Hardware Manual DCN 2657 - Mettler Toledo · ParticleTrack™ G400 Real-Time Particle System...

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ParticleTrack™ GReal-Time Particle System Characteriza

May 2015MK-PB-0065-AC Rev E

DCN 2657

© 2015 Mettler-Toledo AutoChem, Inc. 7075 Samuel Morse DriveColumbia, MD 21046 USAPhone 866-333-8822Fax: 410-910-8101www.mt.com1 May 2015

ParticleTrack™, FBRM®, iC Process™ for FBRM®, iC FBRM™, ParticleView™, iC PVM™, and PVM® are trademarks or registered trademarks of Mettler-Toledo AutoChem, Inc.Kalrez® and Viton® are registered trademarks of E.I. du Pont Nemours and Company. Tri-Clamp® and Tri-Clover® are registered trademarks of Alfa Laval, Inc. Microsoft® and Windows ® are either registered trademarks or trademarks of Microsoft Corporation in the United States and/or other countries.Acrobat® is a registered trademark of Adobe Systems, Inc.All other brand and product names are trademarks or registered trademarks of their respective owners.

METTLER TOLEDO probes with Focused Beam Reflectance Measurement (FBRM) technology are covered by patents or pending patents including:USPN 6,449,042USPN 6,940,064USPN 8,468,642

Address comments to:Mettler-Toledo AutoChem, Inc.7075 Samuel Morse DriveColumbia, MD 21046Tel: + 1 866.333.6822Fax: +1 410.910.8600Internet: www.mt.com/particleFor technical support, contact: [email protected]

The information in this publication is provided for reference only. All information contained in this publication is believed to be correct and complete. Mettler-Toledo AutoChem, Inc., shall not be liable for errors contained herein nor for incidental or consequential damages in connection with the furnishing, performance, or use of this material. All product specifications, as well as the information contained in this publication, are subject to change without notice.

Mettler-Toledo AutoChem, Inc. makes no warranty of any kind with regard to this manual, including but not limited to the implied warranties of merchantability and fitness for a particular purpose.

In conformance with the European Directive 2002/96/EC on Waste from Electrical and Electronic Equipment (WEEE), this device may not be disposed of in domestic waste. This also applies to countries outside the EU, per their specific requirements.

Please dispose of this product in accordance with local regulations at the collecting point specified for electrical and electronic equipment.

If you have any questions please contact the responsible authority or the distributor from which you purchased this device.

Should this device be passed onto other parties for private or professional use, the content of this regulation must also be related.

Thank you for your contribution to environmental protection.

http://www.mt.comhttp://www.mt.com/particle

Contents

Chapter 1 IntroductionGeneral Policies ........................................................................ 7

Installation Policy ...........................................................................7Repair Policy ..................................................................................8Computer Service Policy ..................................................................8

Software Upgrades..................................................................... 8Training Programs ..................................................................... 8Service and Technical Assistance................................................. 9Additional Information ................................................................ 9

Related Documents .........................................................................9

Chapter 2 Site Preparation[__] Space and Weight Requirements .............................................11[__] Area of Intended Use ..............................................................12[__] Environmental Conditions .......................................................12[__] Utilities .................................................................................13[__] Control Software Computer Specifications .................................15[__] Internal Paperwork and Approval for Installation ........................15

Standard and Optional Accessories............................................ 15System Dimensions ................................................................. 16

Fixed Beaker Stand (FBS) Dimensions.............................................17

Chapter 3 SafetySafety Symbols........................................................................ 19Laser Classifications ................................................................ 20CE Compliance........................................................................ 21NRTL Certification .................................................................... 21Equipment Ratings................................................................... 21General Safety ......................................................................... 21

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Chapter 4 Product DescriptionTip Terminology .......................................................................23ParticleTrack G400 System Configurations ..................................23
G400—Single System...................................................................24G400—Dual System.....................................................................24

System Components.................................................................24Interchangeable Probe Tips ............................................................25ParticleTrack G400 Base Unit .........................................................25Power Supply (Auto-Switching AC Adapter) ......................................25Instrument Control Software............................................................26Optional Accessories .....................................................................26

Using FBRM® Technology ........................................................27ParticleTrack G400 Applications .....................................................29ParticleTrack G400 Capabilities ......................................................29

Chapter 5 InstallationAcceptance Criteria...................................................................31Site Preparation (Customer Responsibility)..................................32Installation Instructions .............................................................32

1. Confirm Site Requirements .........................................................322. Verify Hardware Configuration.....................................................333. Place Base Unit at Area of Intended Use.......................................334. Confirm Hardware Service Agreement and Software Version ...........335. Make System Connections .........................................................336. Install Control Software ..............................................................367. Start Up System ........................................................................368. Connect/Configure Instrument in Control Software .........................379. Activate Licenses ......................................................................4210. Set Up Optional Fixed Beaker Stand (FBS) .................................43

Chapter 6 System ReadinessPreparing for ParticleTrack™ G400 Functional Tests ....................45Conducting Functional Tests Using iC FBRM................................45

1. Clean Window..........................................................................462. Laser Power Check at Probe Window ..........................................463. System Check with Marker .........................................................464. Calibration Validation ................................................................47Verify Purge Controller Function (if applicable) .................................47

Functional Test Overall Results...................................................48Acceptance Criteria........................................................................48

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Chapter 7 Routine OperationStarting the Optional ParticleTrack G400 Purge ........................... 49Starting the ParticleTrack G400 System ...................................... 51

ParticleTrack G400—Single Configuration .......................................51ParticleTrack G400—Dual Configuration .........................................51System Power and Status Indicators................................................52

Simple Guides to a Successful Run............................................ 52Always Ensure the Probe is Clean ...................................................52Select the Appropriate Interchangeable Tip........................................52Select Probe Location Relative to Particle System..............................54Select Appropriate Template for the Given Application ........................56

Best Practices for Routine Operation........................................... 58Software Operation .................................................................. 60

Using Linked Views of Experiment Data ...........................................60Using the Live Experiment Toolbar...................................................60

Appendix A Specifications 63

Scan Speed and Measurement Range ........................................ 63Probe ..................................................................................... 63Base Unit Enclosure ................................................................. 64Power Supply (with Switching AC Adapter) ................................. 65Optional Purge Controller (Air/Gas)............................................ 65

Air Tubing ....................................................................................66

Appendix B ParticleTrack™ G400 Accessories and Services 67

Fixed Beaker Stand (FBS) with Mixer.......................................... 67Purge Controller Option ............................................................ 70Probe Mounting Options ........................................................... 71ServicePac and MaintenancePac for ParticleTrack G400 .............. 71

Appendix C Probe Mounting Options 75

1. Mounting the Probe.............................................................. 75Mounting Probe in Fixed Beaker Stand (FBS) ...................................75Mounting Probe in Small Reactors ..................................................77Using Lab-Joint Adapters ...............................................................78Using Compression Fittings ............................................................79Mounting Probe in Flow Cell...........................................................79

2. Custom and Special Order Probe Designs............................... 80

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Appendix D Care and Maintenance 81Maintaining the ParticleTrack G400 System.................................81
Recommended Maintenance Schedule ............................................82Service Contracts ..........................................................................82

Validating Calibration ...............................................................83System Calibration ...................................................................83Cleaning a ParticleTrack G400 System .......................................83

Probe Window Service and Cleaning...............................................83Extending Bearing Life ..............................................................84

Changing Bearings .......................................................................85

Appendix E Troubleshooting and FAQs 87

Troubleshooting .......................................................................87FAQs ......................................................................................87Error Messages........................................................................88Warnings ................................................................................89

Appendix F ParticleTrack™ Glossary 91

General Terms .........................................................................91Software Terms ........................................................................92Hardware Terms.......................................................................94

Index 95

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1Introduction

This manual covers pre-installation, safety, installation, system readiness, routine operation, and maintenance of the portable ParticleTrack™ G400 instrument using FBRM® (Focused Beam Reflective Measurement) technology. ParticleTrack G400 systems are designed for laboratory research, development, and optimization; and include a single or dual-system configuration. A ParticleTrack G400 dual system can simultaneously measure two small-scale vessels or points in a process stream. System probes have fixed or interchangeable tips. See Chapter 4, “Product Description” for details on the FBRM technology and the types of G400 probe tips.

Should you have questions that are not addressed in this document, please contact your local METTLER TOLEDO office or our Customer Care Department using the information under “Service and Technical Assistance” on page 9.

ISO 9001 CertifiedThe quality system at METTLER TOLEDO is registered to the ISO 9001 Quality System Standard.

General PoliciesMETTLER TOLEDO equipment is subject to the installation, repair, and computer service policies described below.

Installation PolicySite preparation for the ParticleTrack G400 equipment is the end user's responsibility. Structural installation details, particularly for installations in process/production environments, should be prepared and supervised by a certified and registered professional engineer who is properly qualified to assure a safe installation at your site.

METTLER TOLEDO is not licensed to provide certification of mechanical, structural, or piping designs that may be required for installation of the ParticleTrack G400 system into specific applications. Such designs must be prepared and supervised by a certified and registered professional engineer in your organization.

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Repair PolicyMETTLER TOLEDO warrants its products against defects in materials and workmanship for twelve months from the date of installation or fifteen months from the date of shipment, whichever comes first. For details, please refer to the warranty provided with the instrument. For assistance, please contact your Technical Applications Consultant (TAC) or send an email to [email protected].

It is recommended that you retain the original packing materials in the event you need to return the ParticleTrack G400. If factory service is required, your METTLER TOLEDO service engineer will issue you a Return Material Authorization (RMA) form.

Computer Service PolicyIf a computer is included as part of your ParticleTrack G400 probe system, it will be from a major manufacturer such as Dell. In the U.S. and some European countries, the manufacturer will provide warranty service if required.

METTLER TOLEDO can assist in diagnosing problems with computers, but the computer manufacturer will provide parts and labor for repairs under the service contract.

Software UpgradesWhen applicable, upgrades to the instrument and office software are available at no additional charge for iCare subscribers. When a new release or service pack is available, all iCare subscribers with a valid subscription will be notified via email so they can download the installer from the AutoChem Community website, https://community.autochem.mt.com. Access to the site requires a password that you can request from the home page. You can also contact Customer Care or your METTLER TOLEDO Technology and Applications Consultant (TAC) using the information on page 9.

Non-iCare subscribers may request a quote for an upgrade by contacting their local salesperson or by sending an email to Customer Care.

Training ProgramsTraining for the hardware and software is available through the user community website (see link above) and through your METTLER TOLEDO TAC. Use the contact information under "Service and Technical Assistance".

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mailto:[email protected]:[email protected]://community.autochem.mt.commailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]

Service and Technical AssistanceMETTLER TOLEDO has offices around the world. Contact the Mettler-Toledo AutoChem, Inc. headquarters in the USA for technical support or service. To arrange for specific application assistance from a METTLER TOLEDO Technology and Applications Consultant, or for assistance, contact CustomerCare through the toll-free number below.

For information on service offerings, please refer to “Service Contracts” on page 72.

Additional InformationIn addition to this introductory chapter, the manual is organized as follows:

Chapter 2, “Site Preparation” on page 11

Chapter 3, “Safety” on page 19

Chapter 4, “Product Description” on page 23

Chapter 5, “Installation” on page 31

Chapter 6, “System Readiness” on page 45

Chapter 7, “Routine Operation” on page 49

Appendix A, “Specifications” on page 63

Appendix B, “ParticleTrack™ G400 Accessories and Services” on page 67

Appendix C, “Probe Mounting Options” on page 75

Appendix D, “Care and Maintenance” on page 81

Appendix E, “Troubleshooting and FAQs” on page 87

Appendix F, “ParticleTrack™ Glossary” on page 91

If you are viewing this document electronically, click any blue-colored link to go to the related information and instructions.

Related DocumentsThe electronic ParticleTrack G400 Hardware Documentation Portfolio, shipped with the instrument, includes the following documents in addition to this manual:

“Calibration Validation in iC FBRM” (MK-PB-0071-AC)

“System Calibration in iC FBRM” (MK-PB-0082-AC)

“Positioning a ParticleTrack or ParticleView Probe” (MK-PB-0050-AC)

“QuickRef-Changing ParticleTrack G400 Interchangeable Tips (MK-PB-080-AC)

“QuickRef-Using the PSC Purge Controller” (MK-PB-0120-AC)

Refer to the iC FBRM Documentation Portfolio for software user guides and associated documents.

Mettler-Toledo AutoChem, Inc.(Columbia, MD headquarters)

http://www.mt.com/FBRMhttp://www.mt.com/iCFbrm

Tel: + 1.410.910.8500Fax: +1.410.910.8600

Email: [email protected] Free: +1.866.333.6822


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2Site Preparation

This chapter outlines the end user’s responsibility to ensure a successful installation of the ParticleTrack™ G400 system and provides information about physical and utility requirements. Use this chapter as a checklist to verify that all prerequisite steps have been completed before a scheduled ParticleTrack G400 system installation.

A link to this hardware manual is provided after instrument purchase to allow adequate site preparation time. The AutoChem Community website has the latest release of this document.

The system ships in one or more cartons. The Field Service Engineer (FSE) responsible for performing system installation will contact you for pre-installation questions and scheduling. During installation, a METTLER TOLEDO FSE sets up, installs, and commissions the ParticleTrack G400 system after verifying site preparation.

[__] Space and Weight RequirementsDimensional drawings begin on page 16 and the space/weight specifications are below. The dimensions include the base unit with probe.

If applicable, provide a level surface for the Fixed Beaker Stand (FBS) that is used for calibration validation procedures along with a reference sample and target data file. Refer to page 67 for more information on the FBS.

FBS dimensions are approximately 502 mm x 330 mm x 305 mm [20 in x13 in x 12 in]. A dimensional drawing is on page 17.

Note:

Access to the site requires a password that you can request from the home page, https://community.autochem.mt.com. Setting up access during pre-installation will facilitate software license activation, which is also done through the Customer Community website.

Table 2-1 Site Preparation—System Size and Weight

Size (HxWxD), Base unit enclosure 89 mm x 241 mm x 492 mm) [3.5 in x 9.5 in x 19.4 in] See drawing in Figure 2-3.

Size (Diameter), Probe 14/9.5 mm or 19 mmSee Figure 2-1 and Figure 2-2 for dimensional drawings.

Size (Length), Probe tip, wetted 14/9.5 mm: 206 mm [8.10 in], or19 mm: 400 mm [15.75 in]

Weight (approximate) 4.5 kg [10 lb]

Conduit Length: 3 m [9.8 ft], Diameter: 11.6 mm [0.46 in]


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[__] Area of Intended UseThe area of intended use requires compliance with the following statements:

Base unit must have adequate space for conduit and probe.

• Probe conduit should not bend beyond 127 millimeters [5 inches]

• Probe conduit should not be put into an “S” shape.

Base unit must be:

• Convenient for access at eye level to view the LED status indicators

• Readily accessible for service

• Securely placed horizontally on a flat surface

• In an area that has access to instrument quality aire, if the probe requires purge gas to be connected to the rear of the instrument. This is required when operating at low temperatures to reduce the risk of condensation build-up inside the probe window.

If optional Fixed Beaker Stand (FBS) will be used, the FBS must be located within one to two meters of the base unit enclosure to accommodate the length of the conduit.

The ParticleTrack G400 system enclosure contains sensitive electronic components that should be protected from severe environmental conditions. Direct, intense sunlight can raise the internal temperatures above operating specifications.

[__] Environmental ConditionsThe ParticleTrack G400 system is designed for indoor use.

Note:METTLER TOLEDO is not liable for damages or other consequences resulting from improper installation of the ParticleTrack G400 base unit.

Table 2-2 Site Preparation—Environmental Conditions—Base Unit Enclosure

Temperature Range 5 °C to 35 °C [41 °F to 95 °F]

Operating Humidity Range 15%–85%, non-condensing

Maximum Relative Humidity 85%

Table 2-3 Site Preparation—Environmental Conditions—Probe

Temperature Range, Probe tip 10 °C to 90 °C [50 °F to 194 °F]NOTE: Purge controller (page 70) required for temperatures below 10 °C.Temperature range with optional purge controller:–80 °C to >90 °C [–112 °F to >194 °F] (with reduced bearing life)

Temperature Range, Probe back end 5 °C to 35 °C [41 °F to 95 °F]

Pressure Range, Probe tip 3 barg [vacuum to 43.5 psig]

Maximum conduit bend radius 127 mm [5 in]

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[__] UtilitiesParticleTrack G400 systems require AC power and communication utilities as follows.

Site Preparation—ElectricVerify that a power outlet is accessible in the area of intended use for the ParticleTrack G400 and the control computer. Provide one outlet for a single system or two outlets for a dual-system configuration according to the power supply specifications below.

Site Preparation—Air/Gas Supply (optional)If the optional purge controller accessory is purchased for cold process conditions below 10 °C to prevent condensation, the ParticleTrack G400 system requires a source of clean, dry, and pressure-regulated instrument air or inert gas.

Quality of the air or gas supply for the purge must meet the specifications of the American National Standards Institute/Instrument Society of America (ANSI/ISA) S7.0.01-1996 Quality Standard for Instrument Air.

The air/gas supply should meet the requirements below.

Have a dew point at least 10 ºC [18 ºF] lower than the minimum temperature to which any part of the system will be exposed.

Contain less than 1ppm total oil or hydrocarbons.

Contain less than 1ppm particulates at a maximum size of 3 microns.

Be free of any corrosive contaminants and flammable or toxic hazardous gases.

Table 2-4 Site Preparation—Utilities (Electric)

AC Power Input 100-240 VAC, 50-60 Hz, 1.2 A

DC Output: Power Supply (provided with system, auto-switching AC to DC)+5 VDC, Min. 0.3 A to Max. 4.0 A+12 VDC, Min. 0.2 A to Max. 1.5 A

Note:

The purge controller includes air tubing to connect from the outlet to the ParticleTrack G400 instrument.

Air inlet tubing is NOT supplied. PN14165600 Tubing, 1/4-inch Parflex PE, 6-foot length, can be ordered with the controller.

Table 2-5 Air/Gas Supply Requirements

Inlet Air Pressure, Maximum 8.6 barg [125 psig]

Operating Pressure, Normal 1.0 barg [15 psig]

Operating Flow Rate 0.15 SLPM [0.005 SCFM]

Operating Temperature, Maximum 58 °C [125 °F]


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Review the following procedures for ensuring air quality:

Procedures to Meet Air Quality StandardsFilter out harmful particulates. Proper particle filtration is easily established by a simple dust filtration element located before other treatment components. A quality, general-purpose prefilter removes particles down to 1 micron. High-efficiency afterfilters can remove particles down to 0.01 micron.

Remove all of the oil. Oil-lubricated compressors can have an oil carryover of 5ppm or more. If lubricated compressors are used, a coalescing filter and activated carbon filter should be installed after particulate prefilter. A clean, activated carbon filter with appropriate prefiltration removes oil vapor down to a concentration of 0.003 ppm at 70 °C [158 °F].

Consider going oil-free if replacing an air compressor. Compressed air is sometimes described as oil-free because filters are used, but filters have limitations. An oil-free compressor is the only way to guarantee compressed air delivery with oil content as close to zero as possible. Oil-free compressors use oil to lubricate bearings and gears, but mechanical seals isolate the compression chamber from any oil. Compressors below the 25- to 30-hp range, termed “oil-less,” have no lubricating oil of any kind. They use sealed bearings and PTFE-coated (PolyTetraFluoroEthylene) mating parts.

Consider an air dryer or filter. A dehydrator, desiccant type air dryer, coalescing filter or other type of air dryer is recommended to keep the air dry for instrument standards. If the air is not dry enough, condensation can build up on the inside the probe window.

Bottled Gas SuppliesIf clean, dry instrument air is not available, bottled gas can be used with the following precautions:

As gas releases from its pressurized bottle, the temperature of the gas can drop quite low. If this gas is directly fed into a ParticleTrack G400 system, it can significantly reduce the temperature of the probe tip. If the probe is in a temperature-driven process, the cold probe can upset the process and/or cause material to coat the probe making the measurement unreliable. If gas temperature becomes a concern, methods to heat the air are available.

WARNING—This system is designed for use primarily with compressed air. Where other inert compressed gases are used (Nitrogen, for example), the user must take suitable precautions so that the buildup of the inert gas does not present a hazard to health.

WARNING—The Safety Officer of the customer must ensure that equipment installation is without risk to the health and safety of the workers. Where a risk of asphyxiation exists, a warning label must be fitted to the equipment

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Site Preparation—Utilities (Communication)The ParticleTrack G400 communicates via USB to a control computer.

[__] Control Software Computer SpecificationsiC FBRM is the control software for the ParticleTrack G400 system. When you order a computer with the system, the iC FBRM software is preloaded. If you provide the control computer, minimum specifications are in the “iC FBRM Installation Guide.” For peak performance of the iC FBRM software, METTLER TOLEDO recommends the computer specifications listed in the “iC Software Computer Specifications Guide.” Access this guide from the METTLER TOLEDO website: http://www.mt.com/iC.

[__] Internal Paperwork and Approval for InstallationIf applicable, complete any necessary internal paperwork and approvals required within your organization for installation and start up of the ParticleTrack G400 system.

Standard and Optional AccessoriesRefer to Appendix B on page 67 for details about optional accessories.

Table 2-6 Site Preparation—Utilities (Communication)

USB 2.0

Cable length 1.83 m [6 ft]

Note:If you are providing the control software computer, discuss computer specifications with your METTLER TOLEDO Field Service Engineer (FSE) prior to the scheduled installation.

Table 2-7 Site Preparation—Standard Components and Accessories

Component or Accessory Standard Optional

Fixed Beaker Stand (FBS) See page 67.* Required with first G400 instrument purchase and IPac QualityPac service *

Purge Controller (required for temperatures below 10 °C) See page 70.

Interchangeable Probe Tips (see page 25)** One tip standard with instrument **

Mounting Options: (Refer to Appendix C on page 75)

EasyMax™ and OptiMax™ reactors

Lab-Joint adapters

Compression fittings

Flow Cell adapters

Custom and specials

Control Software:

iC FBRM Instrument License

iC FBRM Office License


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System DimensionsThis section includes dimensional drawings for the ParticleTrack G400 probe, base unit, and the Fixed Beaker Stand (FBS) accessory.

Below are the dimensions of the G400 14/9.5 mm probe:

Figure 2-1 Dimensions of ParticleTrack G400 14 mm probe

Below are the dimensions of the G400 19 mm probe:

Figure 2-2 Dimensions of ParticleTrack G400 19 mm probe

The figures below show the base unit from the front and side perspectives:

Figure 2-3 Dimensions of ParticleTrack G400 base unit

199 mm[7.83 ”]

206 mm[8.10 ”]

32 mm[Ø 1.25 ”]

9.5 mm[Ø 0.38 ”]

14 mm[Ø 0.55 ”]

70 mm[2.76 ”]

136 mm[5.35 ”]

199 mm[7.83 ”]

400 mm

32 mm[Ø 1.25 ”]

19 mm[Ø 0.75 ”]

[15.75 ”]

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Fixed Beaker Stand (FBS) Dimensions

Figure 2-4 FBS dimensions

502 mm[19.8”]

305 mm[12.0”]

330 mm[13.0”]


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3Safety

This chapter includes the following sections:

“Safety Symbols” on page 19

“Laser Classifications” on page 20

“CE Compliance” on page 21

“NRTL Certification” on page 21

“Equipment Ratings” on page 21

“General Safety” on page 21

In addition to the ISO 9001 procedures followed at METTLER TOLEDO, the ParticleTrack G400 system also conforms to the laser classification and CE compliance standards described in this chapter. While these standards have worldwide recognition, they may not apply to all locations or applications. Requirements for compliance with local regulations may be different. The end user of the equipment is responsible for compliance with all local, corporate, or other applicable regulations.

Safety SymbolsThree levels of information relate to equipment and user safety. To help you recognize information, the following symbols appear throughout this manual. Please pay particular attention to the sections marked by these symbols.

Caution—If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

Table 3-1 Warnings, Cautions, and Notes

WARNING—Extremely Important safety information—Failure to observe the warning may result in serious personal injury or equipment damage.

Caution—Important information that tells you how to prevent damage to equipment, or to avoid a situation that may cause minor injury.

Note:Informational, but not safety-related statement that you should read carefully


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The following symbols identify safety information on the ParticleTrack G400:

Laser ClassificationsAll standard-model ParticleTrack G400 instruments are in compliance with the U.S. Department of Health and Human Services (DHHS) Radiation Performance and in accordance with International Standards.

THE PARTICLETRACK G400 IS A CLASS 1 LASER PRODUCT COMPLIANT WITH DHHS 21 CFR 1040.10 AND 1040.11 EXCEPT FOR DEVIATIONS

PURSUANT TO LASER NOTICE 50 DATED JUNE 24, 2007.

THE PARTICLETRACK G400 IS A CLASS 1 LASER PRODUCT COMPLIANT WITH IEC 60825-1.

Table 3-2 Safety Symbols

Caution—Risk of danger

Off

On

Alternating Current

Direct Current

This mark shows that the equipment complies with all applicable EU directives.

Caution—LASER SAFETY WARNING: Opening the enclosure and making adjustments or performing procedures other than those specified in the hardware manual may result in hazardous radiation exposure.

Caution—There are no user-serviceable components in the laser module.

Caution—Looking directly into the aperture of any laser-emitting device is never advised.

Caution—Only skilled, trained technicians can service this equipment.

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CE ComplianceParticleTrack G400 systems have been tested and comply, as required, with the Electromagnetic Capability (EMC) Directive and Low Voltage Directory (LVD). ParticleTrack instrument testing may not cover local regulations that are not in accordance with other standards.

NRTL CertificationCertificate E113433

Equipment RatingsRefer to “Specifications” on page 63 for detailed equipment ratings and safety-related specifications that include power, temperature, and pressure.

General SafetyThis section provides the basic safety information for the ParticleTrack G400 system.

The customer’s Safety Officer must ensure that equipment installation is without risk to the health and safety of workers by the equipment location.

Caution—The CE mark applies only to unmodified instruments supplied by METTLER TOLEDO. Modifications to ParticleTrack G400 instruments may require on-site testing for compliance verification.

Caution—Looking directly into the probe of any laser-emitting device is never advised. The use of other optical instruments with the ParticleTrack probe increases eye hazard.


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4Product Description

The ParticleTrack™ G400 system consists of three parts—a Base Unit with attached Probe, an external power supply, and a remote computer with iC FBRM software. The iC FBRM software controls the operation of the ParticleTrack system including collecting and processing the measurement data, as well as reporting and saving the results based on default settings or customized settings defined by the operator.

This chapter includes the following sections:

“Tip Terminology” on page 23

“ParticleTrack G400 System Configurations” on page 23

“System Components” on page 24

“Using FBRM® Technology” on page 27

Tip TerminologyRefer to Appendix F on page 91 for a glossary of terms used with ParticleTrack hardware and iC FBRM software. In addition to the glossary, the following terms are specific to ParticleTrack G400 system tips:

Fixed Probe Tip—Factory-installed probe tip that cannot be interchanged. This type of tip must be specified at time of order.

Interchangeable Probe Tips—Removable probe tips design allows the flexibility to use a variety of probe tips with the same G400 back end. A variety of standard and customized probes are available for operation over a wider range of vessel size, pressure, and temperature—including autoclavable and high-pressure versions. Only one probe tip can be used at a time. Each tip is calibrated for use with a particular back end through the iC FBRM software. Refer to “8. Connect/Configure Instrument in Control Software” on page 37 for a single or a dual-system configuration. Table 4-1 lists the standard tips.

ParticleTrack G400 System ConfigurationsParticleTrack G400 systems can be in a single or dual-system configuration. A single configuration consists of one probe and base unit that communicates with the iC FBRM software through a USB cable. A dual configuration consists of two probe-and-base unit systems communicating with the same computer. Each system includes a power supply.

Note:Attempts to disconnect fixed probes leads to loss of calibration and possible damage to probes that are not covered under warranty.


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G400—Single System

Figure 4-1 ParticleTrack G400 system diagram—Single configuration

G400—Dual System

Figure 4-2 ParticleTrack G400 system diagram—Dual configuration

System ComponentsThis section describes the ParticleTrack G400 system components in more detail. Although the probe is permanently connected to the base unit, a G400 probe design includes the option to interchange the probe tips.

Note: A fixed probe tip is also available at time of order.

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Interchangeable Probe TipsTable 4-1 provides the dimensions for the interchangeable ParticleTrack G400 probe tips. Dimensional drawings begin on (page 16).

Figure 4-3 ParticleTrack G400 interchangeable probe tips–14 mm / 19 mm

ParticleTrack G400 Base UnitIndicators on the front of a ParticleTrack G400 base unit show power and status conditions (“System Power and Status Indicators” on page 52). The back of the unit (Figure 5-1 on page 34) is the location for all system connections.

Power Supply (Auto-Switching AC Adapter)

The power supply for each ParticleTrack G400 system includes an auto-switching AC adapter. Refer to “Power Supply (with Switching AC Adapter)” on page 65 for details.

Figure 4-4 Power supply with switching AC adapter

Table 4-1 Interchangeable Probe Tip Dimensions

Probe Type

Probe Tip Diameters Probe Tip LengthsDimensional

DrawingsTip Back End Wetted Total (including back end)

Standard 14 mm 32 mm [7.8 in]

206 mm [8.10 in] 405 mm [15.9 in] See Figure 2-1

Standard 19 mm 400 mm [15.75 in] 599 mm [23.5 in] See Figure 2-2


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Instrument Control SoftwareThe iC FBRM software controls a ParticleTrack G400 instrument. The ‘Instrument’ license is designed to control the instrument and do advanced analysis. An ‘Office’ license is designed for advanced analysis on the data collected from instrument experiments, without an instrument connection.

Optional AccessoriesThis section lists the basic hardware options. Please refer to Appendix B on page 67 for details about hardware accessories and service options.

Purge Controller—The ParticleTrack G400 system has a standard purge option for cold process conditions below 10 °C or the dew point of the operating environment to prevent condensation in the probe. Refer to page 13 for a checklist of site preparation requirements and page 67 for more information.

Interchangeable probe tips (Table 4-1) enable you to keep spare tips of various sizes to monitor different volumes with a single G400 instrument. “Tip Terminology” on page 23 defines the difference between fixed and interchangeable probe tips.

Fixed Beaker Stand with mixer is for use in calibration validation. Refer to page 67.

Probe Mounting ExampleFor probe mounting options, refer to “Probe Mounting Options” on page 75. Figure 4-5 shows a ParticleTrack G400 system mounted in an EasyMax™ workstation along with a ParticleView V19 Particle Vision and Measurement (PVM®) probe and a ReactIR™ probe.

Figure 4-5 ParticleTrack G400 mounted in EasyMax™ workstation

Note:

If you have an earlier model purge controller (rotameter marked for 5 LPM flow rate), an upgrade kit (Part Number 14474831) enables you to swap out the rotameter and re-label the unit with the current air specifications. The kit includes a step-by-step instruction sheet (MK-PB-0120-AC ‘QuickRef-Using the PSC Purge Controller’), which is also in the Hardware Documentation Portfolio.

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Using FBRM® TechnologyThe ParticleTrack G400 system uses Focused Beam Reflectance Measurement (FBRM®) technology to provide in-process particle system characterization in real time. The technology provides a repeatable and reproducible measurement of particle dimension and relative particle count—even in highly concentrated and opaque solutions.

Each FBRM technology probe contains key internal components including a solid-state laser light source that provides a continuous beam of monochromatic light and an intricate set of optics in the probe that focus the light to a small spot. The focused beam is carefully calibrated to a focal position that is between the probe window and the flowing particle system.

Click the image below to see a ‘Show Me’ animation of FBRM technology and continue in this section to read more about FBRM technology.

Figure 4-6 Focused Beam Reflectance Measurement (FBRM) with “Show Me” animation


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Figure 4-7 illustrates the focused laser beam as viewed from the probe window. The beam scans across the particle system in a circular path (scan circle) at a high speed. This scan speed is carefully monitored and controlled throughout the measurement to ensure maximum precision and repeatability of the data.

Figure 4-7 FBRM scan circle

As the focused beam scans across individual particles or particle structures (such as agglomerates or flocculates), the backscattered laser light is detected by the probe as a pulse measured from one edge of the particle to an opposing edge.

Figure 4-8 FBRM particle measurements—Chord lengths

The probe detects these pulses of backscattered light and the FBRM technology translates the pulses into chord lengths. Typically, the FBRM technology measures thousands of individual chord lengths each second.

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The duration of each pulse of backscattered light is multiplied by the scan speed to calculate the Chord Length Distribution that appears in the software (Figure 4-9).

Figure 4-9 FBRM technology—Chord length distribution graph

As a “fingerprint” of the particle system, the chord length distribution enables users to detect and monitor changes in particle dimension and particle count in real time.

ParticleTrack G400 ApplicationsParticleTrack G400 systems can be used to dynamically quantify and control the effect of process variables such as reaction rate, temperature, addition rates, residence time, and mixing speed on a particulate system. ParticleTrack G400 systems can also quantify the effect of the particulate system on downstream performance in factors like separation, reactivity, and dispensability.

FBRM technology can be correlated directly with any upstream or downstream process variable or final product specification (such as size, rheology, and zeta potential) that is a function of the particle shape, dimension, and number of particles in the particle system.

In addition to process optimization and control, the FBRM technology measurement is unique in its ability to “fingerprint” each batch at its process concentration based on particle dimension, particle shape, and particle population. This measurement capability makes the ParticleTrack G400 system an excellent tool to monitor batch-to-batch consistency.

ParticleTrack G400 Capabilities Provides in-process, real-time, particle dimension and high solids concentration particle

count.

Note:

Unlike other particle size analysis techniques, FBRM measurement makes no assumption of particle shape. As a result, the fundamental measurement can be used to directly track changes in the particle system without unnecessary complex mathematical assumptions that could introduce significant errors to the measurement.


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Enables analysis of particle dimensions from 0.5 to 2,000 μm (microns).

Handles a variety of particle shapes or changing shapes—FBRM technology does not assume spherical particles.

Provides both chord length distribution and count measurements in two-second intervals.

Enables monitoring of particle count in specific length regions (such as fine and coarse) to increase precision, sensitivity, and early warning to process dynamics.

Can be used to fingerprint batch endpoint based on particle dimension, shape, and count.

Provides immediate target endpoint detection (through distributions), ensuring consistent downstream particle flow, tableting, and dissolution.

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5Installation

This chapter provides procedures to install or reinstall a ParticleTrack™ G400 system.

Instrument installation and commissioning involves the METTLER TOLEDO service packages executed by a METTLER TOLEDO Field Service Engineer (FSE) plus site preparation, which is the responsibility of the end user. The scope of the installation service includes:

Site requirements verification

Equipment inspection and order validation

System installation and startup

Acceptance CriteriaThe IPac StarterPac or IPac QualityPac requires approval signatures from the METTLER TOLEDO AutoChem Field Service Engineer and your organization’s ‘Responsible User.’

Note:

METTLER TOLEDO offers the following ServicePac offerings related to installation and system commissioning:

IPac StarterPac—ParticleTrack G400 IPac StarterPac is designed for customers in the Academia, Government, Chemical, and Polymer Industries needing professional installation by a trained and authorized METTLER TOLEDO Field Service Engineer (FSE). This installation package is for customers who have no internal requirements for instrument Calibration Validation to a METTLER TOLEDO PVC Standard for data accuracy. For additional information, see page 71.

IPac QualityPac—ParticleTrack G400 IPac QualityPac is designed for customers in the Pharmaceutical, Biotech, and Food Industries needing objective evidence and records to satisfy quality requirements of their organization. This installation package expands the IPac StarterPac for customers who have internal requirements for instrument Calibration Validation to a METTLER TOLEDO PVC Standard by a trained and authorized METTLER TOLEDO FSE to ensure data accuracy. For additional information, see page 72.

A Note about Fixed Beaker Stand (FBS): An FBS, shown on page 67, is required to perform the IPac QualityPac installation service. The Fixed Beaker Stand must be purchased in addition to the IPac QualityPac.

For ongoing instrument validation and calibration, an annual Preventive Maintenance service is available (see page 82).

Note:Place the signed ServicePac document in a readily accessible location for reference during system service or maintenance.


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Site Preparation (Customer Responsibility)The ParticleTrack G400 pre-installation details are sent to you before the system ships. Permanent or temporary installation of a ParticleTrack G400 system must include the following preparation, as detailed in Chapter 2, “Site Preparation”:

Adequate space in area of intended use

Utilities—Electrical supply and optional instrument air

Control computer that meets specifications (if not ordered with system)

A METTLER TOLEDO Field Service Engineer will unpack, set up, and install the ParticleTrack G400 system after verifying site preparation. Site preparation requirements must be completed before the engineer arrives on site.

Installation InstructionsThis section describes the procedures for installing the ParticleTrack G400 system.

“1. Confirm Site Requirements” on page 32

“2. Verify Hardware Configuration” on page 33

“3. Place Base Unit at Area of Intended Use” on page 33

“4. Confirm Hardware Service Agreement and Software Version” on page 33

“5. Make System Connections” on page 33

“6. Install Control Software” on page 36

“7. Start Up System” on page 36

“8. Connect/Configure Instrument in Control Software” on page 37

“9. Activate Licenses” on page 42

“10. Set Up Optional Fixed Beaker Stand (FBS)” on page 43

1. Confirm Site RequirementsA METTLER TOLEDO Field Service Engineer (FSE) checks the ParticleTrack G400 installation site in accordance with the product requirements and completes the first section of the IPac StarterPac or IPac QualityPac, (ServicePac offerings). Customers must ensure the site is ready prior to arrival of the FSE based on the “Site Preparation” in Chapter 2.

Proceed to the next step only after confirming the site is ready.

Caution—Initial installation of a ParticleTrack G400 system should be performed by a trained and qualified METTLER TOLEDO FSE. METTLER TOLEDO is not liable for damages or other consequences resulting from improper installation of the ParticleTrack G400 system.

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2. Verify Hardware ConfigurationUsing the appropriate ServicePac document, perform a visual inspection of the shipment to verify the items on the order.

A typical configuration includes the following components:

ParticleTrack G400 base unit with probe

USB cable

PVC Reference Sample with reference file

ParticleTrack dry erase window marker

ParticleTrack G400 documentation CD, including ParticleTrack G400 Hardware Portfolio that should be copied to the control computer desktop as part of system installation.

iC FBRM control software installation CD, including an iC FBRM Documentation Portfolio that is available through the Help menu.

Optional Accessories and Services include:

Fixed Beaker Stand (FBS)—an accessory used to validate calibration of a ParticleTrack G400 system. This is a required accessory for the first ParticleTrack instrument and is also necessary with the IPac QualityPac service. Refer to Appendix B on page 67 for details.

A computer is included, if ordered with the system.

3. Place Base Unit at Area of Intended UseThe ParticleTrack G400 system is designed to be placed on a flat, secure surface. Refer to “Site Preparation” on page 11 for dimensional drawings.

1. Place the base unit in the location of intended use per the site preparation requirements. For a dual-probe configuration, the base units can be stacked.

2. Place the computer in a suitable work location that allows connectivity to the base unit via a USB cable.

4. Confirm Hardware Service Agreement and Software VersionUse the appropriate sections of the ServicePac document to confirm the hardware and software that was ordered is contained in the shipment. Any service agreement option purchased should be documented in the applicable ServicePac document along with the expiration date.

5. Make System ConnectionsComplete the System Connections in the appropriate ServicePac document while progressing through these instructions to ensure all system hardware is in the proper location with connectivity to utilities and control computer.

Note:The latest ParticleTrack G400 hardware and software documents are on the Customer Community website: https://community.autochem.mt.com).

Notes: The probe conduit is permanently connected to the base unit.


https://community.autochem.mt.com

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ParticleTrack G400 system installation involves two connections to the power and USB communication inlets at the back of the base unit. If the optional purge controller is purchased, a third connection to instrument-quality air is also on the back of the unit. For dual-system configurations, note that the procedure is to connect and configure the first system entirely. Then, connect and configure the second system.

System connections include the following:

“A. Connect Power” on page 34

“B. Connect USB Communications Cable” on page 35

“C. Connect Purge Controller (optional)” on page 35

A. Connect Power1. Connect the pin-terminated end of the country-specific, auto-switching AC Power

Adapter to the Power connection (A) at the back of the ParticleTrack G400 base unit.

Figure 5-1 Base unit—Rear view (power connection)

2. Connect the opposite end to an AC outlet.

3. Press the power button (A) on the front of the base unit and observe that the Power LED indicator (AA) illuminates (Figure 5-2).

Figure 5-2 ParticleTrack G400 Power button and LED indicator

Notes:

Instructions below are for a single-probe configuration. For a dual-system configuration, follow the procedure below for the

FIRST probe. The second system should be installed after full installation of the first system.

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4. Ensure the ParticleTrack G400 system has been powered ON for 30 minutes before performing calibration validation or recording particle system measurements.

B. Connect USB Communications Cable1. Refer to Figure 5-3 and locate the USB inputs at the back of the ParticleTrack G400

enclosure. Then, connect the USB cable to the first input (B).

Figure 5-3 USB communication connection on base unit

2. Plug the other end of the cable to a USB port on the control computer.

C. Connect Purge Controller (optional)The ParticleTrack G400 has an optional purge controller that eliminates condensation by circulating dry instrument air to the inside surface of the probe window during operating conditions below the dew point temperature of the operating environments.

If using the purge controller, connect the purge tubing to the purge fitting on the rear of the base unit (C in Figure 5-4) near the probe connection.

Figure 5-4 Optional purge—Fitting connection on back of base unit

Note:The Communications LED will not illuminate until the software connection is complete (software connection procedure begins on page 37.)


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Steps to set up the purge controller are under “Purge Controller Option” on page 70. Instruction on operating the purge are in Chapter 7, “Routine Operation” under "Starting the Optional ParticleTrack G400 Purge".

6. Install Control SoftwareiC FBRM is the control software for a ParticleTrack G400 instrument. Prior to installing iC FBRM, verify the PC meets the minimum specifications in the software installation guide. For peak performance of iC FBRM, refer to the “iC Software Computer Specifications Guide” on the Customer Community site:https://community.autochem.mt.com or the METTLER TOLEDO website:http://www.mt.com/iC.

Install the iC FBRM instrument control software by following instructions in the “iC FBRM Installation Guide.’ An installation wizard guides the installation process.

1. In the installation wizard, answer Yes to “Will this computer be used to control an instrument?”

2. Choose “ParticleTrack G400” from the Select Instrument window.

Accepting or Changing Computer System SettingsVerify the system date and time by viewing in the System Tray, and edit as necessary in accordance with the local time zone. If applicable, change the system language to the local language via Control Pane: Region and Language.

7. Start Up System

Start up the ParticleTrack G400 system(s) as follows.

1. Apply power to the base unit by pressing the power button on the front of the unit (Figure 5-2). If the configuration does not include the optional purge controller, proceed to section “8. Connect/Configure Instrument in Control Software” on page 37.

2. If the optional purge controller is required, start the purge as described on page 49 (step 1 through step 3 on page 50). Then, return to section "8. Connect/Configure Instrument in Control Software".

WARNING—In configuration with the optional purge controller, make sure the air inlet is securely attached to the purge controller before applying air pressure to the ParticleTrack G400 system. Failure to check connections can result in serious personal injury.

Note:iC FBRM control software requires an Instrument License for instrument control. You will need the instrument license included with your order to operate the ParticleTrack G400. License activation steps begin on page 42.

Note:DO NOT proceed with the 'Start Up System' section until all applicable ServicePac installation documents are complete.

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https://community.autochem.mt.comhttp://www.mt.com/iC

8. Connect/Configure Instrument in Control SoftwareSteps below assume the ParticleTrack G400 instrument was selected during iC FBRM software installation as described under “6. Install Control Software” on page 36. Connection procedures are separated for a single-(below) and a dual-system (page 39) configuration.

As a result of the ParticleTrack instrument on-board memory, the majority of instrument configuration information automatically transfers to the software configuration.

Steps for Single ParticleTrack G400 Configuration1. Log on to the computer and wait a minute so the FBRM server is up and running. Then,

start the iC FBRM software application.

2. Create the instrument connection.

a. From the Start Page menu bar, select Tools > Instrument Connections.b. In the Instrument Connections window, click Edit to scan for a connected device.

Figure 5-5 Instrument Connections—Edit

c. Click OK in the Edit Instrument message window that appears after the software scans for the instrument connection.

Figure 5-6 Edit Instrument message (connection verified)


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Complete Instrument Configuration Wizard1. From the Start Page menu bar, click Configure Instrument.

Figure 5-7 Configure Instrument wizard in iC FBRM

2. Confirm the instrument as a ParticleTrack G400.

3. The Manage Probes window is shown here for information only.

The window contains preconfigured values for a ParticleTrack G400 base unit: Serial #, Probe Tip Diameter, Scan Circle Diameter, and CP1/CP2/CP3.

During initial installation and for new interchangeable tips, a METTLER TOLEDO Field Service Engineer (FSE) checks the Manage Probes configuration.

If a ParticleTrack G400 base unit has more than one interchangeable probe tip, an FSE configures it in the Manage Probes window as shown in Figure 5-8.

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Figure 5-8 Manage Probes window (showing an interchangeable 19 mm tip)

If you have opened the Manage Probes window, click Cancel.

4. In the Hardware Settings—Scan Speed window, click Next to accept the 2 meters/second setting.

5. In the Select the Chord Selection Model (CSM) window, do the following:

a. Mark the check box in the Save column next to each CSM. b. Select Primary as the default CSM to display in the Distributions Viewer.

6. Click Finish.

If this is a single system configuration, proceed to “9. Activate Licenses” on page 42.

If this is a dual-system configuration, continue to the next section.

Steps for a Dual-System Configuration

These steps assume the first probe has already been connected and configured.

1. Create the instrument connection.

a. From the Start Page menu bar, select Tools > Instrument Connections.

Note:Never change the Scan circle diameter, CP1/CP2/CP3 values unless directed by a METTLER TOLEDO representative.

Note:

Both systems in a dual-system configuration must be ParticleTrack systems—mixing and matching a ParticleTrack G400 system with an FBRM G400 system is not supported. Contact METTLER TOLEDO for information on the hardware upgrade necessary to convert an FBRM G400.


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b. In the Instrument Connections dialog box, click Edit to scan for a connected device.

Figure 5-9 Instrument Connections—Edit

c. Click OK in the Edit Instrument message window that appears after the software scans for the instrument connection.

Figure 5-10 Edit Instrument message (connection verified)

2. Repeat the instrument configuration and Manage Probes procedure for the second probe system, as follows.

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Complete Instrument Configuration Wizard1. From the Start Page menu bar, click Configure Instrument.


2. Confirm the instrument as a ParticleTrack G400 and select the second probe (ProbeB) from the Probe drop-down list.

3. The Manage Probes window is shown here for information only.

The window contains preconfigured values for a ParticleTrack G400 base unit: Serial #, Probe Tip Diameter, Scan Circle Diameter, and CP1/CP2/CP3.

During initial installation and for new interchangeable tips, a METTLER TOLEDO Field Service Engineer (FSE) checks the Manage Probes configuration.


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Figure 5-12 Manage Probes window (showing an interchangeable tip)

If you have opened the Manage Probes window, click Cancel.

4. In the Hardware Settings—Scan Speed window, click Next to accept the 2m/sec setting.

5. In the Select the Chord Selection Model (CSM) window, do the following:

a. Mark the check box in the Save column next to each CSM. b. Select Primary as the default CSM to display in the Distributions Viewer.

6. Click Finish.

9. Activate LicensesSeveral types of licenses can be activated through the iC FBRM control software, including—(1) software licenses and (2) an iCare subscription, (3) Chord Selection Model (CSM) licenses, and (4) site licenses. Have the license key(s) provided with your software available as you will need to enter the key(s) during the activation process.

Activate the software license (or iCare subscription) by copying the machine ID from the control computer, then logging on to the AutoChem Customer Community site where you:

Enter the license keys shipped with the instrument.

Generate an activation code.

Return to the License Manager and enter the activation code.

Detailed instructions are in the software installation guide.

1. In iC FBRM, select Help > License Manager from the menu bar.

2. Follow the license activation steps in the License Manager window.

a. Copy Machine ID (Click Copy button next to step 1 in License Manager).

Note:Never change the Scan circle diameter, CP1/CP2/CP3 values unless directed by a METTLER TOLEDO representative.

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b. Activate license key at the AutoChem Community website (step 2). If required, detailed instructions are in the software installation guide under Setting Up a New User Account.

c. Return to the License Manager after copying the activation code from the website.d. Enter Activation Code received from the website (Click Paste next to step 3).e. Click Apply Activation Code (step 4).

Follow the same steps to activate Chord Select Model (CSM) licenses.

10. Set Up Optional Fixed Beaker Stand (FBS)Purchase of an IPac QualityPac installation service requires purchase of the optional Fixed Beaker Stand (FBS) with mixer. The FBS enables ongoing calibration validation. Refer to the “Calibration Validation in iC FBRM” procedure document in the ParticleTrack G400 Hardware Portfolio. An FBS can also be used in the laboratory for particle system measurements.

Refer to Appendix B on page 67 for setup instructions.

Mounting the ProbeIn addition to the Fixed Beaker Stand (FBS), ParticleTrack G400 systems include a variety of options for mounting the probe in a laboratory particle or droplet system vessel. Refer to Appendix C, “Probe Mounting Options” beginning on page 75 for additional options.


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6System Readiness

This chapter describes the procedures for system readiness in the following sections:

“Preparing for ParticleTrack™ G400 Functional Tests” on page 45

“Conducting Functional Tests Using iC FBRM” on page 45 “Functional Test Overall Results” on page 48 .

Preparing for ParticleTrack™ G400 Functional TestsThe second phase of system installation consists of performance tests of the ParticleTrack G400 system. This phase follows system installation and is performed by a METTLER TOLEDO Field Service Engineer (FSE). The system is assumed to be powered on and communicating with the control software.

1. Ensure that Instrument Configuration is completed as described under section “8. Connect/Configure Instrument in Control Software” on page 37.

2. Verify the ParticleTrack G400 Power and Communication LEDs on the front of the base unit are illuminated, indicating the system is powered ON and communicating with the control software. Refer to “System Power and Status Indicators” on page 52.

Conducting Functional Tests Using iC FBRMPerform functional tests in the following sequence:

“1. Clean Window” on page 46

“2. Laser Power Check at Probe Window” on page 46

“3. System Check with Marker” on page 46

“4. Calibration Validation” on page 47

“Verify Purge Controller Function (if applicable)” on page 47

During system installation, a METTLER TOLEDO Field Service Engineer (FSE) performs functional tests according to the ServicePac installation document.

Caution—If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.


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1. Clean Window The Clean Window test is a basic check of particle or droplet counts to determine sapphire window cleanliness. This test is designed to be run when the probe is available; that is, it is not installed in the Flexible Mounting (Appendix C on page 75).

1. Click New Experiment from the Start Page.

2. Select to ‘Start with a new file.’

3. Enter an ‘Experiment Name.’

4. Enter or select the ‘Folder Location.’ (The ‘Template’ field is not applicable.)

5. Select the applicable ‘Probe’ and click Next to proceed to the Experiment Schedule.

a. Set the Duration: 1 hourb. Set the Interval to: 3 secondsc. Press Next to proceed to Clean Probe window.

6. Wait until the ‘Clean Probe’ status bar is green.

If the counts fall outside the Alarm Limits set in the software, a warning message appears.

7. Click Finish to complete the wizard and start an experiment.

2. Laser Power Check at Probe WindowDuring installation, the FSE will measure the laser power at the probe window and adjust it, if necessary, to obtain the optimal laser power measurement. Refer to the ServicePac installation document.

3. System Check with Marker To check basic system function of measuring particle and droplet system characteristics, use the dry erase marker shipped with the system. The steps below assume the system is already configured and the instrument is communicating with the software.

The experiment started under readiness test "1. Clean Window" is in ‘Pause’ mode to allow time to set Data Treatment and Statistics definitions.

Data Treatments SettingsIn the iC FBRM Toolbox, select Data Treatments and accept or enter the following settings:

1. Edit Averaging: None

2. Edit Channel Grouping, as follows:

a. Number of Bins: 250b. Range: 0–100 micronsc. Spacing: Linear

Note:If the ‘Clean Probe’ status indicates the probe requires cleaning, use a Kimwipe and acetone to wipe the probe window. Rinse it with clear water and dry it. Repeat the test until the ‘Clean Probe’ status bar is green.

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3. Select ‘Display distribution’: Primary

4. Keep ‘Enable Stuck Particle Correction’ unchecked.

Statistics Settings1. In the Statistics Viewer, click the Edit button .

2. In the Edit Statistics window, select the following statistic: counts, No Wt,

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Functional Test Overall ResultsVerify the test results meet the pass criteria in Table 6-1.

Complete the signatures on the appropriate ServicePac document.

If the functional tests have met the criteria to pass, an FSE marks the appropriate section of the ServicePac document that indicates the ParticleTrack G400 system functions in accordance with METTLER TOLEDO Test Specifications.

If any test did not meet the criteria, each non-conformance must be documented in the ServicePac document along with the action to resolve.

Acceptance CriteriaThe ServicePac document requires approval signatures from the METTLER TOLEDO AutoChem Field Service Engineer and your company’s responsible ParticleTrack G400 user. Warranty and service contracts officially start at this point.

Table 6-1 Function Test Pass Criteria

Functional Test Results—Passing Criteria

“1. Clean Window” Counts, No Wt =

7Routine Operation

This chapter describes operational procedures for:

“Starting the Optional ParticleTrack G400 Purge” on page 49

“Starting the ParticleTrack G400 System” on page 51

“Simple Guides to a Successful Run” on page 52

“Best Practices for Routine Operation” on page 58

“Software Operation” on page 60

The steps below assume that the iC FBRM is already installed on the PC and all instrument connections have been made as described in Chapter 5, “Installation” and that Chapter 6, “System Readiness” testing is complete.

Starting the Optional ParticleTrack G400 PurgeIf no optional purge controller is included in the ParticleTrack G400 system configuration, skip this section and proceed to “Starting the ParticleTrack G400 System” on page 51.

If the optional purge controller is used for conditions below 10 °C to ensure there is no condensation in the probe, start the purge. Pre-purging must occur for one hour at 1.2 standard liters per minute before the probe is used to measure particle system data.

1. To meet the warm up requirement, the system should already be powered on and the air supply regulated per Table 7-1

WARNING—Use of this product in a manner not specified by the manufacturer may result in serious injury and/or damage to the equipment and will void the warranty, the protection provided by the equipment may be impaired.

WARNING—Before applying air pressure to the ParticleTrack G400 system, always make sure the air inlet tubing is securely attached to the purge controller (A in Figure 7-1). Failure to check connections can result in serious personal injury.

Table 7-1 Air Settings/Maximum Temperature

Operating Pressure, Normal 1.0 barg [15 psig]

Pre-purge for one (1) hour 1.2 SLPM [0.042 SCFM]

Operating Flow Rate 0.15 SLPM [0.0005 SCFM]

Operating Temperature, Maximum 58 °C [125 °F]


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2. For each ParticleTrack G400 probe supplied with air, adjust the dial on the purge rotameter (D) to the pre-purge flow rate—1.2 SLPM (ball in glass rotameter window will be near the top).

Figure 7-1 Operating flow rate—0.15 SLPM

3. Verify that air is exiting the exhaust holes on the probe.

Figure 7-2 Purge exhaust on probe (one of three holes)

4. Run the probe for one hour to eliminate all condensation before operating in particle or droplet systems.

5. After the one-hour purge, set the operating flow rate to 0.15 SLPM to run an experiment.

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Note: Do not block the purge air exhaust holes during purge operation.

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Starting the ParticleTrack G400 SystemAfter applying power to the base unit, there is a warm-up period because the PIN diode and laser are temperature-controlled. A temperature alarm sounds at power ON to allow adequate time for the thermoelectric heater/cooler to stabilize to a controlled temperature. After reaching the control temperature—usually within one to two minutes—the alarm stops.

Below are the startup instructions for single and dual-system ParticleTrack G400 configurations. The instructions assume the instrument is already connected and configured per section “8. Connect/Configure Instrument in Control Software” on page 37 and that . is complete.

If the optional purge controller is included in the configuration and the particle system temperature is below specification, the purge and system should already be on as described in “Starting the Optional ParticleTrack G400 Purge” on page 49. Therefore, skip this section and proceed to “System Power and Status Indicators” on page 52.

ParticleTrack G400—Single Configuration1. Press the Power button (A) on the front of the ParticleTrack G400 base unit and verify

the Power On indicator (AA) illuminates.

Figure 7-3 ParticleTrack G400 power button and LED indicator

2. Allow 30 minutes for the instrument electronics to warm up before taking critical measurements.

3. Turn on the computer and start the iC FBRM software.

4. Allow the probe temperature to equilibrate before starting an experiment.

ParticleTrack G400—Dual Configuration1. Press the Power button on the front of each ParticleTrack G400 base unit and verify the

Power On indicators illuminate (Figure 7-3).

2. Allow 30 minutes for the instrument electronics to warm up before taking critical measurements.

3. Turn on the computer and start the iC FBRM software.

4. Allow the probe temperature to equilibrate before starting an experiment.


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System Power and Status IndicatorsIndicator lights on the face of the ParticleTrack G400 base unit indicate the system status.

5. Ensure the ParticleTrack G400 system has been powered ON for 30 minutes before beginning tests.

Simple Guides to a Successful RunGetting the most out of your ParticleTrack G400 requires simple steps that lead to the optimal particle system characterization. The data will then be of the highest quality for easy conversion to statistics that you can use for better understanding of the particle system or droplet dynamics.

“Select Appropriate Template for the Given Application” on page 56.

Refer to “Best Practices for Routine Operation” on page 58 for additional guidelines.

Always Ensure the Probe is CleanAlways ensure the probe window is clean before taking critical measurements, as described on page 46.

Select the Appropriate Interchangeable TipInterchangeable probe tips enable you to monitor the progression of particle or droplet systems to larger vessels. If interchangeable tips have been configured for the given probe and a larger (or smaller) probe diameter would be better suited to the current particle system vessel, change the probe tip.

Table 7-2 ParticleTrack G400 System Status Indicators

Indicator Color State Description

Power GreenON System powered ON

Off No power supplied

Communication GreenON System communicating with the iC FBRM server.

Off Computer is off or software application is not started

HW Status RedON

HARDWARE STATUS—Red when hardware error exists that results in loss of particle/droplet measurements. Check iC FBRM Events Viewer for detailed alarm description. See Table E-3 on page 88.

Off Normal status

SW Status RedON

SOFTWARE STATUS—Red when a software issue exists or an error occurs for calculating Chord Length Distribution that may cause loss of measurement. Check iC FBRM Event Viewer for detailed description.

Off Normal status

Note:This warm up period is recommended before performing a calibration validation or taking particle system measurements.

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Basically, unscrew the retaining nut and slide the current tip straight out from the back end, insert the replacement tip by aligning the pin between the tip and the probe back end, then screw the retaining nut back in place. Figure 7-4 shows the first step–removing a probe tip from the probe back end. The process begins by unscrewing the retaining nut (C) between the probe back end (B) and the probe tip (A). Follow the step-by-step instructions in the quick reference guide shipped with the instrument (and in your hardware documentation portfolio):

‘QuickRef-Changing ParticleTrack G400 Interchangeable Tips’ (MK-PB-080-AC)

Figure 7-4 Removing an interchangeable tip (14 mm)

1. During the New Experiment setup, refer to the serial number etched on the probe (a label is also on the probe cap)

2. On the Configure Instrument wizard, select the appropriate probe tip.


AB

C


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Probe tip configuration is usually performed by a METTLER TOLEDO FSE during system installation. For reference, probe tip configuration steps begin under “8. Connect/Configure Instrument in Control Software” on page 37.

Select Probe Location Relative to Particle SystemThe location and orientation of the ParticleTrack G400 probe window in the flow material is critical for obtaining proper representation of the particle system distribution. Mount the probe in the best possible location to obtain accurate measurements.

Flow Patterns at Various Probe Locations The illustrations in this section show that careful consideration must be given to probe location to provide the best material presentation to the probe window.

Illustration A—Probe Flush Mounted with Pipeline or Vessel WallThe probe window is mounted flush with the pipeline or vessel wall. Because friction at the wall causes the velocity of the stream to be slower here than near the center of the flow stream, particles or droplets being carried by the higher flow velocities do not readily enter the slow layer and are thus prevented from getting close to the window.

Note:

Consistent Location and Orientation—For precise comparative measurements, you must use the same probe location and orientation every time measurements are taken, even if the location and orientation are not ideal.

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Illustration B—Probe Inserted into Stream (Parallel)The probe is inserted further into the stream, but with the probe window still parallel to the flow. This location creates an obstruction at right angles to the flow, causing a shock wave that deflects the flow away from the window and creating a dead zone in front of the window. Particles are carried by the deflected stream and do not come near the probe window.

Illustration C—Probe Inserted into Stream as a Flat ObstructionThe probe window is a flat obstruction. The pressure against the obstruction forms a shock wave around which most of the material flows. Once again, there is a dead zone in front of the window. The dead zones in both illustrations B and C prevent representative measurement of particles in the flow stream and allow deposits to form on the probe window.

Illustration D—Probe Orientation at Optimum Angle This is the only probe orientation that impinges the flow onto the window surface. The flow carries particles close to the window for the best measurement presentation. The action of the particles against the window prevents buildup of scale on the window surface. The best orientation is achieved when the angle of the probe window is between 30° and 60° to the flow, though 45° is the optimum angle.


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Locating the Probe in a Mixed VesselFlow in reactors or other mixed vessels can be more chaotic and random than in a pipe. This is good as long as it means the material at the probe window is well mixed and representative of the particle populations of interest.

Frequently, there are areas in mixed vessels that are not completely homogeneous, see Figure 7-6. Many mixed reactors have baffles that help create vertical motion and turbulence. In many cases upward flow is located in the area of the leading side of the baffle. If, as is most common, the probe is inserted from the top of the reactor, the probe tip should be located near the leading side of the baffle. The trailing side should be avoided, as there are dead areas and eddies on the trailing side where particles may settle or segregate.

Figure 7-6 Mixed vessel (top view)

Often, special mounting hardware for mixed vessels must be made to maximize the angle of the probe window to the general flow direction. Appendix C, “Probe Mounting Options” has examples of several mountings recommended by METTLER TOLEDO.

Select Appropriate Template for the Given ApplicationiC FBRM software includes the option to save templates with specific data treatments and setting designed for a particular particle or droplet system. When starting an iC FBRM experiment, select a template appropriate for the particle or droplet system to ensure consistent data collection, display, recording, and reporting.

Sample IntervalThe sample interval determines how often the system takes a measurement during a continuous or bath process run. A sample interval is defined within the selected template.

Note that the instrument is continually measuring chord lengths from the particle system and tabulating them into a histogram recording the number of chord lengths measured within each channel. The sample interval simply determines how often the tabulated results are reported. A longer sample interval will permit collection of a larger sample size of particle chord lengths, and will therefore result in greater statistical stability.

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In general, selecting an optimal sample interval should be based on consideration of three factors: particle system dynamics, measurement stability, and duration of the experiment. In many situations these factors will conflict, and the user must optimize based on their requirements. In most cases, particle system dynamics will have highest priority.

Averaging TypeAveraging is a signal processing tool used to reduce measurement-to-measurement variability. The averaging functions improve the statistical robustness of the real-time measurement by averaging the most recent measurement with the previous data. Note that there is a trade-off between measurement precision and sensitivity to change. While averaging improves measurement precision, it also dampens the dynamic response of the measurement to real-time changes in the trended statistics. Caution should be used to avoid over use of averaging, which can impact measurement sensitivity and reduce the ability to detect change over time.

The Averaging Settings Editor is available from the Data Treatments toolbox in iC FBRM. The settings window includes a graph that illustrates the changes made, as follows.

Moving

Figure 7-7 Averaging Data Treatment—Moving

A Moving averaging uses a moving average calculation based on a specified number of equally weighted raw signals in the measurement. The moving average window size is an integer that defines the number of consecutive measurements from 2 to 60 that are averaged to provide the real-time data. For example, a moving average window size of 5 will display

Table 7-3 Sample Interval Considerations

Factors to Consider Shorter Sample Interval Longer Sample Interval

Process Dynamics—Sample interval should be small to ensure the true process dynamics are measured and signal aliasing is avoided.

Captures more data points in a given time period.

Better for unstable samples or processes with fast dynamics.

Captures fewer data points in a given time period.

Better for stable samples or processes with slow dynamics.

Impact on Measurement St

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