Fluid Bed Laboratory Unit Operation Manual - ssllc.com Strea 1 Fluid Bed Dryer.pdf · Fluid Bed...

Fluid Bed Laboratory Unit

Operation Manual

Model STREA-1

Niro Incorporated Pharma Systems Division

9165 Rumsey Road Columbia, MD 21045

410-997-7010 Fax 410-997-5021

Niro Inc.

Aeromatic-Fielder Division

Fluid Bed Laboratory Unit Operation Manual, Revision 0.0

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TABLE OF CONTENTS

1. Introduction ............................................................................................................ 4 2. Description ............................................................................................................. 7 2.1. Basic Fluid Bed Dryer.......................................................................................... 7 2.2. Fluid Bed Dryer with Spray Granulation Option................................................... 8 2.3. Fluid Bed Dryer Aerocoater or Film Coater ....................................................... 10 3. Installation Instructions......................................................................................... 12 3.1. Equipment Placement ....................................................................................... 12 3.2. Air Supply.......................................................................................................... 12 3.3. Power Requirements......................................................................................... 17 3.4. Exhaust Air Vent Connection............................................................................. 18 4. Operating Instructions .......................................................................................... 19 4.1. Setup................................................................................................................. 19 4.1.1. Connection of the Solution Delivery Pump .................................................. 19 4.1.2. Selection of the Container ........................................................................... 21 4.1.3. Selection of the Distributor Plate and Bottom Screen.................................. 25 4.1.4. Installing the Distributor Plate and Product Screen ..................................... 28 4.1.5. Loading the Product Container.................................................................... 29 4.1.6. Assembly of the Film Coating Container (Spray Coater Option) ................. 30 4.1.7. Loading the Film Coating Container (Spray Coater Option) ........................ 31 4.1.8. Assembly of the Exhaust Air Grid................................................................ 33 4.1.9. Selection of the Exhaust Air Filter ............................................................... 34 4.1.10. Assembly of the Exhaust Air Filter............................................................... 36 4.1.11. Installation of the Coarse Dust Filter ........................................................... 39 4.1.12. Installation of the Container......................................................................... 40 4.1.13. Selection of the Top Spray Nozzle .............................................................. 41 4.1.14. Selection of the Bottom Spray Nozzle (Film Coater Option)........................ 42 4.1.15. Selection of the Air Distributor Plate (Aerocoater Option) ........................... 43 4.1.16. Selection and Installation of the Booster Tube (Aerocoater Option)............ 44 4.1.17. Securing the Distributor Plate/Product Screen (Aerocoater Option)............ 44 4.1.18. Loading of the Container with Product (Aerocoater Option) ........................ 44 4.1.19. Mounting of the Two-Fluid Nozzle (Aerocoater Option)............................... 45 4.2. Equipment Operation ........................................................................................ 46 4.2.1. Operation of Solution Delivery Pump .......................................................... 46 4.2.2. Turning the Unit On ..................................................................................... 47 4.2.3. Setting the Air Flow Rate............................................................................. 48 4.2.4. Setting the Drying Temperature .................................................................. 51 4.2.5. Turning on Filter Cleaning ........................................................................... 52 4.2.6. Display of the Measured Parameters .......................................................... 55 4.2.7. Adjustment of Atomizing Air Pressure ......................................................... 56 4.2.8. Setting Liquid Flow Outside of this Nozzle (Aerocoater Option) .................. 57 4.2.9. Setting the Compressed Air Flow Rate (Aerocoater Option) ....................... 57 4.2.10. Starting Up the Spray Nozzle for Coating/Granulating ................................ 58

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4.2.11. Termination of Run...................................................................................... 60 4.2.12. Emergency Stop.......................................................................................... 60 5. Maintenance Procedures ..................................................................................... 62 5.1. Compressed Air Filter........................................................................................ 62 5.2. Distributor Plate and Product Screen ................................................................ 64 5.3. Exhaust Air Grid ................................................................................................ 64 5.4. Exhaust Air Filter ............................................................................................... 64 5.5. Coarse Dust Filter ............................................................................................. 64 5.6. Product Screen and Spray Nozzle (Aerocoater Option) .................................... 64 5.7. Nozzle Cleaning (Top and Bottom Spray) ......................................................... 65 5.8. Pump Roller Lubrication (Granulation and Aerocoater Option) ......................... 65 6. Calibration Procedures......................................................................................... 66 6.1. Drying Timer...................................................................................................... 66 6.2. Outlet Air Temperature (Digital Display) ............................................................ 67 6.3. Drying Temperature (Digital Controller and Display) ......................................... 68 6.4. Pressure Gauge Atomizing Air (Front Panel Left Hand Side)............................ 69 6.5. Pressure Gauge Filter Cleaning (Front Panel Right Hand Side) ....................... 70 6.6. Pressure Gauge Exhaust Filter and Product Differential (Side Panel) .............. 71 6.7. Airflow Reading (Side Panel)............................................................................. 72 7. Troubleshooting ................................................................................................... 73 7.1. Escape of Dust .................................................................................................. 73 7.2. Malfunctioning Filter Cleaning Device ............................................................... 73 7.3. Insufficient Agglomeration or Coating................................................................ 74 7.4. Unusual Pressure Drop in Air Line .................................................................... 75 7.5. Insufficient Fluidization ...................................................................................... 76 7.6. Temperature Not Attained ................................................................................. 77 8. Technical Data ..................................................................................................... 79 9. Diagrams and Schematics ................................................................................... 80 9.1. Control Panel Faceplate.................................................................................... 80 9.2. Digital Version Electrical Diagram ..................................................................... 81 9.3. Electrical Diagram for Filter Cleaning ................................................................ 82 9.4. Electrical VAC Schematic (Digital Version) ....................................................... 83 10. O & M Information ................................................................................................ 84 11. Spare Parts Information ....................................................................................... 85 12. Appendix .............................................................................................................. 86

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The Aeromatic-Fielder Division of Niro Incorporated is a leading worldwide manufacturer and supplier of process equipment systems to the chemical, food and pharmaceutical industries. Manufactured equipment systems include laboratory, pilot, and production scale fluid bed dryer, spray dryer, particle coater, high shear granulation, and microwave dryer systems. This Operating Instructions Manual provides all installation, setup, maintenance, and calibration procedures for the tabletop multiprocessor Fluid Bed Laboratory Unit. The following options are available. • Fluid Bed Dryer Aerocoater • Fluid Bed Dryer with Top Spray Granulation Option • Fluid Bed Dryer with Spray Film Coating Option The tabletop fluid bed laboratory unit possesses the following features: • Easily fits on top of a laboratory bench • Multifunction operation includes drying, top spray granulation, and bottom

spray coating • Standard utility connections • Easy to operate • Simple to clean and maintain • Special air distributor plate for controlled fluidization • Continuous blow-back filter cleaning A picture of a tabletop fluid bed laboratory unit is shown on the following page in Figure 1-1. Note that some of the figures in this manual show the new STREA laboratory unit with digital instrumentation and some of the figures may show the old style analog instrumentation.

1. Introduction

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Figure 1-1 Tabletop Fluid Bed Laboratory Unit

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The Fluid Bed Laboratory Unit Size 1, Strea-1, was originally developed in 1972 in order to enable customers to carry out small product quantity drying, granulating, and coating operations. This unit is especially well suited for academic, industrial, and contract research laboratories. This manual is intended for technician, scientific, engineering, and maintenance personnel involved with Fluid Bed Laboratory Unit equipment operations. It is expected that all personnel involved with using this piece of equipment have basic laboratory equipment knowledge and skills. This manual is organized into a series of sections dealing with the setup, operation, and maintenance of the fluid bed laboratory unit. These sections are: • Section 2, Description.

Provides an overview of the functionality of each mode of operation. • Section 3, Installation Instructions.

Describes physical placement and utility requirements and connections. • Section 4, Operating Instructions.

Describes setup and operation of the equipment. • Section 5, Maintenance Procedures.

Describes preventative maintenance procedures. • Section 6, Calibration Procedures.

Describes instrument calibration procedure. • Section 7, Troubleshooting.

Describes common operating problems and solutions. • Section 8, Technical Data.

Provides a summary of technical specifications. • Section 9, Diagrams and Schematics.

Provides equipment layout, electrical and pneumatic drawings. • Section 10, Spare Parts.

Provides part numbers, component drawings and photos. • Section 11, Supplementary Appendices.

Provides additional technical information on vintage Strea-1 equipment.

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2.1. Basic Fluid Bed Dryer A sketch of the basic fluid bed dryer with blow-back is shown below in Figure 2-1.

Figure 2-1 Sketch of Fluid Bed Unit with Blow-Back

This equipment configuration functions as a standard fluid bed dryer. The product container (4) contains a moist product in either the granulated or powder form. The product particles are fluidized by means of an upward flowing hot air stream and are carefully dried until the required moisture content is reached. The air necessary for this process is obtained from the work area by means of an extractor fan (1). The air stream is first passed through the coarse dust filter (2) in order to purify the air. Moisture removal is accomplished by heating the air stream to the desired temperature in the air heater (3). The prepared air flows upward through the material in the product container (4) and absorbs the moisture present in the product particles. The exhaust filter (5) retains any product material in the fluid bed dryer. An automatic blow-back device is installed on top of the filter surface and returns it to the container area. The exhaust air escapes though the socket (6) and the tube (7) into the open air or an exhaust duct system.

2. Description

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2.2. Fluid Bed Dryer with Spray Granulation Option

A sketch of the basic fluid bed dryer with the top spray granulation option is shown below in Figure 2-2.

Figure 2-2 Sketch of Fluid Bed Unit with Spray Granulation Option

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SPRAY GRANULATION Granulation is a process by which smaller particles are bonded together to make larger particles or granules. Fluidized bed granulation is a process by which these granules are produced in a single piece of equipment by spraying a binder material and solvent onto fluidized particles. See Figure 2-2. This equipment configuration functions as a granulator and standard fluid bed dryer. The product container (4) contains a moist start-up material ranging from fine-powder to granular form that is to be converted to a homogenous granulate. The start-up material is fluidized by means of an upward flowing air stream and a binder material is sprayed from above onto the particles by a peristaltic pump (8) and nozzle (9). This operation results in an agglomeration of the particles. Subsequent careful drying stabilizes these agglomerates. The air necessary for this process is obtained from the work area by means of an extractor fan (1). Passing the air stream through the coarse dust filter (2) purifies the air. Moisture removal is accomplished by heating the air stream to the desired temperature in the air heater (3). The prepared air flows upward through the product material in the product container (4) and absorbs the moisture present in the product and agglomerate particles. The exhaust filter (5) retains any product material in the fluid bed dryer. An automatic filter cleaning device is installed on top of the filter housing to release any product material that accumulates on the filter surface and returns it to the container area. The exhaust air escapes through the socket (6) and the tube (7) into the open air or an exhaust duct system.

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2.3. Fluid Bed Dryer Aerocoater or Film Coater A sketch of the basic fluid bed dryer with the bottom spray coating option is shown below in Figure 2-3.

Figure 2-3 Sketch of Fluid Bed Unit with Coater

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FILM COATER

A bottom nozzle can be used for the coating of tablets, pellets, and other solid particles. See Figure 2-3. This equipment configuration functions as a film coater and standard fluid bed dryer. The product container (4) contains pellets, pellet-kernels, granules, and other particles that can be fluidized, coated, and dried. The coating film is atomized and sprayed from below by a peristaltic pump (8) and nozzle (9). The product particles are fluidized by means of an upward flowing hot air stream and after coating are carefully dried until the required final moisture content is reached. The air necessary for this process is obtained from the work area by means of an extractor fan (1). Passing the air stream through the coarse dust filter (2) purifies the air. Moisture removal is accomplished by heating the air stream to the desired temperature in the air heater (3). The prepared air stream flows upward through the product material in the product container (4) where coating occurs. The protective grating (5) retains any product material in the fluid bed coater. The exhaust air escapes through the socket (6) and the tube (7) into the open air or an exhaust duct system.

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3.1. Equipment Placement Upon removal from the shipping crate, the fluid bed dryer unit should be placed on a flat and level surface. There are four adjustable feet beneath the dryer to aid in leveling. Enough space should be allowed for future changes in equipment operation. The basic laboratory unit does not require any ancillary equipment. The basic laboratory unit with granulation or spray drying capability requires room for a solution reservoir and peristaltic pump. Front, side, and rear access to the unit is required. All modes of operation of the fluid bed dryer require a compressed air source and electrical power source (check the equipment label). Placement of the equipment should be made to facilitate these utility connections.

3.2. Air Supply The fluid bed dryer requires a source of clean, dry, and oil-free compressed air with a supply pressure of 4-6 bar (45-75 psig). Consumption of compressed air for the spray device is approximately 10Nm3/h (6scfm) standard conditions and for the filter blow-off device approximately 5-10 Nm3/h (3-6sfcm). The diameter of the compressed air line should be at least ½”. Diagrams of the pneumatic system for laboratory units with filter cleaning, granulation, and spray dryer options are given in Figures 3-1, 3-2, and 3-3 respectively. A rear view picture of the laboratory unit is shown in Figure 3-4.

3. Installation Instructions

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Figure 3-1 Pneumatic System of Basic Unit with Filter Cleaning

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Figure 3-2 Pneumatic System of Basic Unit with Granulation Capability

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Figure 3-3 Pneumatic System of Basic Unit with Spray Coating Capability

Figure 3-3 Pneumatic System of Basic Unit with Spray Coating Capability

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Figure 3-4 Rear View of Laboratory Unit

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3.3. Power Requirements Before starting the laboratory unit, the supply voltage information engraved on the data plate needs to be compared with the actual supply voltage provided. The data plate is fixed to the right hand side of the unit below the emergency stop button. The unit supplied with either 110 or 220 VAC service. The connecting power cable (10/4) should be installed according to the following color code: Red = Phase 1 Black = Phase 2 Blue = Neutral Feeder Yellow/Green = Ground Wire It is possible to connect the power cable to either a single-phase 110 or 220 VAC plug. If the cable is connected to a single-phase plug, then the fan speed is slightly reduced when switching on the heater. This situation can be avoided by using a three-phase machine. This unit must be ordered for 3 phase 220 VAC operation.

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3.4. Exhaust Air Vent Connection The exhaust air is vented through the exhaust air tube (1). The exhaust air tube should be attached by a collar (2) (not supplied) to the socket as shown in Figure 3-5. The length of the tube should not exceed 3 meters. It is not recommended that the exhaust air tube be open to the immediate work space area for safety reasons. This requires an exhaust vent system to be designed and installed prior to unit operation. 1,2

Figure 3-5 Laboratory Unit Exhaust Air Tube Connection

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4.1. Setup

4.1.1. Connection of the Solution Delivery Pump Figure 4-1 shows a typical solution delivery reservoir and pump connection arrangement for top spray granulation. A similar arrangement is used for a bottom spray coating operation.

Figure 4-1 Solution Delivery Pump Setup

4. Operating Instructions

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SOLUTION PUMP

Connect the compressed air line (1) to the atomizing air pipe (2). Insert the pump tubing (9) into the peristaltic pump by performing the following steps: • Open the protective pump head cover (3) • Place the tubing between the roller (4) and the guide rail (6) • Turn the head of the roller (5) by hand until the tubing lies on the entire guide

rail • Pull the tubing and clamp it tightly in the two clips (7) by means of the knurled

screws • Close the protective pump head cover • Connect the pump outlet tubing to container connection (10) • Place and secure the pump inlet tubing to the liquid reservoir Adjust the roller for optimum pressure on the tubing by moving the guide rail (6) backward and forward. Full pumping capacity can only be achieved with a completely seated and squeezed tube. The guide rail should always be parallel to the front of the pump.

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4.1.2. Selection of the Container Several different container shapes and materials are available for matching equipment operation and product material properties. Plexiglas Plexiglas (Acrylic) is used for the basic drying of products up to a maximum temperature of 80 degrees Celsius. Plexiglas should be cleaned with warm water not to exceed a temperature of 80 degrees Celsius. Figure 4-2 is a picture of the two Plexiglas container options available for drying/spray granulating (left) and film coating (right). Note: Plexiglas is not resistant to all chemicals and solvents. Check to make sure that the solvent in use is compatible with Plexiglas. Please contact Aeromatic-Fielder if there are any solvent compatibility questions.

Figure 4-2 Plexiglas Container Options

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Glass A glass container should be used in situations where the product or solvent materials is incompatible with Plexiglas. The use of a glass container also allows for unobstructed viewing of the process operation. Glass containers should be cleaned with hot water or steam. Figure 4-3 is a picture of the glass container options available for drying/spray granulating (left) and film coating (right).

Figure 4-3 Glass Container Options

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Stainless Steel A stainless steel container should be used for product or solvent that is incompatible with Plexiglas and where a sight glass is sufficient for observations of the process. Stainless steel containers should be cleaned with hot water or steam. Figure 4-4 is a picture of the stainless steel container options available for drying/spray granulating (left) and film coating (right).

Figure 4-4 Stainless Steel Container Options

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Polyvinyl Chloride (PVC) The PVC container should be used for product particle sizes that may cause mechanical damage to the other container types. PVC may only be used up to a temperature of 50 degrees Celsius. A PVC container should be cleaned with warm water with maximum temperature of 50 degrees Celsius. Figure 4-5 is a picture of the PVC container available for drying/spray granulating. A PVC container is not available for film coating.

Figure 4-5 PVC Container

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4.1.3. Selection of the Distributor Plate and Bottom Screen Selection of the perforated bottom depends on the degree of fluidization desired for a particular application. Flow through a perforated plate generates a pressure drop or resistance. A larger resistance across the bottom plate results in a higher or finer degree of fluidization. Smaller free cross sectional area plates result in a finer fluidization, while a higher area results in a coarse or rough fluidization. A picture of a bottom plate is shown in Figure 4-6. Three sizes of free cross sectional area are available 8%, 12%, and 16%.

Figure 4-6 Perforated Bottom Plate

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The product screen is present in order to prevent product particles from falling and clogging the air supply. Table 4-1 displays the available options for screen size. Figure 4-7 shows a picture of a product screen.

Bottom Screen Wire Mesh Size

Application

60 mesh, 250µm (standard)

Products with low percentage of fine dust particles

100 mesh, 140µm

Products with medium percentage of fine dust particles

150 mesh, 100µm

Products with high percentage of fine dust particles

200 mesh, 75µm 325 mesh, 50µm

Products with very high percentage of fine dust particles

Table 4-1 Product Screen Sizes and Applications

Figure 4-7 A Product Screen

CONIDUR ASSEMBLY

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A modified bottom plate and screen is available for light products. The Conidur plate (3% OA) provides for better distribution of air. Figure 4-8 shows a picture of a Conidur screen retainer plate.

Figure 4-8 Conidur Plate

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4.1.4. Installing the Distributor Plate and Product Screen There are two steps to installing and securing the distributor plate and product screen to the container. First, place the product screen (1) on top of the distributor plate (2). Place the container (4) over the distributor plate and secure the two together by inserting the four snap closures (3) into place. Figure 4-9 illustrates the placement of the distributor plate and product screen.

Figure 4-9 Installing the Distributor Plate and Screen

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4.1.5. Loading the Product Container It is recommended for energy efficiency to fill the product container as high as possible. The goal is to load the laboratory unit with product in a manner such that complete fluidization is achieved at maximum fan speed with no damage to the product particles. Normally, 0.25 to 2.0 kilograms of product material can be loaded into the container. Product material can be loaded into the container using a scoop or by pouring the material into the container from another transfer container.

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4.1.6. Assembly of the Film Coating Container (Spray Coater Option) The distributor plate (1) is attached between the container (4) and the nozzle housing (3) by the four snap closures (2). If particles with a diameter less than 3.5 mm are to be coated, then a product screen must be fitted between the distributor plate and the container. Next, the proper spray nozzle is inserted in the nozzle housing (3) and locked in place with the rubber knob (5). It is crucial for proper operation that the air stream is directed precisely into the center of the container. Figure 4-10 illustrates the placement of the container, plate, and nozzle housing. See Figure 4-11 for a picture of the Film Coater wire screen grid.

Figure 4-10 Assembly of the Film Coating Container

4

3

5

1

2

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4.1.7. Loading the Film Coating Container (Spray Coater Option) It is recommended for energy efficiency to fill the product container as high as possible. The goal is to load the laboratory unit with product in a manner such That complete fluidization is achieved at maximum fan speed with no damage to the product particles. Normally, 0.25 to 1.0 kilograms of product material can be loaded into the container. Product material can be loaded into the container using a scoop or by pouring the material into the container from another transfer container.

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Figure 4-11 Spray Coater Exhaust Air Grid

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4.1.8. Assembly of the Exhaust Air Grid Place the exhaust air grid (1) on the top of the container (2) in such a way that the pin (3) lines up with the corresponding hole as shown in Figure 4-12.

Figure 4-12 Exhaust Air Grid

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4.1.9. Selection of the Exhaust Air Filter There are four different exhaust filter materials available depending on the type of powder being processed in the fluid bed unit. Temperature, solvent and pH resistance are the three major parameters that need to be addressed in selecting an appropriate exhaust air filter. Nylon 1103 Nylon 1103 is a coarse-porous filter cloth with a smooth surface. Nylon 1103 should only be selected if the percentage of dust present is very low. Temperature Resistance: 80 to 90º C with a maximum of 100º C Acid Resistance: Moderate to Poor Alkali Resistance Very Good Nylon Pa-CF (Conductive) Nylon PA-CF is a fine-porous filter cloth with a very smooth surface that has a good filter effect for fine-grained products. It is electrically conductive having been woven with carbon fiber. This material is very easy to clean by manual tapping or automatic blow-off. Temperature Resistance: 80 to 90º C with a maximum of 100º C Acid Resistance: Moderate to Poor Alkali Resistance Very Good

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Gore-Tex Gore-Tex is a polyester needle felt with a membrane-like porous coating of PTFE (Teflon). This filter has a superior capability of retaining particles up to 2 µm. Temperature Resistance: A maximum of 140ºC Acid Resistance: Very Good Alkali Resistance: Moderate PA-S PA-S is a filter cloth made of fine pore Polyester. PA-S is an electrically conductive material due to the presence of 2-2.5% stainless steel fibers and is especially recommended for product material with flammable solvents in order to prevent electrostatic charges. The surface of the filter is rougher than the other three fibers, but the filter retention for fine-grained products is still very good. Temperature Resistance: A maximum of 140ºC Acid Resistance: Very Good Alkali Resistance: Moderate

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4.1.10. Assembly of the Exhaust Air Filter

Drape each of the four filter bags (1) over the four filter baskets (2) as shown in Figure 4-13.

Figure 4-13 Exhaust Air Filters and Housings Side View

1

2

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FILTER FRAME ASSEMBLY

Insert the filter bags and turn each one 90 degrees in order to bring the round rim part under the washer (3) as shown in Figures 4-13 and 4-14.

Figure 4-14 Exhaust Air Filter and Housing Installation

3

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When changing the gasket of the filter support (6), attention must be paid that the hole (9) in the filter support (5) is between the two flanges (10) fixed to the filter support as shown in Figure 4-15. Hole (9) should be oriented to the left rear when facing the dryer. This is the pickup point for the filter differential pressure.

Figure 4-15 Exhaust Air Frame and Housing Top View

5

9

10

8

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4.1.11. Installation of the Coarse Dust Filter The coarse dust filter (8) can be installed or removed by pulling out or pushing in the clamp rods (7) as shown in Figure 4-18.

Figure 4-18 Inserting the Coarse Dust Filter

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4.1.12. Installation of the Container The product container (7) must be inserted in such a way that the cam (3) fits into the groove (4) so that it is fixed to the upper part of the housing. Close the unit by pulling down the lever (1) until the unit top (2) contacts the container and a seal is made as shown in Figure 4-16.

Figure 4-16 Installing and Sealing the Container

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4.1.13. Selection of the Top Spray Nozzle The standard nozzle is applicable for most granulating liquids for agglomeration of pharmaceutical products. A standard nozzle is shown in Figure 4-17.

Figure 4-17 Standard Top Spray Nozzle

A jacketed nozzle with warm water can be used for the atomization of liquids that may tend to harden or crystallize in the nozzle. (Optional).

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4.1.14. Selection of the Bottom Spray Nozzle (Film Coater Option) The bottom Film Coater nozzle is used for most pellet or granule coating operations. A Film Coater nozzle is shown in Figure 4-19.

Figure 4-19 Film Coater Nozzle

A jacketed nozzle with warm water can be used for the atomization of liquids that may tend to harden or crystallize in the nozzle (optional).

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4.1.15. Selection of the Air Distributor Plate (Aerocoater Option) There are three different conical shaped distributor plates (2) available. The free cross sectional area of the flat middle part is 40% on all bottoms. The conical exterior for the coating of tablets is 2, 4, 6, or 8% and for the processing of pellets is 2, 4, or 6%. Depending on the product, the perforated bottom must be selected to ensure that the product is swirled upwards inside the booster tube (3) spray zone without being damaged and then to slowly settle outside the interior pipe while still in a fluidized condition. If the product is not in the fluidized condition when it reaches the exterior zone outside of the interior pipe, then a distributor plate with a larger free cross sectional area is required. Placement of the distributor plate is shown in Figure 4-20.

Figure 4-20 Selection of Aerocoater Distributor Plate

F

L

ARCHIVE DWG: 07325

2

5

8

9

7

63

1

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4.1.16. Selection and Installation of the Booster Tube (Aerocoater Option) Two interior pipes of different lengths are supplied with the laboratory unit. Choose the pipe with the better coating effect for the product under development. The interior pipe can be adjusted in height. Choose the best distance between the interior pipe and the perforated bottom in order to ensure a proper product flow from the exterior to the interior.

4.1.17. Securing the Distributor Plate/Product Screen (Aerocoater Option) The wire mesh (1) must be placed on top of the distributor plate (2) after the nozzle (5) has been removed. Next, push the base of the nozzle underneath the distributor plate. Secure the upper part of the nozzle with screws above the product screen. Place the distributor plate with product screen and nozzle on top of the lower container (7) piece. Set the product container (6) onto the lower part. The liquid duct (8) is connected to the solution delivery pump and the pressure duct (9) is connected to the compressed air line. See Figure 4-20.

4.1.18. Loading of the Container with Product (Aerocoater Option) When loading product into the container it makes no difference whether the product is in the interior or exterior of the injection device or evenly distributed in both areas. To save energy, it is advisable to fill the product container to as high a level as possible. There are limits to the fill level when there is excessive attrition or irregular coating of the product.

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4.1.19. Mounting of the Two-Fluid Nozzle (Aerocoater Option) Clean both connection pipes by blowing compressed air line through each line. The compressed air is to be connected to the right-angle socket marked “L”. The solution delivery line is to be connected to the socket marked “F”. It is vital that both of these connections to be as tight as possible. A picture of a two-fluid nozzle is shown in Figure 4-21.

Figure 4-21 Two-Fluid Nozzle

L

F

L = compressed air

F = fluid

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4.2. Equipment Operation

4.2.1. Operation of Solution Delivery Pump The pump is normally powered by 110 VAC. A power switch is located at the rear of the pump. Before turning on the pump the atomizing air supply must be turned on. The peristaltic pump is used to delivery the granulating or spray coating liquid solution from the dispensing reservoir to the nozzle. The pump functions by the rotation of the rollers (4) which squeeze the pump tubing (3). The volumetric flow through the pump is a function of the inner diameter of the tubing and the pump motor speed. Various sizes of tubing are available and the pump speed is adjustable using the speed control knob (1). Figure 4-22 illustrates the roller operation.

Figure 4-22 Solution Pump

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4.2.2. Turning the Unit On The laboratory unit is switched on by setting the timer (K12) as shown in Figure 4-23.

Figure 4-23 Timer Location

Setting the timer turns on the fan, electrical heater, and if present the filter blow-back device. The time necessary for mixing, granulation, coating, and drying can only be determined by experimental testing. Turn the dial clockwise until the time desired is shown on the display. Press “start”, this will initiate the drying process. On older models, the time is simply dialed in by rotating a mechanical timer clockwise to the desired, indicated time segment. A pointer will indicate the minutes displayed on the dial.

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4.2.3. Setting the Air Flow Rate The fan speed/airflow rate setpoint can be adjusted by the speed controller (1). The air flow can be adjusted from 0.0 to 130.0 m3/h / 0-7cfm at standard conditions. A higher fan speed for air delivery results in more intensive fluidization of the product in the laboratory unit. Figure 4-24 shows the location of the speed controller setpoint adjustment knob.

Figure 4-24 Fan Speed Controller Location

1

Emergency Stop

DryingTemperature

Filter Cleaning Dwell

Fan Control

000000

NIRO-AEROMATIC

Outlet AirTemperature

Drying Timemin sec

Start Stop

000000

+-

000000

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There are three general fluidization patterns that result from adjustment of the air flow rate. Air Flow Too Low Light particles are brought to a fluidized state. The remaining product settles at the bottom of the container. This is shown in Figure 4-25.

Figure 4-25 Fan Speed Too Low

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Air Flow Correct When a proper air flow rate has been established the whole mass of the product is fluidized and good heat and mass transfer is achieved between the air and the product particles. This is shown in Figure 4-26.

Figure 4-26 Proper Airflow

Air Flow Too High The high velocity of air forces product particles to cling and clog the exhaust air filter or screen. This is shown in Figure 4-27.

Figure 4-27 Fan Speed Too High

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4.2.4. Setting the Drying Temperature The optimum drying temperature for each product needs to be experimentally determined. The temperature setpoint is set at the temperature controller as shown in Figure 4-28. For each mode of operation, there is a slightly different operating procedure. Drying Begin with as high an initial temperature as possible and then slowly reduce the temperature. Granulating Begin with as small a temperature as possible or decrease nozzle pressure. Increase the temperature while drying and then slowly reduce the temperature. Coating A constant temperature is sufficient for most product materials. The setpoint temperature is reached after a heating time of approximately one to five minutes. The heating time is reproducible.

Figure 4-28 Location of Temperature Controller

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4.2.5. Turning on Filter Cleaning Place the filter cleaning speed flip switch (1) to position 1. Set the desired blow-off air flow rate using pressure regulator (2). A pressure gauge (3) is located on the front right hand side of the laboratory unit. If the cleaning effect is not strong enough, the pressure can be increased or the flip switch set to position 2. Figure 4-29 shows the placement of these devices.

Figure 4-29 Turning on Filter Blow-off Device

2,3

1

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FILTER CLEANING

The filter cleaning device serves to continually blow-off product particles sticking to the exhaust air filters and returns them to a fluidized state. With the flip switch (1), it is possible to set the time interval of the blow-off device as follows: In Position 1, the filter is blown-off every 15 seconds. In Position 1, the filter is blown-off every 7.5 seconds By adjusting the pressure regulator (2), the blowing effect is decreased or increased according to the product particle size. The eccentric disc (4) and the distribution disc fixed to the same shaft are driven by a motor (3). As soon as the spring-actuated rollers (5) of the two switches (6, 7) fall into the corresponding slot of the eccentric disc (4), the respective switch closes the contact to the solenoid valve. The solenoid valve opens so that compressed air reaches the air distributor (8). The compressed air flows through the air line (9) into one of the four filter bags. Further turning of the eccentric disc leads to pressing the roll (5) out of the slot, thus interrupting the contact to the solenoid valve so that it closes. These operations are shown in Figure 4-30 on the next page.

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Figure 4-30 Blow-off Device Components and Operation

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4.2.6. Display of the Measured Parameters Two pressure gauges and an airflow display are provided on the right hand side of the unit as shown in Figure 4-31. Pressure Display 1 The pressure drop over the exhaust air filter is shown by display 1 in units of mm WC (Water Column). This device indirectly shows the level of clogging of the filter. A large pressure drop is indicative of greater filter clogging. Pressure Display 2 The pressure drop of the product and perforated bottom with wire screen is shown by display 2 in units of mm WC (Water Column). If the height of the batch remains constant, then the product pressure drop is constant. In this situation, pressure display 2 indirectly shows the grade of contamination (plugging) of the perforated bottom. Pressure Display 3 Indicates relative airflow through the unit in m3/hr.

Figure 4-31 Measured Parameters

000

0-300 mm

High

LowFilterResistance

High

Low

ProductResistance

0-300 mm

0-130m3/hr

Airflow

(0-70cfm)

High

Low

Strea-1 Pneuamtic Schematic

Archive 7319.dwg

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4.2.7. Adjustment of Atomizing Air Pressure The supply air pressure necessary for fluidization can be set with pressure controller (1) between 0.4 and 4 bar and is visually displayed with pressure gauge (2). In order to prevent clogging of the nozzle, it is recommended to switch on the fluidizing air pressure at the beginning of the process. The liquid line is to be emptied before switching off the fluidizing air supply. Figure 4-32 shows the location of the atomizing air pressure controller and gauge.

Figure 4-32 Air Pressure Controller and Gauge

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4.2.8. Setting Liquid Flow Outside of this Nozzle (Aerocoater Option) By altering the pressure of the liquid or compressed air, the performance of the nozzle can be varied within a certain range. The nozzle works from .04 bar atomizing air pressure and higher. A higher atomizing air pressure increases the air throughput or gives a finer degree of atomizing.

4.2.9. Setting the Compressed Air Flow Rate (Aerocoater Option) Depending on the field of application, the most suitable air cap position must first be established by experimental testing. When turning the air cap (1) clockwise, the air throughput decreases and dispersion cone becomes more tapered. Turning the air cap (1) counter clockwise, the air throughput increases and the dispersion cone becomes bigger. Figure 4-33 shows the air cap.

Figure 4-33 Two-Fluid Nozzle Assembly (Aerocoater)

(1) aircap

(2) securing nutL

F

L = compressed air

F= fluid

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4.2.10. Starting Up the Spray Nozzle for Coating/Granulating The most suitable spray pattern can only be obtained by experimental testing. The following steps present a general guide for setting up an experiment and adjusting the important equipment parameters. See Figure 4-34 for a side view of a nozzle. • Connect the compressed air and solution delivery lines. • Fill the container with the granulating liquid. • The air pressure required to atomize the granulating liquid is set by means of

the pressure regulator labeled “atomizing pressure” and is displayed on the pressure gauge located above the regulator. As a general rule, this atomizing pressure will be 1.5 – 4 bar. There is an air cap (1) on the nozzle end that allows the ring gap (2) to be adjusted. The 0 position indicates that the nozzle is closed and four turns of the cap open the nozzle as far as possible. Usually, two turns of the cap are sufficient for normal operation. By turning the air cap clockwise, the air flow and spray cone will decrease. Turning the air cap counter clockwise increases the air flow and spray cone. Increasing the air pressure increases the air throughput and delivers a finer atomization.

• Setting the solution delivery pump speed changes the liquid pressure that can

alter the nozzle performance within a certain range. Usually, delivery is set slightly above the rate of use. Do not overpressure the supply, tubing rupture or leaks will result.

• Visually check the resulting spray pattern for acceptability. Adjust the

atomizing air pressure as required. • Insure that there is no leaking or dripping at the nozzle. • Center the nozzle over the product bed in the container and tighten the hand

nut (Top Spray Nozzle). See Figure 4-34. • Center the nozzle in the booster tube in the container and then tighten the

securing nut (2). (Bottom Spray Coating). See Figure 4-33.

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Figure 4-34 Spray Nozzle

5

21

Liquid

Air In

In

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4.2.11. Termination of Run After the timer has timed out, the laboratory unit automatically switches off. The fan, electrical heater, and filter blow-off device if present, are all turned off. In the event the laboratory unit needs to be turned off before completion of the timer cycle, the timer can be manually turned back to zero, press “stop” on the electronic timer or press the “E” stop button. Set the atomizing air pressure controller to the minimum before attempting to remove the container.

4.2.12. Emergency Stop An Emergency Stop button is located on the bottom of the control panel a s shown in Figure 4-35. Depressing this button turns off all of the electrical machine functions.

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CONTROL PANEL

Figure 4-35

NIRO -A E RO M A T IC

Eme rg e n c y Sto p

D ry in gTe mp e ra tu re

Filte r C le a n in g D w e ll

Fa n C o n tro l

000000

O u tle t AirTe mp e ra tu re

D ry in g Timemin sec

S tart S top

000000

+-

000000

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5.1. Compressed Air Filter A compressed air filter (4) for cleaning the compressed air is supplied separately with the unit as shown in Figure 5-1. The filter is to be attached to the rear of the hinged cover of the unit in a vertical position with the gasket (2) and the thread bushings (3) as shown in Figure 5-2. On newer models, simply plug the filter into the socket on the back of the hinged cover and attach an air source to the filter. The filter works automatically and does not require any adjustments. Filters with manually operated water discharge (7) have to be emptied regularly. The water is not allowed to exceed the static disc (5), otherwise it could enter the unit and consequently disturb the functioning of the machine. The maximum working pressure is 12 bar and the admissible temperature range is 0-60ºC. Increasing drop in pressure indicates that the filter has to be exchanged. Before dismantling the filter the air supply to the filter has to be closed and the system vented by means of the water discharge (7). The filter glass (6) can then be unscrewed and the filter element removed and replaced as shown in Figure 5-2. Note: The filter must not come into contact with carbon tetrachloride, trichlorethylene, toluol, diluents, acetone or similar solvents. For cleaning the filter use a pure soap solution. If the supply filter is not utilized, then only clean, dry, filtered instrument air, per ISA standards, can be supplied.

5. Maintenance Procedures

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Figure 5-1 Compressed Air Filter

Figure 5-2 Compressed Air Filter Details

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5.2. Distributor Plate and Product Screen The distributor plate and the product screen need to be periodically removed for cleaning. Product sticking to the bottom plates influences the performance of the unit.

5.3. Exhaust Air Grid The exhaust air grid needs to be periodically cleaned in order to prevent clogging.

5.4. Exhaust Air Filter The exhaust air filter should be cleaned with 40-50 degree Celsius water plus a suitable detergent. Boiling water should NOT be used. Gore-Tex filters are cleaned only by tapping or water spraying. Depending on frequency of use, filter media should be replaced every 1-2 years.

5.5. Coarse Dust Filter The coarse dust filter should be cleaned every third or fourth month depending on the level of contamination. Cleaning can be accomplished by spraying the filter with water having a maximum temperature of 40 degrees Celsius. The filter should be replaced after 1 year of service.

5.6. Product Screen and Spray Nozzle (Aerocoater Option) The product screen and spray nozzle must be cleaned at regular intervals in order to avoid any blockage.

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5.7. Nozzle Cleaning (Top and Bottom Spray) The Aerocoater nozzle requires no special maintenance since it has no sealing elements. Cleaning at regular intervals is sufficient depending on the properties of the spray solution. Pumping hot water through the nozzle is the preferred method of cleaning. A mild solvent may be used instead of water. The standard bottom spray nozzle contains 2 ‘O’ Rings and they should be inspected prior to each use. If damaged they should be replaced. If the nozzle is very dirty, the nozzle should be removed and dismantled for cleaning. For this purpose a special spanner tool is used. Unscrew the air cap (1), liquid insert (2), and the blind plug (3) (Aerocoater only). By unscrewing the clamp nut (5) the nozzle can be removed from the perforated bottom (6). See Figure 5-3.

5.8. Pump Roller Lubrication (Granulation and Aerocoater Option) The solution delivery rollers should periodically be lubricated. The lubricant should not contain any solvent material.

Figure 5-3 Nozzle Cleaning

5

2

3

1

GRANULATION NOZZLE

AEROCOATER NOZZLE

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Note: This is a feasibility piece of equipment. Calibration is not normally required for general operation. Calibration is at the discretion of the owner. It is not calibrated during assembly and test. All instruments are as setup by the manufacturer. Should calibration be required, the procedures are as indicated.

6.1. Drying Timer Required Equipment: Verified functioning timer or stopwatch (reference

timer) General Procedure: Verification of the timer is sufficient for this application. The electronic countdown timer supplied with the laboratory unit has a range of 99 minutes and 99 seconds. This procedure is used to verify that the timer is counting down properly. 1. Enter a 99 minute timer interval. 2. Prepare to start the (calibrated) reference timer.

3. Simultaneously start both timing devices.

4. Allow the timer to countdown to zero and stop the reference timer at the

instant of a zero reading.

5. Compare the laboratory unit timer to the reference timer. The laboratory unit timer should be 99 minutes +/- 4 seconds.

6. Calibration Procedures

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6.2. Outlet Air Temperature (Digital Display) Required Equipment: Reference Low Temperature Bath Reference High Temperature Bath Calibrated Temperature Measurement System General Procedure: Note: Observe all safety precautions for working with high temperature equipment and materials. 1. Cool down the low temperature reference bath to 0.0 degrees Celsius and let

stabilize for at least 30 minutes. 2. Remove the outlet air temperature element from the laboratory unit.

3. Place the temperature element into the low temperature reference bath and

let stabilize for at least 30 minutes.

4. Verify with the calibrated temperature measurement system that the outlet air temperature digital display reads within +/- 0.25 degrees Celsius of the value displayed by the calibrated temperature measurement system. Following the manufacturers procedure, adjust the display ZERO to match the value displayed by the calibrated temperature measurement system.

5. Place the temperature element into the high temperature reference bath and


6. Reinstall the temperature element into the laboratory unit.

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6.3. Drying Temperature (Digital Controller and Display) Required Equipment: Reference Temperature System or Bath and

Calibrated Temperature Measurement System General Procedure: Note: Observe all safety precautions for working with high temperature equipment and materials. 1. Cool down the low temperature reference bath to 0.0 degrees Celsius and let

stabilize for at least 30 minutes. 2. Remove the outlet air temperature element from the laboratory unit.

3. Place the temperature element into the low temperature reference bath and


4. Verify with the calibrated temperature measurement system that the outlet air temperature digital display reads within +/- 1.0 degrees Celsius of the value displayed by the calibrated temperature measurement system. Following the manufactures procedure, adjust the display ZERO to match the value displayed by the calibrated temperature measurement system.

5. Place the temperature element into the high temperature reference bath and


6. Reinstall the temperature element into the laboratory unit.

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6.4. Pressure Gauge Atomizing Air (Front Panel Left Hand Side) Required Equipment: Calibrated pressure gauge and pressure hand pump

system Range: 0-6 bar General Procedure: 1. Disconnect the tubing from the pressure gauge. 2. Attach the calibrated pressure gauge and hand pump system to the pressure

gauge.

3. Verify a low pressure of 0.0 bar to the gauge.

4. Verify that the reading on the spray line pressure gauge is within +/- 0.25 bar of the value displayed on the calibrated pressure gauge. If the reading on the spray line pressure gauge is not within the specified tolerance, reference the manufacturer operating manual and follow the procedure for performing a ZERO adjustment.

5. Apply a high pressure of 6.0 bar to the gauge.

6. Verify that the reading on the spray line pressure gauge is within +/- 0.25 bar

of the value displayed on the calibrated pressure gauge. These pressure gauges are SPAN set at the factory and do not have a user SPAN adjustment. If the reading on the spray line pressure gauge is not within the specified tolerance, then replace the pressure gauge.

7. Vent pressure from the system.

8. Reattach the process tubing back to the spray line pressure gauge.

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6.5. Pressure Gauge Filter Cleaning (Front Panel Right Hand Side) Required Equipment: Calibrated pressure gauge and pressure hand pump

system. Range: 0-6 bar General Procedure: 1. Disconnect the tubing from the pressure gauge. 2. Attach the calibrated pressure gauge and hand pump system to the pressure

gauge.

3. Verify a low pressure of 0.0 bar to the gauge.

4. Verify that the reading on the spray line pressure gauge is within +/- 0.25 bar of the value displayed on the calibrated pressure gauge. If the reading on the spray line pressure gauge is not within the specified tolerance, reference the manufacturer operating manual and follow the procedure for performing a ZERO adjustment.

5. Apply a high pressure of 6.0 bar to the gauge.

6. Verify that the reading on the spray line pressure gauge is within +/- 0.25 bar

of the value displayed on the calibrated pressure gauge. These pressure gauges are SPAN set at the factory and do not have a user SPAN adjustment. If the reading on the spray line pressure gauge is not within the specified tolerance, then replace the pressure gauge.

7. Vent pressure from the system.

8. Reattach the process tubing back to the spray line pressure gauge.

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6.6. Pressure Gauge Exhaust Filter and Product Differential (Side Panel) Required Equipment: Calibrated pressure gauge and pressure hand pump

system. Range: 0-300 mm WC General Procedure: 1. Disconnect the high and low tubing lines from the pressure gauge. 2. Attach the calibrated pressure gauge and hand pump system to the high side

of the pressure gauge.

3. Verify a low pressure of 0.0 mm WC to the gauge.

4. Verify that the reading on the exhaust filter pressure gauge is within +/- 2% of full scale mm WC of the value displayed on the calibrated pressure gauge. Make any adjustments to the zero reading by using the pressure gauge front face adjusting screw.

5. Apply a high pressure in the 280-290 mm WC range. Note that over pressure

may cause damage to the sensing element.

6. Verify that the reading on the exhaust filter pressure gauge is within +/- 2% of full scale mm WC of the value displayed on the calibrated pressure gauge. Follow the manufacturer’s literature for making any SPAN adjustments. The pressure gauge will need to be removed and dismantled.

7. Vent pressure from the hand pump system.

8. Reattach the process tubing back to the exhaust filter pressure gauge.

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6.7. Airflow Reading (Side Panel) Required Equipment: Calibrated pressure gauge and pressure hand pump

system. Range: 0-300 mm WC corresponding to 0-136 m3/h or 0-70

CFM. General Procedure: 1. Disconnect the high and low tubing lines from the pressure gauge. 2. Attach the calibrated pressure gauge and hand pump system to the high side

of the pressure gauge.

3. Verify a low pressure of 0.0 mm WC to the gauge.

4. Verify that the reading on the exhaust filter pressure gauge is within +/-2% of full scale mm WC of the value displayed on the calibrated pressure gauge. Make any adjustment to the zero reading by using the pressure gauge front face adjusting screw.

5. Apply a high pressure in the 280-290 mm WC range. Note that over pressure

may cause damage to the sensing element.

6. Verify that the reading on the exhaust filter pressure gauge is within +/- 2% of full scale mm WC of the value displayed on the calibrated pressure gauge. Follow the manufacturer’s literature for making any SPAN adjustments. The pressure gauge will need to be removed and dismantled.

7. Vent pressure from the hand pump system.

8. Reattach the process tubing back to the exhaust filter pressure gauge.

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7.1. Escape of Dust

Problem

Resolution

1. Defective frame gasket

Replace frame gasket.

2. Incorrect insertion of container

Install container properly. Verify alignment cam on container is located in housing.

3. Defective filter support gasket

Replace filter support gasket.

4. Clogging of exhaust air filters

Clean or replace exhaust air filters.

5. Filter Blow-by

Replace filter bags, tighten filter hand nuts securely, check/replace filter DP sensor seal.

7.2. Malfunctioning Filter Cleaning Device

Problem

Resolution

1. Insufficient compressed air contacting

filter

a) Increase regulator output pressure b) Check compressed air line or air line filter for clogging.

2. Exhaust air filters clogged

a) Clean exhaust air filters. b) Increase blow-off pressure

7. Troubleshooting

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7.3. Insufficient Agglomeration or Coating

Problem

Resolution

Improper operation of nozzle

a) Install nozzle in proper axial position.

Ensure that the distance between the nozzle and fluid bed is chosen in such a way that no spraying of the inner wall of the container is possible. Check the nozzle size (liquid orifice) and air cap adjustment.

Clogged nozzle

a) Clean the nozzle and nozzle insert. If

the nozzle becomes clogged again, the atomizing air pressure needs to be set to 0.2-0.5 bar during setup. Further clogging can be avoided by spraying appropriate solvent or warm water immediately after termination of the batch run. Insert (orifice) may be too small.

b) If the granulating product is not completely dissolved, the solution must be filtered or dissolved further.

Malfunction of peristaltic pump

a) Check fuse at rear of pump. b) Consult pump manufacturer.

Incorrectly adjusted atomizing pressure

a) Properly adjust atomizing pressure.

Incorrect pump rate

a) Change the pump rate. b) Install different inside diameter tubing.

Incorrect air volume

Adjust the air flow rate at the control panel.

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Pump tubing clogged or twisted

Clean the pump tubing or replace.

Incorrect liquid temperature

The operating temperature may have to be adjusted for each product.

Forming of lumps

May be caused by liquid dripping after the granulation or coating process is complete. It is recommended to empty the liquid pipe before termination of the spraying process and then interrupt the atomizing airflow.

Material too coarse

Use a finer initial product.

7.4. Unusual Pressure Drop in Air Line

Problem

Resolution

1. Clogged compressed air filter

The filter should be serviced.

2. Leaking compressed air system

Detect and seal leak.

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7.5. Insufficient Fluidization

Problem

Resolution

1. Coarse dust filter clogged

Wash or exchange coarse dust filter.

2. Bottom screen clogged

Clean or exchange bottom screen.

3. Fan speed too low

Increase fan speed or replace controller if defective.

4. Exhaust air duct clogged

Dismantle exhaust air duct and check visually for obstruction.

5. Perforated bottom gasket leaking

Replace perforated bottom.

6. Electrical air heater housing leaking

Seal housing flange with silicone.

7. Fan not running

a) Check that fluid bed dryer is plugged in. b) Check for proper supply voltage. c) Check/replace PC board fuse

8. Difficulty in fluidizing product

Set speed controller in short intervals to maximum and minimum speed.

9. Exhaust air duct too long

Place unit closer to Exit area.

10. Product is too heavy to fluidize

a) Check for over wetting of material. b) Remove some of the product. c) Exchange Distributor plate.

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7.6. Temperature Not Attained

Problem

Resolution

Heater defective (no output)

Replace heater element.

Tube between fan and product container leaking

Determine location of leak and seal with silicone sealant.

Thermal overload relay defective

Replace thermal overload relay. Check for electrical short.

High temperature limit switch has tripped

Wait for 20-30 minutes for unit to cool down and restart. If temperature switch continues to trip: a) Check the temperature setpoint b) Check for a faulty thermostat c) Check for too low of an air flow rate Important: Remove the grid behind the coarse dust filter only if the equipment is unplugged. ( Continued next page )

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Temperature Not Attained Thermal Overload If the electrical heater overloads, the thermal overload relay switches off the heater until the temperature has fallen below the maximum allowable temperature. The overload relay is attached to the lower part of the heater tube as shown in Figure 7-1.

Figure 7-1 Thermal Overload Relay

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Dryer Housing Exhaust Air Filter Surface 0.93 ft2 / 0.0856 m2 Coarse Dust Filter Surface 0.18 m2 Standard Filling Weight 0.2 – 4 kg Product Container Capacity 16.5 liters Base 0.009 m2

Aerocoater Filling Weight 0.2 – 2 kg Product Container Capacity 13.5 liters Base 0.009 m2 Filmcoater Filling Weight 0.2 – 1 kg Product Container Capacity 7.0 liters Base 0.005 m2 Low Volume Filling Weight 0.2 – 2 kg Product Container Capacity 15.0 liters Base 0.005 m2

Exhaust Fan & Motor Air Volume 70 CFM / 2 m3/min Static Pressure 20 in. H2O / 5000 N/m2 Motor Output 0.75 kW Voltage 110 or 220 Frequency 60 Hz Air Heater Heating Capacity 1.5 kW @ 80 °C 2.2 kW @ 110 °C Pneumatic System Compressed Air Usage 9.0 SCFM / 15 Nm3/h Spray Nozzle Maximum Liquid Delivery 10 Liter/h Minimum Air Pressure 60 psi / 4 bar Maximum Pump Pressure ∼ 0.025 bar Delivery Pump Power Usage 0.075 kW Weight Unit with Plexiglas Container 95 lbs. / 43 kg

Pump 15 lbs. / 7 kg

8. Technical Data

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9.1. Control Panel Faceplate

Figure 9-1 Control Panel Faceplate

9. Diagrams and Schematics

NIRO-AEROMATIC

Emergency Stop

DryingTemperature

Filter Cleaning Dwell

Fan Control

000000

Outlet AirTemperature

Drying Timemin sec

Start Stop

000000

+-

000000

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9.2. Digital Version Electrical Diagram

Figure 9-2 Electrical Diagram for Digital Version

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9.3. Electrical Diagram for Filter Cleaning

Figure 9-3 Electrical Diagram for Filter Blow-Back

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9.4. Electrical VAC Schematic (Digital Version)

Figure 9-4 110 VAC Schematic

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10. O & M Information

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11. Spare Parts Information

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Acrylic plastic is highly resistant to water, alkali, watery solutions of inorganic salts, and most diluted acids. However, some dilute acids such as hydrocyanic acid and hydrofluoric acid as well as concentrated sulfuric acid, nitrous acid and chromic acid affect acrylic plastic. The effect of organic substances on this material depends on the nature of the relevant substance. Some of the effects include no interaction, swelling, hair cracking and attenuation, and complete dissolution. Acrylic plastic is not affected by food material and the acrylic plastic does not affect the food material. The following abbreviations have been used in Table 11-1. B = Satisfactory No effect with the exception that staining of the acrylic plastic might occur. A = Moderate corrosion by the liquid or absorption Slight swelling or cracking of the acrylic plastic may occur. The structural strength remains unchanged. U = Unsatisfactory The acrylic plastic has disintegrated, dissolved, swollen, or lost structural strength. The ratings shown in the table are for the acrylic plastic Perspex at 20ºC.

12. Appendix

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Table 11-1 Acrylic Plastic Resistance

Rating Chemical or Substance

U Acetaldehyde, 100% U Acetone, 100% U Acetone Nitrile U Acetophenone U Ethyl Acetate U Ethylene Bromide U Ethyl Dichloride A Alcohol, ethyl-, 10% A Alcohol, ethyl-, 50% U Alcohol, ethyl-, 100% U Alcohol, allyl- U Alcohol, amyl- U Alcohol, benzyl- U Alcohol, n-butyl- A Alcohol, isopropyl-, 10% A Alcohol, isopropyl-, 50% A Alcohol, isopropyl-, 100% A Alcohol, methyl-, 10% A Alcohol, methyl-, 50% A Alcohol, methyl-, 100% B Formic Acid, 10% U Formic Acid, 90% B Liquid ammonia, density 0.880 B Ammonium Chloride, saturated U Amyl Acetate U Aniline U Benzol B Calcium Chloride, saturated U Chloroform U Cyclohexane U Cyclohexanol U Cyclohexanone U Cyclohexene U Decahydronaphthalene U Diethyl Ether

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