Inc. is committed to protecting the environmentand understands the importance of proper recycling. The“crossed out wheelie bin” symbol on the product or on itspackaging indicates that this product must not bedisposed of with domestic household waste. Instead, it isthe user’s responsibility to dispose of their wasteequipment by handing it over to a designated collectionpoint for the recycling of electrical and electronicequipment waste. The separate collection and recyclingof your waste equipment at the time of disposal will helpto conserve natural resources and ensure that it isrecycled in a manner that protects human health and theenvironment.

For more information about where you can drop off yourwaste equipment for recycling, please contact your localcity office, your local distributor or Distek, Inc.

2.4.2 Ambient Laboratory Temperatures

Distek recommends that the laboratory temperaturecontrol system fans be kept on at all times. This shouldimprove set point control, and minimize short-termexcursion range.

Maximum Conditions:1. To achieve the full range of controlled operation within specified tolerances the Distek

ezfill 4500 system is designed to be installed and operated in laboratories where themaximum operating temperature does not exceed 25°C.

2. The maximum allowable ambient operation temperature is 30°C.

Operating environments above 25°C limit the range forsatisfactory operation of the system.

Minimum Conditions:To assure controlled operation within specified tolerances, the system is designed to beoperated in laboratories where minimum operating temperatures do not drop below 15°C.

Variability or Short Term Fluctuations:To assure controlled operation within specified tolerances, the system used to control the



temperature of the laboratory where the system is installed must be able to maintain theambient air temperature within ±2.5°C of set point (worst case).

2.4.3 Ambient Laboratory Humidity

Distek recommends that the laboratory humidity controlsystem fans be kept on at all times if possible. Thisshould result in better set point control and reduce theshort term excursion range.

Maximum:The Distek ezfill 4500 system may add to the humidity of the laboratory during operation. Water vapor and/or hydrogen chloride vapor, from dissolution media, can cause seriouseffects when condensed on electrical components and contacts. The lab’s environmentalcontrols should maintain the humidity level below the dew point, to minimize the risk ofcondensation.



Minimum:It is important that the humidity level be kept at or above 30% relative humidity, to minimizethe risk of damage to control circuits caused by static discharge.

2.4.4 Air Quality Considerations

Distek ezfill 4500 system is designed to be operated in a lab environment that has no visibledust problem, and with organic solvent vapor levels as low as possible. Operation is notrecommended in dusty lab environments, or in labs with significant chlorinated or reactivesolvent vapor levels. Dust or vapors may have serious effects on system components. Absorption of vapors into dissolution media may bias test results. Some dissolution testsmay require dissolution and drug release media prepared from USP quality water. Absorbedvapors may cause difficulty in complying with USP requirements.



2.5 Operation Warnings and Notes

For your safety, the information in this manual must befollowed to minimize the risk of fire or explosion,electrical shock, or to prevent property damage,personal injury or loss of life.

Use this equipment only for its intended purpose asdescribed in this Operation Manual.

Never attempt to operate this instrument if it isdamaged, malfunctioning, partially disassembled, orhas missing or broken parts, including a damaged cordor plug.

Improper servicing or adjustment practice can causeequipment failure or serious physical injury. Thisequipment must be adjusted and serviced by qualifiedelectrical maintenance personnel who are familiar with theconstruction and operation of the equipment and thehazards involved. Take diligent care during adjustment. Allexposed points on the control circuit boards are electricallyhot with respect to earth ground.

Dangerous voltages exist on the circuit boards whenpowered. Disconnect AC power from the units whiletroubleshooting. Be alert. High voltage can causeserious or fatal injury.

All units equipped with heaters have thermocoupleprotection. In the event of a malfunction, the heater willautomatically cut off. The thermocouple willautomatically reset after cooling down.

Take proper precautions when handling dissolutionmedia. Liquid in vessel may be HOT. Wear splashprotection to avoid exposure to scalding, acidic, caustic,or pharmaceutical hazards. Bacteria have been shownto thrive in certain media, especially at testtemperatures.

The Distek ezfill 4500 system is capable of handling allof the commonly used dissolution media such as 0.1 NHCL, phosphate buffers and sodium lauryl sulphate.



In the event of a hazardous material spill on the externalsurface of the instrument, the unit can be cleaned with adisposable cloth or paper wipe, then rinsed with waterand dried. The same approach can be used for internalspills but the power must be disconnected first!

Prior to performing any cleaning or decontaminationmethod, the user should verify the method with Distek.

Improper remote PC control of the Distek ezfill 4500system may lead to unexpected motor and/or heateroperation.

The Distek ezfill 4500 system is supplied with propercomponents and settings for the specified operatingvoltage (see label for information). Do not attempt toconvert unit to another mains supply without contactingDistek's factory first!

External cables (excluding power cable) are limited toless than 3 meters length in order to maintainelectromagnetic compliance.

Some forms of electromagnetic interference may causeunexpected operation. If this occurs, the unit will returnto normal operation once the interference is removed.



2.6 General Instrument Overview

Front View



Back View

Installation

Part

III

InstallationDistek ezfill 4500 28


3 Installation

This chapter will describe the steps necessary to properly unpack and install the instrument.



3.1 Unpacking

Please take a few moments when unpacking the unit to check for all items indicated onpacking list. Notify Distek, Inc. or your shipper immediately with any discrepancies ordamage to cartons or contents in transit.

The Distek ezfill 4500 will arrive in 1 box containing the instrument.

To avoid injury, two people should remove the Distek ezfill4500 from the shipping carton.

1. Cut through the tape at the top of carton and open the four top flaps.2. Carefully remove the packing inserts and lift the instrument from the shipping carton. See

warning above.3. If applicable, identify and remove all tie-wraps from the various locations on the unit.



3.2 System Setup

The Distek ezfill 4500 comes standard with a Dispensing nozzle that gets attached to theoutlet port. An optional Remote Dispensing Handle can be purchased for mobile units. SeeInstalling the Remote Handle and Holder for further instructions.

Install Dispensing NozzleUpon unpacking the unit from the shipping box there will be a separate bag containing thewash tube and dispensing nozzle. The dispensing nozzle must be installed prior to use.

If the optional Remote Handle module was purchased, continue to the next section,"Installing the Power Cord". See Installing the Remote Handle and Holder for installationinstructions.

1. Remove the nozzle from the plastic bag.2. Insert the quick connect dispensing nozzle on the outlet port on the main unit.

Ensure that the connector is fully inserted (a clicking sound should be heard). Seethe image below.



Install Power Cord

The Distek ezfill 4500 system is supplied withproper components and settings for the specifiedoperating voltage (see serial label for information).Proper voltage with the corresponding power cordmust be utilized.

1. Insert the power cord into the power inlet module located on the back of the unit.2. Plug the power cord into the wall outlet.

Arrange Inlet TubeWhen shipped, the inlet tube located on the back panel will be bundled against the back ofthe unit. It is necessary to unbundle the inlet tube and place it into the media source.

1. Locate the inlet tube that exits the unit on the back panel.2. Unbundle the tubing.3. Place tube in the media source.



3.3 Installing the Remote Handle and Holder (if applicable)

If the Distek ezfill 4500 was purchased with the Remote Dispensing option then the RemoteHandle will need to be installed upon receiving the unit. Installation entails connecting aquick connect fluid fitting, an electrical connection and the Remote Handle holder.

Installing the Remote Handle holder:1. Remove the two screws from the right hand side panel (if applicable).2. Screw in the two thumb screws provided with the Remote Handle. Do not tighten

these screws.3. Insert the two slots on the Remote Handle holder onto the two thumb screws.4. Tighten the thumb screws.

Installing the Fluid and Electrical Connectors (see images below):1. Insert the quick connect fluid fitting on the outlet port on the main unit. Ensure that

the connector is fully inserted (a clicking sound should be heard).2. Insert the electrical connector into the fitting located next to the outlet port on the

Distek ezfill 4500's front cover. Once the connector is fully inserted, a collar locatedon the connector should be rotated to lock the connector in place.

3. The unit will automatically detect when the handle is installed and adjust the Distekezfill 4500's program for the additional tubing length.

Remote Handle



Front Cover Installation Connections



3.4 Installing the autofill (if applicable)

If the Distek ezfill 4500 was purchased with an autofill option then the autofill will need to beinstalled upon receiving the unit. Installation entails connecting the autofill to the main ezfillunit, an electrical connection and a tubing connection.

Installing the autofill to the main ezfill unit:1. Place the autofill on the installation site (ie. sturdy bench).2. If the ezfill does not have the connector ring located on the bottom (grey circular

ring) this needs to be installed first. Screw the connector ring on the bottom of theezfill with the supplied screws.

3. Place the ezfill on top of the autofill.4. Orient the Upper Fluid Connection and the Lower Fluid Connection to be in line

vertically. This should align the screw hole on the autofill with the connector ringlocated on the bottom of the ezfill.

5. Screw the two units together with the supplied screws.

Installing the Fluid and Electrical Connector:1. If applicable, disconnect the ezfill fill nozzle from the main unit (Upper Fluid

Connection).2. Connect the fluid connection from the Lower Fluid Connection to the Upper Fluid

Connection. Ensure the fitting are fully engaged (a click should be heard).3. In the back of the unit connect the wiring harness from the autofill to the connector

on the back cover of the ezfill.



3.5 Installation Checkout

The following checklist should be verified upon completion of the installation.

· Unpack the instrument from the shipping container and place on a sturdy bench (orMobile Cart if applicable).

· Connect dispensing nozzle or Remote Handle.· Connect the autofill (if applicable).· Connect the power cord.· Place the inlet tube into media source.

Operation

Part

IV

OperationDistek ezfill 4500 38


4 Operation

This chapter describes the user interface for the instrument and provides step-by-stepinstructions to perform many common tasks.



4.1 Main Control Keypad

The image and table below describe the Distek ezfill 4500's keypad and its functionality.

Keypad Item FunctionalityFlush Press this button to run a flush cycle.

Run Press this button to begin a standard cycle.

Wash Press this button to begin a wash cycle. Hold this button for 2-3seconds to configure a wash cycle.

Abort Press this button to abort the current action.

Setup Press this button to configure a standard cycle. This button is also usedin conjunction with certain advanced features (i.e. volume calibration,temperature calibration, etc.).



Up/Down Arrows Keys

These buttons are used to toggle the values shown on the display.

Vessel Volume LED

Activated when the set volume is displayed. This will occur either duringthe setup procedure or while the system is running.

Vessel Temp. LED

Activated when the set temperature is displayed. This will occur eitherduring the setup procedure or while the system is running.

Automation LED Activated while configuring automation options (i.e. multiple dispensingcycle, etc.).

Error LED Activated during a system error. An error number will be displayed. See Error Codes for more information.



4.2 Remote Handle Keypad (Optional)

The image and table below describe the Distek ezfill 4500's Remote Handle keypad and itsfunctionality.

Keypad Item FunctionalityFlush Press this button to run a flush cycle.

Run Press this button to begin a standard cycle.

Wash Press this button to begin a wash cycle. Hold this button for 2-3seconds to configure a wash cycle.

Abort Press this button to abort the current action.



4.3 Running a Flush Cycle

In order to prepare the system to dispense media for a dissolution test it is recommended torun a Flush prior to dispensing. This cycle allows the unit to equilibrate properly and reducethe likelihood of cross contamination when changing media.

If the system is empty (i.e. a WASH was previously ran),a FLUSH cycle is required prior to running a cycle if usingthe Remote Handle or autofill.

If either of the following two criteria are met, it is recommended to run a Flush cycle.· Media change· System has been idle for over 45 minutes

Running a Flush Cycle:1. Place the inlet line into the test media.2. Place a vessel or empty beaker under the dispensing nozzle or remote handle.3. Press the Flush button.4. When complete the unit will display IDLE. Discard the media.



4.4 Running a Standard Cycle

Running a Standard Cycle:1. Place the inlet line into the test media.2. Press the Setup button.3. The Vessel Volume LED will illuminate. Using the Up/Down arrow keys enter the desired

volume in mls (increments of 5 mls).4. Press the Setup button.5. The Vessel Temperature LED will illuminate. Using the Up/Down arrow keys enter the

desired temperature in degrees Celsius (°C, maximum of 45°C).6. Press the Setup button.7. If the set volume is greater than 500 mls proceed to Step 9.8. If the set volume is less than or equal to 500 mls the Automation LED will illuminate. The

unit will display VSL.X where X represents the number of vessels to dispense. Using the Up/Down arrow keys set the value to 1. See Automation Information below for moreinformation.

9. Place a vessel under the dispensing nozzle or place the remote handle into the vessel.10.Press the Run button.

If the system is empty (i.e. a WASH was previously ran),a FLUSH cycle is required prior to running a cycle if usingthe Remote Handle or autofill.



4.5 Displaying Realtime System Pressure/Vacuum

It is possible to display the system's pressure or vacuum during a dispensing cycle. Viewingthis information helps to verify that the system is operating properly. This feature isactivated by holding the Down arrow during a cycle.

This feature is only operational while the system isrunning a dispensing cycle.

1. Press Run to start a standard cycle.2. While the system is running hold the Down arrow.3. The display will show the system pressure or vacuum depending on the point in the cycle.

When media is being pulled into the system, a vacuum reading is displayed. If media is inthe dispensing stage a pressure reading is displayed.

A negative number represents vacuum in in.Hg units and a positive number is a pressure inpsi. Typically the system should reach a maximum vacuum of approximately 25-28 in.Hgand the pressure should not exceed 15 psi for an extended period of time (momentaryspikes are acceptable).



4.6 Displaying Realtime System Temperature

It is possible to display the system temperature during a dispensing cycle. Viewing thisinformation helps to verify that the system is operating properly. This feature is activated byholding the Up arrow during a cycle.

This feature is only operational while the system isrunning a dispensing cycle.

1. Press Run to start a standard cycle.2. While the system is running hold the Up arrow.3. The display will show the system temperature inside the heater mechanism. This

displayed temperature will not exactly correlate to the set temperature (desired outputtemperature) as certain heating algorithms are used to control the output temperature.



4.7 Running a Multiple Dispensing Cycle

This action is only valid for volumes equal to or less than500 mls.

Automation Information:The unit dispensing mechanism is capable of drawing up to 1000 mls per cycle. In order tominimize cycle time it is possible to dispense multiple vessels within one cycle. Forexample, if dispensing 500 mls the unit can dispense two vessels in one action. Thisvirtually cuts the dispensing time in half for two vessels. For 250 mls volume, the unit candispense four vessels in one cycle. The maximum number of vessels is automaticallycalculated.

Running a Multiple Dispensing Cycle (valid for volumes equal to or less than 500mls):1. Place the inlet line into the test media.2. Press the Setup button.3. The Vessel Volume LED will illuminate. Using the Up/Down arrow keys enter the desired


desired temperature in degrees Celsius (°C, maximum of 45°C).6. Press the Setup button.7. The Automation LED will illuminate. The unit will display VSL.X where X represents the

number of vessels to dispense. Using the Up/Down arrow keys set to the desired value.See Automation Information below for more information.

8. Press the Setup button.9. Place a vessel under the unit or place the remote handle into the vessel.10.Press the Run button.11.Once the first vessel is complete the unit will beep. Remove the vessel and place an

empty vessel under the dispensing nozzle or place the remote handle in the next vessel.12.Press the Run button.13.Repeat Steps 8-10 until all vessels have been dispensed.



4.8 Washing the System

The system should be thoroughly washed at regular intervals and always when switchingmedia types. The Wash Cycle can be configured to wash a certain number of times orcontinuously until aborted.

Running a Wash Cycle:1. Hold the Wash button for 2-3 seconds.2. The unit will display RUN.X where X represents the number of Wash cycles. Using the

Up/Down arrow keys set to the desired value (1-8 cycles).3. Press the Wash or Setup button to save the setting.4. Disconnect the dispensing nozzle using the quick release button and connect the supplied

wash tubing line.5. Place the inlet line into DI Water (or other suitable media) and the wash tubing line into a

waste container.6. Press the Wash button to begin the cycle.7. The unit will display IDLE upon completion.



4.9 Emptying the System

It is not recommended to run the system dry; therefore, the best method to empty the Distekezfill 4500 is to run a Wash cycle. Upon completion of a Wash cycle the system will beempty.

See Washing the System for more information. It is only necessary to run one wash cycle toempty the system.



4.10 Automation Setup

The autofill optional module adds an additional element of automation to the ezfill. Theautofill allows for automatic dispensing of 1-8 vessels. The user is able to set the volume,temperature and number of vessels. Once the cycle is complete all vessels will bedispensed in the autofill.

The autofill is activated in the Advanced Options (Activate autofill) which allows for anadditional automation step (selecting number of vessels to dispense) when setting up acycle.

This section is only valid if the autofill option waspurchased. Contact Distek for more information.



4.10.1 autofill (Optional)

This section is only valid if the autofill option waspurchased. Contact Distek for more information.

ezfill Firmware 1.30 or higher is required.

If the system is empty (i.e. a WASH was previously ran),a FLUSH cycle is required prior to running a cycle if usingthe autofill.

Running a autofill Cycle:1. Place empty vessels into the two position vessel racks. Depending on the number of

vessels to dispense, install the necessary number of two position racks starting at theautofill position labeled 1.

2. Press the Setup button.3. The Vessel Volume LED will illuminate. Using the Up/Down arrow keys enter the desired


desired temperature in degrees Celsius (°C, maximum of 45°C).6. Press the Setup button.7. Enter the number of vessels to dispense and press Setup to exit.8. Ensure the number of vessels setup up in the previous step corresponds the number of

vessels loaded in the autofill.9. Press the Run button.



4.11 Advanced Setup

Improper setup can cause unexpected results. Theequipment must be configured by qualified personnel whoare familiar with the operation of the equipment. Takediligent care during setup.

Advance Setup Mode allows the configuration of the following settings:

· Dispensing Principle: The unit can be configured to use a dispensing principal based onWeight or Volume. The default setting is weight.

· Activate Remote Handle: This option is used to verify the activation of the remote handle.

4.11.1 SLS Setup



When using SLS or an equivalent media type (ie. SDS, etc.) it is recommended to activateSLS mode on the ezfill. This is an optimized mode that prevents excessive foaming thattypically occurs with soapy media types.

SLS mode is activated in the Advanced Setup Mode:1. Simultaneously select the Setup button and Up arrow.2. Press Setup button until the following message flashes: SLS ON or OFF.3. If necessary, use the Up or Down arrow to toggle between ON and OFF.4. Hold the Setup button for 2-3 seconds to exit the Advanced Setup Mode.



4.11.2 Setup Dispensing Principle


The Distek ezfill 4500 can be configured to dispense using either of the following twooptions:· Dispense by Weight (Default Setting):

This option does not account for the weight change at an elevatedtemperature. For example dispensing 900 mls at 40°C will dispense 900grams when placed on a scale; therefore, the actual volume will be slightlyhigher than 900 mls.

· Dispense by Volume:This option will account for the weight change at the set temperature. Forexample dispensing 900 mls at 40°C will dispense 893 grams when placed ona scale, equaling a volume of approximately 900 mls.

The following equation can be used to calculate the expected result:Dispensed Weight in Grams = Set Volume - [(Set Volume) x (Coefficient of Thermal Expansion ofWater) x (Set Temperature - 4°C)]

where the coefficient of thermal expansion of water is 0.00021per 1°C at 20°C.

It is assumed that one milliliter of water is equal to onegram.

All internal calculations are based on the physicalproperties of water.

This can be configured in the Advanced Setup Mode following the procedure:1. Simultaneously select the Setup button and Up arrow.2. Press Setup button until the following message flashes: CALC BY VOL (Note: The

value VOL or WGHt will be displayed depending how the unit is configured).3. If necessary, use the Up or Down arrow to toggle between VOL and WGHt.4. Hold the Setup button for 2-3 seconds to exit the Advanced Setup Mode.



4.11.3 Activate autofill



If the system is empty (i.e. a WASH was previously ran),a FLUSH cycle is required prior to running a cycle if usingthe autofill.

The autofill is activated in the Advanced Setup Mode:1. Simultaneously select the Setup button and Up arrow.2. Press Setup button until the following message flashes: AUTOFILL ON (Note: The

value ON or OFF will be displayed depending if the handle is installed).3. If necessary, use the Up or Down arrow to toggle between ON and OFF.4. Hold the Setup button for 2-3 seconds to exit the Advanced Setup Mode.



4.11.4 Activate Remote Handle


This section is only valid if the Remote Handle option waspurchased. Contact Distek for more information.

The Remote Handle allows dispensing directly into the vessel using an attachment that isconnected to the main unit. The handle has a keypad that controls many of the unit'sfunctions. See Remote Handle Keypad for more information.

The unit will automatically detect if the Remote Handle is installed; however, it is possible toverify the unit's handle detection or to manually enable/disable the handle.

This can be verified in the Advanced Setup Mode following the procedure:1. Simultaneously select the Setup button and Up arrow.2. Press Setup button until the following message flashes: HANDLE ON (Note: The

value ON or OFF will be displayed depending on handle installation).3. If necessary, use the Up or Down arrow to toggle between ON and OFF.4. Hold the Setup button for 2-3 seconds to exit the Advanced Setup Mode.

Maintenance

Part

V

MaintenanceDistek ezfill 4500 57


5 Maintenance

This chapter gives a brief overview of how to properly maintain the Distek ezfill 4500 system.To ensure consistent performance, a Preventive Maintenance (PM) Qualification should beconducted periodically. Contact Distek for more information.



5.1 General Information

1. Unit should be cleaned periodically by wiping with a slightly damp cloth. Do not use anyharsh chemicals or detergents.

2. Electronics require no customer attention. In the event of a malfunction, please call thefactory before attempting any repairs. See Service for more information.

3. Turn off the unit and unplug the power cord. Remove the front cover. Rotate the drivebelt in small increments and apply a small amount of Dow Corning High Vacuum Greaseto the lead screw attached to the piston. (This should be done every 6 months.) Replacethe front cover. Drive motor and bearings are permanently lubricated. Belt tension isfactory adjusted.

4. Inspect the internal and external tubing and replace if necessary.

Do not clean plastic and rubber parts with organicsolvents.



5.2 Piston and O-ring Maintenance

Improper servicing or adjustment can cause equipmentfailure or serious physical injury. The equipment must beadjusted and serviced by qualified personnel who arefamiliar with the construction and operation of theequipment and the hazards involved. Take diligent careduring adjustment.


Cleaning the Piston and O-ring Replacement:

1. Turn the power off and remove the power cord from the back of the instrument.2. Disassemble the rear cover by removing the 4 pan head screws on the inside flange and

4 pan head screws on the back of the instrument.3. Disconnect the tubing from the 2 ports located on the piston cover.4. Remove the piston cover screws.5. Use the piston cover screws in the open screw holes (aligned with the rim of the glass

cylinder) to pry the piston cover off the piston. (Note: Use cation to carefully store thepiston cover without putting strain on the wire harness connected to the pressure sensor.)

6. Once the piston cover is removed move the piston to its lowest position by turning thepulley located under the piston.

7. Clean the glass cylinder with an appropriate cleaning product.8. If it is necessary to replace the o-ring, move the piston up until the o-ring is exposed

beyond the top of the glass cylinder.9. Remove the o-ring. For removal, it might be necessary to cut the o-ring.10. Replace the o-ring. In order to ease installation, it is suggested to soak the o-ring in hot

water for several minutes. This will make the o-ring more flexible.11. Coat the o-ring with a small amount of diluted soapy media. This prevents the o-ring

from damage when lowering into the cylinder.12. Lower the piston into the cylinder to its lowest position.13. Clean the cylinder.14. Replace the piston cover.15. Replace the rear cover.16. Plug in the power cord to the back of the unit and power on the unit.17. Run several WASH cycles to ensure the unit is clean.



5.3 Tubing Replacement



Every six months a visual inspection should be conducted to determine if the Distek ezfill4500 tubing needs to be replaced. The tubing replacement timeframe will be dependent onusage.

There are a total of 9 tubing lines in the system for replacement. The majority of fittings arequick disconnect style for fluid fittings. To disconnect, simply pull on the tubing line andpress down on the circular connector sleeve attached to the tube. To install, fully press thetubing line into the connector.

Contact Distek to purchase a Tubing Replacement Kit. See Service for more information oncontacting Distek.

The following procedure describes how to replace all the tubing lines; however, after visualinspection it might not be necessary to replace every line.

1. Turn the power off and remove the power cord from the back of the instrument.2. Disassemble the front cover by removing the 3 flathead screws on the inside flange.3. Disassemble the rear cover by removing the 4 pan head screws on the inside flange

and 4 pan head screws on the back of the instrument.4. Disconnect and discard each tubing line one at a time and replace with the same

length tube from the Replacement Kit. If a filter is used on the inlet line, disconnect,discard and replace only the tubing lines; do not discard the actual filter as that canbe reused.

5. With the covers open connect the power cord and turn the unit on.6. Run a few cycles to ensure there are no leaks. 7. Be careful not to touch the inside of the unit as high current exists. If there is

a leak immediately abort the cycle, turn the power off, disconnect the powercord and repair!

8. If there are no leaks, reinstall the front and rear covers.9. Requalify the unit if necessary.



5.4 Volume Calibration

In order to ensure consistent operation, at times it might be necessary to perform a volumecalibration. The calibration procedure will adjust the unit's flow rate and account for tubingvolume inaccuracies. The procedure requires a calibrated scale (upper limit of at least 1800grams) and a beaker capable of holding at least 1800 mls.

Depending on the unit's configuration it might be necessary to calibrate the system both as astandalone bench top unit and with the remote handle. The instrument will store separatecalibration files for a standalone unit and for Remote Handle operation. The following tabledescribes the required calibration depending on the desired mode of operation.

Unit configuration: Calibrate as Standalone Calibrate with Remote HandleBench top Only

Remote Handle Only

Bench top and Remote Handle

Autofill


To ensure the unit and all lines are empty, a WASH cycleshould be run prior to calibrating the unit.

For tighter volume accuracy repeated calibrations can beperformed.

The procedure below can be run with either as standalone unit or with the remote handle.

1. Fill a beaker with at least 1500 mls of water at room temperature (approximately 22ºC).

2. Place the beaker on a scale and tare the scale.3. Place the inlet tube into the beaker.4. Simultaneously press the Run and Setup buttons. 5. The unit will begin to draw media into the instrument. Ensure the inlet is at the

bottom of the beaker.6. The unit will beep upon completion.7. Remove the inlet tube and place the beaker on the scale.8. Enter the weight (in grams) on the Distek ezfill 4500 using the Up and Down

arrows.9. Empty the beaker.10. Place the empty beaker on the scale and tare the scale.



11. Place the beaker under the dispensing nozzle or place the remote handle on top ofthe beaker.

12. Press Setup.13. Once the unit begins beeping, place the beaker back on the scale.14. Enter the weight (in grams) on the Distek ezfill 4500 using the Up and Down

arrows.15. Press Setup to complete the calibration.



5.5 Temperature Calibration

The ezfill 4500 is capable of storing both low and high temperature calibration data. Although performing both a low and high temperature calibration is not required it isrecommend for more accurate temperature results.

Improper servicing or adjustment can cause equipmentfailure or serious physical injury. This equipment must beadjusted and serviced by qualified personnel who arefamiliar with the construction and operation of theequipment and the hazards involved. Take diligent careduring adjustment.

The following procedure can be run for both a low and high temperature calibration. If themedia temperature is less than 30ºC a low temperature calibration is run. If the media isgreater than 35ºC a high temperature calibration is run.

Recommended calibration temperature:Calibration Setting

Low Temperature 25ºCHigh Temperature 38ºC

1. Fill a 1000 ml beaker with media at a temperature of approximately 40ºC.2. Simultaneously press the Setup, Down arrow and Up arrow.3. Measure the temperature in the beaker and enter this value on the Distek ezfill 4500

using the Up and Down arrows.4. Place the inlet tube in the beaker.5. Press Setup.

Troubleshooting

Part

VI

TroubleshootingDistek ezfill 4500 65


6 Troubleshooting

This chapter provides troubleshooting information to identify the most common problemsand their solution.



6.1 Troubleshooting

Before performing any procedure in this section, please disconnect AC power from the unit.

Improper servicing or adjustment can causeequipment failure or serious physical injury. Thisequipment must be adjusted and serviced by qualifiedpersonnel who are familiar with the construction andoperation of the equipment and the hazards involved. Take diligent care during adjustment.

HIGH VOLTAGE IS EXPOSED WHEN THE FRONTOR REAR COVERS ARE OPENED ON THESYSTEM. Dangerous voltages exist on the circuitboards when powered. Disconnect AC power from theunit while troubleshooting. Be alert. High voltage cancause serious or fatal injury.

Symptom Possible Cause Possible Solution

Error Code 1 isdisplayed.

The internal heatertemperature sensor hasreached its maximum setpoint. The unit might berunning dry.

Place the inlet tube into a roomtemperature media source. Power cycle (restart) the Distekezfill 4500. Run a cycle with theset temperature around 20ºC tolower the unit's internaltemperature.

Error Code 2 isdisplayed.

Fluid fitting for the remotehandle or nozzle was notproperly installed.

Due to the added resistance onthe motor it is possible the fuselocated on the internal PCB wasblown. Contact Distek Service.

System runs but nomedia is dispensed.

If the motor cannot be heardrunning inside the unit, then itis possible that the motor fusewas blown.

Replace the motor fuse. ContactDistek Service for assistance andreplacement parts.



6.2 Error Codes

In the event that an error occurs, the Error LED will illuminate and the two-digit error codewill be displayed. The following table describes the error codes.

Before performing any procedure in this section, please disconnect AC power from the unit.

Improper servicing or adjustment can causeequipment failure or serious physical injury. Thisequipment must be adjusted and serviced by qualifiedpersonnel who are familiar with the construction andoperation of the equipment and the hazards involved. Take diligent care during adjustment.

HIGH VOLTAGE IS EXPOSED WHEN THE FRONTOR REAR COVERS ARE OPENED ON THESYSTEM. Dangerous voltages exist on the circuitboards when powered. Disconnect AC power from theunit while troubleshooting. Be alert. High voltage cancause serious or fatal injury.

Error Code Problem Possible Solution

1 Overheating · Ensure the inlet line is placed in themedia source and the unit is notrunning dry.

· Run a few cycles through the unitat room temperature to cool downthe heaters.

2 Main Motor Stuck · Remove the front cover and checkthat the motor can move the pistonsmoothly by rotating the belt andpulley.

· Replace fuse located on PCB.· Contact Distek Service.

3 Keypad Error · Main keypad is not functioningproperly. Contact Distek Service.

4 IIC Communication Error · Contact Distek Service.

5 Display · Contact Distek Service.

6 Motor CPU · Contact Distek Service.

7 Leak · Open the front cover and inspectthe system for a leak.

8 Isolation Power Supply Failed · Contact Distek Service.

9 Poor Vacuum · The error occurs if the vacuum isless than approximately 20 in.Hg. Ensure the inlet line is placed in a



Error Code Problem Possible Solution

media source, all valves arefunctioning properly & there are nosystem leaks. Poor degassingresults are possible.

10 Dry Operation (No Media) · Error occurs if the pressure isapproximately less than 0.9 psiwhen dispensing media.

· The error occurs if the vacuum isless than approximately 3 in.Hg.

· Ensure the inlet line is placed in amedia source.

· This error requires the unit to berestarted.

11 High Pressure · A blockage in the system whichcould be caused by a bad valve, apinched tubing or the inlet line notproperly connected. This occurs ifthe pressure is greater thanapproximately 32 psi.

12 High Pressure · A blockage in the system which isprobably caused by either thedispensing nozzle not connected(or not properly connect) or a valvenot opening properly. Verify thedispensing nozzle's connection andall valves.



6.3 Service

If you have a problem with the instrument or need parts information, contact the DistekService Department by e-mail at [email protected] or call our toll-free number(888)234-7835.

Items returned for repair or exchanges require an R.A. number. Please contact the DistekService Department to obtain an R.A. number.

Please send the return or repair to:

Distek, Inc.Service Department121 North Center DriveNorth Brunswick, NJ 08902Attention: R.A. # ___________

mailto:[email protected]

Appendix A: Spare Parts andAccessories

Part

VII

Appendix A: Spare Parts and AccessoriesDistek ezfill 4500 71


7 Appendix A: Spare Parts and Accessories

Part Number Description

2600-00041 Tubing Replacement Kit - Distek ezfill 4500

2800-0027 Vessel Rack, 4 Position

3250-0189 Dispensing Nozzle

5720-90261/4" NPT Thread Insert with Shutoff (Connected to DispensingNozzle)

2800-0033 Wash Tubing Line

5570-0036 Filter Holder

5570-8022 FEP-Encapsulated O-ring

5720-9205 Solenoid Valve (3/unit)

5720-0036 Solenoid Valve (1/unit)

5300-0005 Belt

2800-0169 Remote Dispense Nozzle

2600-0105 Mobile Cart

Model autofill 8 Position autofill. Includes cables and four 2 position vessel racks.

2800-0089 Vessel Rack, 6 Position

2800-0172 Vessel Rack, 2 Position for autofill

Appendix B: Pre-InstallationConsiderations - Electrical

Power Supply

Part

VIII

Appendix B: Pre-Installation Considerations - Electrical Power SupplyDistek ezfill 4500 73


8 Appendix B: Pre-Installation Considerations - ElectricalPower Supply

1. Locations using 115V, 60-cycle AC should provide a 15A circuit for each Distek ezfill4500.

2. Similarly, if 220V, 50 cycle AC systems are being installed, each system should be wiredto an 8A circuit.

3. Because of the extensive use of microprocessor technology, it is recommended, wherepossible, that 12-gauge stranded-copper wiring be used for all circuit wiring. In caseswhere the distance from the circuit breaker sub-panel to the outlet exceeds 500 feet(150m), 12-gauge wire is the minimum that should be used. The use of larger diameterwiring reduces the voltage drop in the wiring, helps reduce power consumption, andincreases the inductive impedance of the circuit which helps smooth voltage fluctuations.

4. In addition, an isolated ground wire should be used and the site should be wired in a3-phase, 4-wire configuration with an approximate load balancing among the phases. Insites where many systems are being installed, the number of systems wired to eachphase should be balanced as much as possible.

5. To minimize the risk of damage to a system from electrical system problems:· Verify that the power wiring configuration is proper.· If possible, verify the current dissipation capacity of the “ground” and the “neutral” lines

in the circuit wiring.· Building mains should be protected with “lightning suppressors” and, ideally, each

circuit should be terminated by the appropriate “surge protection” receptacle. (In theUnited States, suitable receptacles are supplied by Hubbell, Inc. Alternately, a sizedcomputer-grade surge-suppression accessory with the appropriate current rating canbe added to existing circuits.)

-----------------Although the Distek ezfill 4500 is designed with internal surge protection, failure to follow theserecommendations may compromise the operation of the system and, should the system be damaged by powersurges, lightning or other significant power fluctuations, such system damage is not covered by Distek’swarranty.

Appendix C: CE Declarationof Conformity

Part

IX

Appendix C: CE Declaration of ConformityDistek ezfill 4500 75


9 Appendix C: CE Declaration of Conformity

CE DECLARATION OF CONFORMITYNOT TRANSFERABLE

Responsible Company: Distek, Inc.

121 North Center Dr.

North Brunswick, NJ. 08902

Equipment Type & Model: Distek Dissolution Media Degasser:

ezfill 4500

autofill 4500

Equipment Classification: Electrical equipment formeasurement, control and laboratoryuse.

Declared Compliance & TestStandards:

EMC Directive89/336/EEC/93/68/EEC

EN 61326-1:2006

UL 61010-1: 2nd Edition

CAN/CSA C22.2 No.: 61010-1 2nd

Edition

IEC 61010-1:2001 (Second Edition)

EN 61010-2-010: 2003

Jeff Brinker

Vice President

July 17, 2007

IndexDistek ezfill 4500 76


Index- A -Abort 39

Accessories 71

Advanced Setup 52, 53

Air Quality 22

Ambient Laboratory Humidity 21

Ambient Laboratory Temperatures 20

Audience 9

autofill 34, 51, 52, 54

autofill installation 34

Automation 39, 49, 51

- C -Calibration 61, 63

CE 75

CE Declaration of Conformity 75

Cleaning 59

Contents 10

Conventions 13

- D -Dispensing 52, 53

Dispensing Tip 30

Documentation 12

- E -Electrical Connectors 32, 34

Empty 48

Error 39, 67

Error Codes 67

- F -Fluid Connectors 32, 34

Flush 39, 42

- I -Inlet Tube 30

Instrument Overview 25

- K -Keypad 39, 41

- M -Maintenance 57

Multiple Dispensing 46

- O -Overview 17

- P -Physical Site 19

Power Cord 30

Power Supply 73

Pre-Installation 73

Prerequisites 11

Pressure 44

Purpose 8

- R -Remote Handle 32, 41, 52, 55

Revision History 14

Run 39, 43

- S -Service 69

Setup 39

SLS 52

SLS Setup 52

Spare Parts 71

Specifications 18

IndexDistek ezfill 4500 77


- T -Temperature 45

Troubleshooting 66

Tubing 60

- U -Unpacking 29

- V -Vacuum 44

Volume 53

- W -Wash 39, 47

Weight 53

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