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Media-Mate Plus
Media-Mate Plus: p/n 25-710-101
Operation Manual
25-710-800
DATE: 23Apr2015
Rev. O
Hanson Research Corporation
9810 Variel Avenue • Chatsworth, CA 91311 USA
(800) 821-8165 • (818) 882-7266 • FAX (818) 882-9470
www.hansonresearch.com
This product is covered under one or more of the follow ing US P atents: 3,572,648 4,108,602 4,274,286 5,198,109 5,296,139 5,639,953 5,639,974 5,682 ,001
6,006,777 6,076,410 6,422,098 Des.377,152 Des.424,458 & Other Patents Pending.
2014 Hanson Research Corporation
(blank page)
Media-Mate Plus Operation Manual 25-710-800-O
Table of Contents
What’s New________________________________________________________________________ iii
Section One – Safety Considerations ____________________________________________ 1
General ____________________________________________________________________ 1
Safety Markings_____________________________________________________________ 1
Section Two – Introduction _____________________________________________________ 3
Design Features ____________________________________________________________ 3
Section Three – Specifications __________________________________________________ 4
Section Four – How It Works ____________________________________________________ 5
Section Five – Installation ______________________________________________________ 9
Location ___________________________________________________________________ 9
Unpacking _________________________________________________________________ 9
Parts Identification _________________________________________________________ 10
System Check-out __________________________________________________________ 10
Installation ________________________________________________________________ 14
Start Up __________________________________________________________________ 15
Section Six – Validation and Calibration _________________________________________ 16
Pre-Heat Temperature Calibration_____________________________________________ 16
Adjustment of Sensor Display Temperature ____________________________________ 16
Volume Delivery Calibration _________________________________________________ 17
Fine Adjustment of the Delivery Volume _______________________________________ 17
Deaeration Validation _______________________________________________________ 20
Temperature Controller (PID) Set-Up __________________________________________ 20
Temperature Calibration Record ______________________________________________ 21
Volume Calibration Record __________________________________________________ 22
Deaeration Validation Record ________________________________________________ 23
Volume Selection __________________________________________________________ 24
Temperature Setting ________________________________________________________ 24
Fill Time Setting ___________________________________________________________ 25
Configuring the Dispense Head ______________________________________________ 26
Media-Mate Plus Interface with Distek 2100 and 2100B ___________________________ 27
Test Cycle ________________________________________________________________ 29
Volume Delivery Problems ___________________________________________________ 30
Temperature Control Problems _______________________________________________ 30
Deaeration Problems _______________________________________________________ 31
Service Procedures ________________________________________________________ 31
Liquid in Vessels ___________________________________________________________ 32
Section Nine – Maintenance ___________________________________________________ 33
General Cleaning___________________________________________________________ 33
Cleaning the Media Tank and Fluid Lines ______________________________________ 33
Lubrication ________________________________________________________________ 34
Replacing the Filter Element _________________________________________________ 34
Fuse Replacement _________________________________________________________ 35
Section Ten – Moving and Storage ______________________________________________ 37
Section Eleven – Parts, Sup plies, and A cc esso ries ________________________________ 38
Spare Parts and Kits ________________________________________________________ 38
Tools and Accessories ______________________________________________________ 38
Section Twelve – Sales and Support ____________________________________________ 39
Section Thirteen – General Warranty ____________________________________________ 40
Table of Contents ii
Media-Mate Plus Operation Manual 25-710-800-O
What’s New
Revision O
Section Three - Specifications
Changed Tank Capacities to “about 18 liters”.
Section Seven – Operating Instructions
Changed Temperature Setting to “at least the 18-liters mark.”
Section Eight – Troubleshooting
Changed Temperature Control Problems to “Fill Tank to at least the 18-liter mark.”
Revision M
Section Six – Validation and Calibration:
Updated Adjustment of Sensor Display Temperature steps.
Updated new Watlow controller.
Section Seven – Operating Instructions:
Added newer dissolution tester models.
Revision L
Section Three – Specifications:
Changed “Media Tank Volume (unusable)” to 2 L to reflect low volume tank upgrade.
Revision K
Section Five – Installation:
Added photo of filter housing.
Section Seven – Operation:
Adjusted fill time recommendations for new 0.007” gap fill tubes.
Section Nine – Maintenance:
Added procedure for replacing filter on systems equipped with a filter housing.
Section Eleven – Parts, Sup plies, and A cc esso ries:
Added new fill tube to parts list.
Revision J
Section Six – Validation and Calibration:
Calibration Gauge Set (p/n 91-902-045) added.
Section Eleven – Parts, Sup plies, and A cc esso ries
Numerous spare parts, kits, tools, and accessories added.
Section Twelve – Sales and Support
Hanson Research Corporation contact information and procedure updated.
What’s New iii
Media-Mate Plus Operation Manual 25-710-800-O
Control Panel
Caution! Keep media and other liquids away from the
Control Panel
Caution! Do not press start switch until indicator lights
Control Panel
Caution! Do not restart Instrument with liquid in flasks
Interface Panel
Caution: No operator-accessible parts inside. Refer
qualifié. Risque d’ electrocution. Ne pas ouvrir.
Interface Panel
Caution! Turn Instrument off and remove power cord
fuse holder.
Heater
Caution! Heater is hot; do not touch.
Section One – Safety Considerations
General
1. The Instrument should be on its own circuit to prevent problems and circuit overload.
2. Never work on the electrical components in the system while there is power to the
Instrument. Disconnect power: Do not run Instrument with the protective cover removed from the electrical control cabinet.
3. Do not fill the tank thr ough the filter port on the tank; the Instrum ent ma y not handle the
back-pressure.
4. Review all safet y and environm ental precaut ions pertaining to any chem icals that ar e to
be used in conjunction with this Instrument.
Safety Markings
For your own safety, you must observe the following safety warning signs. The safety warning
signs indicate a possible source of danger and provide preventative information.
Sign Location Safety Warning
Heater
control panel and away from all electrical components.
are off.
without consulting troubleshooting section.
servicing to qualified personnel only. Risk of electrical
shock. Do not open.
Achtung: Es gibt keine vorn Benutzer zo wanenden
Teile. Oberlassen Sie Reparaturen dem qualifizierten
Service-fachmann. Hochspannung. Nicht öffnen.
Attention: Aucune pièce remplaçable par l’utilisateur.
Toute réparation doit être effectuée par un technicien
before replacing fuses. Fuses must be replaced with
the same current rating and type described next to the
Section 1 Safety Considerations1
Media-Mate Plus Operation Manual 25-710-800-O
Interface Panel
Note! Line and Neutral fused separately.
Inside Control
Note! Protective conductor terminal.
Pump Panel
Caution! Withdraw power cord to mark prior to plugging
Sign Location Safety Warning
into grounded electrical outlet. Withdrawing the full
length of the cord may jam the retracting mechanism.
Section 1 Safety Considerations2
Media-Mate Plus Operation Manual 25-710-800-O
Section Two – Introduction
The Hanson Research Media-Mate Plus is a portable, automatic dissolution prep system. The
Instrument will prehea t, filter, measure, dea erate and deliver diss olution media to numerous
Dissolution Test Stations.
Design Features
1. Portable Cart: The cart is compact and easy to maneuver.
2. Control: The electron ics are enclosed within the cart for protection and may be easil y
removed for service. T he control panel is a user-f riendly design with digita l readout of
actual media temperature and temperature set point.
3. Pressure/Vacuum Air Pump: The air pump is enc losed within the cart fram e for quiet
operation. It is easily removed for service.
4. Dispense Head: The dispense head connects to the dispense tubing with quick
disconnects and is user-configurable for filling six or seven dissolution vessels in parallel.
The dispense head is designed t o interface with the Hanson Researc h SR-6, SR-8, and
SR8-Plus Dissolution Test Stations as well as most test stations made by other
manufacturers.
5. Heater Assembly: The heater is an integral design comprised of the heater element,
temperature sensor, overload sensor, and level sensor. The heater is easily removed for
cleaning or for placement in spare media tanks.
6. Volume Setting: T he dispens e vo lum e is user -sel ectable fr om 250 to 1 000 mL in 50 mL
increments. The m easure s ystem has been f actory-calibrate d and is e asily recalibr ated
by the user.
7. Media Tank: The tank is chemically inert and is equipped with a 5-micron filter and
standard hose bib for quick and easy connection. The tank is easily removed for cleaning
or for replacem ent with spare tank s. A chem ically iner t cover preve nts evaporat ion and
provides a docking location for the dispense head.
8. Retractable Cord Re el: The Instr ument is eq uipped with a 14-gauge , 3-conducto r, 20 ft
cord-reel.
Section 2 Introduction3
Media-Mate Plus Operation Manual 25-710-800-O
Weight
Without media:
67 kg (148 lbs)
With 40 liters of media:
107 kg (236 lbs)
Size
Length:
80.9 cm (31.9 in.)
Width:
53.4 cm (21.0 in.)
Height:
114.0 cm (44.8 in.)
Electrical
Voltage:
115 VAC or 230 VAC ± 10%
Frequency:
50/60 Hz
Current:
13 Amp (115 VAC) or 8 Amp (230 VAC)
Phase:
single
115 VAC Units
230 VAC Units
4 Fuses (TT Type):
One 1/2 Amp, 250 VAC,
One 15 Amp.
One 1/2 Amp, 250 VAC,
One 8 Amp, 250 VAC.
Environment
Maximum ambient temperature:
5°C below temperature set point
Maximum humidity:
< 85 %
Performance
Cycle time:
less than 5 minutes
Pre-heat temperature range:
30°C to 45°C
Pre-heat temperature control accuracy:
± 0.5°C
Pre-heat temperature readout accuracy:
± 0.2°C
Pre-heat time (21 to 37 deg C):
60 minutes
Delivery volume range:
250 mL to 1000 mL
Delivery volume accuracy:
± 1.0 %
Deaeration:
95% saturation maximum
Filtration:
5 micron nominal
Tank Capacities
Media Tank Volume (usable):
40 liters (10.5 gal)
Media Tank Volume (unusable):
2 liters (0.53 gal)
Media Volume to Top of Filter:
8 liters (2.1 gal)
Media Volume when low water level sensor turns heater off:
about 18 liters
Materials Wet
Tank
High Density Polyethylene
Heater
Teflon Coated
Filter
Polyethylene
Flask
S.A.N (Styrene/Acryli c/Nit rile )
Fittings and Fill Hose
PVC
Tubing
Stainless Steel and Tygon
Section Three – Specifications
One 3/4 Amp, 250 VAC,
One 8 Amp, 250 VAC,
NOTE: Accuracy may be improved by fine adjustment (see
Section 6 – Fine Adjustment of the Delivery Volume).
One 3/8 Amp, 250 VAC,
One 5 Amp, 250 VAC,
Section 3 Specifications4
Media-Mate Plus Operation Manual 25-710-800-O
Section Four – How It Works
The Hanson Resear c h Med ia-Ma te P lus us es a s e lf -tuning PID controller and a Teflon heater
to heat the media. Media is moved by low pressure or vacuum and directed by a two-position,
multi-channel pinch valve. The media is deaerated by a thin film vacuum process. The media
volume is accurately measured by a user-set incremental measuring system. A programmable
timer controls the following sequence of events:
1. Fill (Fill Light “ON”)
Vacuum draws heated media from the media tank into the measure vessels. The fill time
thumbwheel has been set such that actual f ill time is suff icient to fill m easure vessels s lightly
above the required volum e. The media is deaerat ed during the fill c ycle by thin film vacuum
technology.
Figure 4-1
Section 4 How It Works5
Media-Mate Plus Operation Manual 25-710-800-O
2. Level (Level Light “ON”)
Pressure in the m easure vessels r eturns excess media back to the media tank . The volum e
of media remaining in the vessels is the amount set by the adjustment of the incremental
standards.
Figure 4-2
Section 4 How It Works6
Media-Mate Plus Operation Manual 25-710-800-O
3. Dispense (Dispense Light “ON”)
The pinch valve is shifted, opening the dispense lines and closing the fill lines. Pressure in the
measure vessels delivers media out the dispense manifold.
Figure 4-3
Section 4 How It Works7
Media-Mate Plus Operation Manual 25-710-800-O
4. Standby (no lights on)
The Instrument is waiting f or the operator command to start a cycle. Air flo ws through the
measure vessels and ou t the f ill lines int o the m edia tank . T his provides m edia circulat ion f or
optimum temperature control.
Figure 4-4
Section 4 How It Works8
Media-Mate Plus Operation Manual 25-710-800-O
Section Five – Installation
Location
Environment
The media tank temperature must exceed ambient room temperature by at least 5°C for
maximum perform ance of the temperature control system. Therefore, for best results, the
ambient temperature should not be allowed to exc eed 32°C (90°F) for 37°C t ests, or 27°C
(81°F) for 32°C tests.
Easy access to a water sou rc e and waste d isposa l for f illing an d em ptying of t he water bath is
convenient, although not nec es sary.
Space
The Media-Mate Plus System is designed to be mobile up to 6.25m (20 ft). The laboratory floor
should be level and flat to prevent the Instrument from moving when left unattended.
Electrical
The Media-Mate Plus System requires a single, grounded electrical outlet, within 5.63 m (18 ft)
of the location of the Instrument.
The Instrument is available in two configurations, 115VAC and 230VAC. The voltages are set
at the factory and cannot be changed (see model number label on control interface panel next
to fuses to determine voltage). The electrical requirements are summarized in Section 3 of this
operation manual.
Unpacking
The Media-Mate Plus is s hipped ful ly assem bled in one box . The shipp ing box is specificall y
designed to provide m aximum shipping protect ion and to facilitate unpac king. The shipping
box consists of a lower cardboard tra y secured to a pallet with a large box placed over the
Instrument. The upper box is strapped to the lower tray and pallet.
NOTE: Shortages or damages must be reported immediately to the freight carrier and to Hanson
Research. Notif y Hanson Research b y telephone (818) 88 2-7266 or FAX (818) 88 2-
9470.
To Unpack:
1. Move package close to final destination with pallet-moving equipment.
2. Cut and remove straps.
3. Remove upper box taking care not to damage box.
4. Remove Instrument from box.
5. Reassemble empty box and store for possible future use.
Section 5 Installation9
Media-Mate Plus Operation Manual 25-710-800-O
Parts Identification
Throughout this operation manual, reference is made to various components by name. Figures
5-1 through 5-6 are provided to assist in the visual identification of these components.
System Check-out
1. After removing the Instrument from the box, remove all other shipping materials.
2. Visually inspect the Instrument for damage or missing parts
3. Remove the Heater Assembly from its shipping position within Tank.
4. Remove Dispense Head (see Figure 5-5) from shipping position within Tank, remove from
bubble pack, and place as shown.
5. Ensure filter housing has slots facing down.
6. Visually inspect all electrical and pneumatic connections at Interface Panel.
7. Review Operating Instructions. (see Section 7)
Figure 5-1
Section 5 Installation10
Media-Mate Plus Operation Manual 25-710-800-O
Figure 5-2
Figure 5-3: Control Panel
Section 5 Installation11
Media-Mate Plus Operation Manual 25-710-800-O
Figure 5-4: Interface Panel
Figure 5-5
Section 5 Installation12
Media-Mate Plus Operation Manual 25-710-800-O
Figure 5-6
Filter Housing Assembly
Note: The filter housing assembly will function best if the slots are facing the bottom of the tank.
Removed from tank to provide clear view. Clear Filter housing shown only to provide clarification
on function.
Section 5 Installation13
Media-Mate Plus Operation Manual 25-710-800-O
Installation
CAUTION
The Instrument should not be plugged in until installed as per the instructions below.
1. Clean the inside of the Tank as necessary to remove any packing debris and fill with
approximately 40L of DI water (see Section 9 – Cleaning the Tank and Fluid Lines).
2. Install the Heater Assem bly into the Tank as shown (see F igure 5-2). Place Tank Cover
onto Tank (see Figure 5.5).
CAUTION
The filled Tank is heavy and solution may spill. This installation requires two people. The
person holding and p ushin g the Tank onto the Cart legs should be capa bl e of s uppor ti n g
the weight of the Tank.
3. One person aligns the Media-Mate Plus cart legs with steps on T ank fr om the back. T ip
the Tank just enough so that the Cart legs can be pushed under the Tank. Lift the opposite
side of the Tank and push as you slide the Cart legs under.
HINT: Keep the front wheels of the Cart straight.
4. Remove the Fill Hose Assembly from its hol ding position on the side of the Tank and
connect to the Fill Manifold (see Figure 5-2).
5. Connect the Heater connector into the Interface Panel (see Figure 5-4).
6. Connect the Dispense Tubing to the Dispens e Head and positio n over the holes in th e
Tank Cover (see Figure 5-5).
NOTE: Configure the Dissolution Test Station Vessel Pattern (see Section 7 – Configuring
the Dispense Head).
Section 5 Installation14
Media-Mate Plus Operation Manual 25-710-800-O
USA
Color Code
Wire
Description
International
Color Code
Start Up
CAUTION
The voltage indicated on the Media-Mate Plus System must be the same as the power source.
If the incorrect voltage is indicated, do not plug in the Instrument and contact Hanson Research
immediately.
CAUTION
Do not press the Start S witch until the ind icator lights are of f as this may cause overfilling of
the System.
The Instrument must be plugged into a grounded power outlet.
1. Pull the power cord out of the retractable cord reel and plug th e other end of the power
cord into a grounded three-prong power outlet.
NOTE: T he power cord plug may need to be replac ed for so me countries’ po wer outlet
configurations. Ensure t hat the r eplac ement plug is approved and properly rated
for voltage and amperage by following the Power Cord Color Code below:
Black Live Brown
White Neutral Light Blue
Green Ground Green with Yellow Stripe
2. Turn on the Main Power Switch, located on the Pump Panel next to the power cord outlet.
3. Turn on the Air Pump and Heater power switches, loc ated on the C ontrol Panel.
4. Run a Test Cycle (see Section 7 – Test Cycle) while observing Instrument performance.
5. During the Test C ycle, ver ify th e cor rect s equence of events by obs ervi ng the Seq uence
LEDs on the Control Panel and by visually observing fluid flow at the measure vessels.
6. During the Test Cycle, verify Heater operation by observing the “1” LED on the
Temperature Controller (“1” is energized when the Heater is on).
7. Turn off the Heater and Air Pump switches.
8. Turn off the Main Power Switch and remove the power cord from the grounde d threeprong power outlet and return into retractable cord reel.
Section 5 Installation15
Media-Mate Plus Operation Manual 25-710-800-O
Secti o n Six – Validation and Calibration
Pre-Heat Temperature Calibration
Calibration of the temper at ur e contr ol system is recommended every six months f or 32°C and
37°C set points. A Temperature Calibr ation Log is prov ided and may be co pied for entry of
temperature calibration data.
1. Place Calibrated T hermometer ( p/n 65-233-401) in the 3/8 in. hole pro vided in the T ank
Cover (hole located furthest from Heater Assembly).
2. Set Temperature Set Po int to 32°C (see Section 7 – Temperature Sett ing) and al l o w it to
stabilize.
3. Record set point tem perature and sens or displa y temperatur e from the dig ital disp lay on
the Control Panel. Record actual temperature from Calibrated Thermometer.
4. Set Temperature Set Po int to 37°C (see Section 7 – Temperature Sett ing) and al l o w it to
stabilize.
5. Record set point tem perature and sens or displa y temperature f rom the dig ital disp lay on
the Control Panel. Record actual temperature from Calibrated Thermometer.
Adjustment of Sensor Display Temperature
CAUTION
The sensor displa y temperature has been a djusted at the factor y and should not require an y
additional adjustm ent. Adjustm ent may be made on ly when Calibrat ion indicates m ore than
0.2°C difference between Display Temperature and Actual Temperature (see Section 6 – Pre-
Heat Temperature Calibration).
1. Press both the Up (↑) and Down (↓) keys simultaneously until you s ee “LO C” equ al to “5”
(if “2”, change number using Up key to “5”).
2. Press the (
3. Add or subtract to the number in order to equal the standard temperature.
4. After calibrating, press the (
simultaneously until you see “LOC”, which needs to be changed to “2”. Press the (
to finish.
5. Recalibrate per Sect ion 6 – Pre-Heat Temperature Calibration.
∞) key, thenpress the key repeatedly until you see “i.CA”.
∞) key, then press both the Up (↑) and Down (↓) keys
∞) key
Section 6 Validation and Calibration16
Media-Mate Plus Operation Manual 25-710-800-O
Volume Delivery Calibration
Calibration of volume delivery is recommended for all volume settings that will be used.
Recalibration is recom mended every six m onths for each s etting used. Recal ibration is also
required whenever the delivery volume has been fine adjusted (see Section 6 – Fine Adjustment of Delivery Volume). To facilitate volume calibration, Hanson Research
recommends the Volume Calibration Kit (p/n 25-710-705).
1. Set Volume to desired increment (see Section 7 – Volume Selection).
2. Hanson Research recom m ends per f orming volume calibration at room tem per atu r e. Se t
temperature control to the desired temperature and allow the media temperature to
stabilize (see Section 7 – Temperature Setting).
3. Place the Dispense Head over pre-numbered, plastic vessels (ref. p/n 25-710-705).
4. Start the Media-Mate Pl us cycle (see Section 7 – Operating Instructions).
5. Using a calibrated laboratory scale, tare with empty vessel, weigh filled vessels, and
record the actual media weight of the delivered volume for each vessel.
6. Empty and dry the vessels and repeat Steps 1 through 5 for a total of 5 cycles.
7. Calculate and rec ord the media volume for each v es sel. The density of the media at th e
calibration temperature is required for the calculation below.
Media Volume = media weight divided by media density at calibration temperature.
8. Repeat all of the above steps for each incremental volume setting that will be used.
Fine Adjustment of the Delivery Volume (one incremental setting only)
When dissolution rate calculations are corrected for actual mean delivery volumes recorded, it
should not be neces s ar y to f ine-adjust the delivery volume. F or app lic a tio ns that do require a
more accurate delivery volume, adjust as follows:
1. Calibrate volume at desired incremental setting (see Section 6 – Volume Delivery Calibration).
2. Review Calibration Data and identify adjusters that require finer adjustment.
3. Fine adjustment is ac complished by accurate ly adjusting the Pointer position on the Fill
Tube (see Figures 6-1 and 6-2). T he Pointer must be moved approxim ately 0.0048 in.
per mL of volume delivery change.
EXAMPLE: To c hange delivery v olume by 2.5 m L [ 2.5 X 0.0048 = 0.012 ], the Po inter
must be moved 0.012 in.
Section 6 Validation and Calibration17
Media-Mate Plus Operation Manual 25-710-800-O
When delivery volume is too high, reduce by raising the Pointer as follows:
1. Loosen the Upper Lock Scre w so that the F ill Tube m ay be m oved. Use 1/4 in. Wrench
(p/n 91-902 037).
2. Using the Micro Drill B lank Set (p/n 91-902-036) or Calibration G auge (p/n 91-902-045),
select a size whic h corresponds with the requ ired volume change [ Volum e Change X
.0048 ] or refer to the conversion chart in Figure 6-1.
3. Place the Calibration Gau ge or Drill Blank between th e Pointer and the u pper sid e of the
incremental standard notch (see Figure 6-1).
4. Move the Fill Tube up until the Pointer and Calibration Gauge or Drill Blank are tight
against the upper side of the incremental standard notch.
5. Tighten the Upper Lock Screw and remove the Calibration Gauge or Drill Blank.
6. Use 3/4 in. Wrench (p/n 91-902-037) to loosen the Pointer Handle Lock Nut and slide the
Pointer up to the top of the increm ental standard notc h and retigh ten the Poin ter Handle
Lock Nut.
7. Loosen the Upper Lock Screw and move the Dispense Tube down until the Pointer is tight
against the bottom side of the increm ental standard n otch and retig hten the Upp er Lock
Screw.
8. Repeat Steps 1 through 7 as necessary for each vessel.
9. Calibrate per Section 6 – “Volume Delivery Calibration.”
Figure 6-1
Section 6 Validation and Calibration18
Media-Mate Plus Operation Manual 25-710-800-O
When delivery volume is too low increase by lowering th e Pointer as follows:
1. Loosen the Upper Lock Scre w so that the F ill Tube m ay be m oved. Use 1/4 in. Wrench
(p/n 91-902-037).
2. Using the Micro Drill Blank Set (p/n 92-902-036) or Calibration Gauge (91-902-045), select
a size which corresponds with the required volume change [ Volume Change X .0048 ] or
refer to the conversion chart in Figure 6-2.
3. Raise the Fill Tube as nece s s ar y and place t h e Cal ibra tion G a uge or D ril l Blank between
the Pointer and the lower side of the incremental standard notch (see Figure 6-2).
4. Lower the Fill Tube so that the Pointer and C alibration Gauge or Drill Blank are tight
against the lower side of the incremental standard notch.
5. Tighten the Upper Lock Screw and remove the Calibration Gauge or Drill Blank.
6. Use 1/4 in. Wrench to loosen the Pointer Handle Lock Nut and slide the Pointer down tight
against the bottom of the incremental stan dard notch and retig hten the Pointer Hand le
Lock Nut.
7. Repeat Steps 1 through 6 as necessary for each vessel.
8. Calibrate per Section 6 – “Volume Delivery Calibration.”
Figure 6-2
Section 6 Validation and Calibration19
Media-Mate Plus Operation Manual 25-710-800-O
Deaeration Validati on
Deaeration is validated by running a standard instrument cycle and then measuring the
dissolved oxygen content in each filled dissolution vessel. Dissolved Oxygen Meters are readily
available from laboratory suppliers such as Cole Parmer, (800) 323-4340.
To avoid dissolution problems, the maximum dissolved oxygen content should not exceed 95%
saturation at operating temperature (Handbook of Dissolution Testing, William Hanson, 3
The USP Dissolution Toolkit recom mends a diss olved oxygen leve l of not more t han 6 ppm.
The Media-Mate Plus will meet this at 37 °C with 500 mL and higher volumes and/or
temperatures.
Deaeration Validatio n m ust be perfor m ed with all us er-input adjustments set and recorded on
the Deaeration Vali dation Log. Val idation is recom mended for eac h set of user adjustments
that will be used. Validation is recommended prior to the first use of the instrument and should
be repeated every six months.
1. Set all user-input adjustments (see Section 7).
2. Initiate an instrument cycle (see Section 7 – “Test Cycle”).
3. Using a Calibrated Dis solved Oxygen Meter, measure t he dissolved oxygen content in
each dissolution vessel.
4. Record all user-input adjustment settings and dissolved oxygen readings on the
Deaeration Validation Log.
Temperature Controller (PID) Set-Up
The Temperature Co ntroller (see Figure 6-3) has been pro grammed at the facto ry to obtain
optimum temperature c ontrol an d quic k heat-up tim e. The progr am s et points are lock ed and
should not require changing or resetting. If the factory program has been altered for any
reason, it may be restored in accordance with Hanson Research Corporation Procedure
Number 25-710-807, “Pr ogramm ing Procedures f or Tem perature Contr oller.” T his procedure
is available on request from Hanson Research Corporation (see Section 12).
rd
ed.).
Figure 6-3: Temperature Controller
Section 6 Validation and Calibration20
Media-Mate Plus Operation Manual 25-710-800-O
Set Point
(°C)
Display
(°C)
Actual
(°C)
Temperature Calibrat ion Record
Instrument Model Number:
Instrument Serial Number:
Temperature
Temperature
Temperature
Date Tested By
Section 6 Validation and Calibration21
Media-Mate Plus Operation Manual 25-710-800-O
Set Up
Number
Media
Volume
(mL)
Temperature
(°C)
Media Density
(g/mm)
Fill Time
(seconds)
1
2
Cycle
Number
1 2 3 4 5 6 7
1
2
3 4
5
Cycle
Number
1 2 3 4 5 6 7
1
2
3 4
5
Volume Calibration Record
Instrument Model Number:
Instrument Serial Number:
1. Loosen the Upper Lock Screw so that the Dispense Tube may be moved.
2. Grasp the Pointer handle and rotate 45
3. Raise or lower the Disp ens e T ube as neces sar y to al ign th e Pointer with t he app ropriat e
incremental standard notch.
NOTE: The increm ental standard has been m arked with a volumetric s cale so that the
appropriate notch may be readily located.
4. Rotate the Pointer handle until the Pointer engages the incremental standard notch.
5. Move the Pointer d own tight against the lower side of the notch and tighten the Upper
Lock screw.
6. Repeat Steps 1 through 5 for each vessel position.
° in either direction.
Temperature Setting
See Figure 5-3.
The Temperature Contr oller is located in the approx imate center of the Control Pan el. The
Temperature Control ler has t wo di gital d ispla ys that di spla y in ten ths of a d egre e. T he upp er
display shows actual media temperature while the lower display shows Set Point Temperature.
To Set Temperature:
1. Verify that the media Tank has been filled to at least the 18-liters mark.
2. Verify that the Heater Ass em bly is installed i n the Tan k and is plugged into the I nterfac e
Panel.
3. Plug the retractab le power cord into an appro priate A C power r eceptacle (see Section 5 – “Electrical” for retracting requirements of cordage).
4. Turn on Heater power and Air Pump power at the Control Panel.
5. Increase or decrease Set Point Temperature using the “UP”/”DOWN” Arrow Keys located
just below the Set Point Di splay on the Tem perature Controll er. Allow adequat e time for
the temperature to stabilize.
Section 7 Operating Instructions24
Media-Mate Plus Operation Manual 25-710-800-O
Vol. Setting, mL
250
400
500
600
700
800
900
1000
Fill Time, sec
45
50
55
60
65
70
75
80
Fill Time Setting
See Figure 5-3.
The Fill Time Setti ng determ ines the am ount of tim e the system will allocat e to the F ill Cycle
and is dependent on the Delivery Volume Setting. The amount of time allocated must be
sufficient to fill the meas ure vessels 50-100 mL above the Fill Tube slot. T he Fill Tim e is set
by adjusting the Fill Time Thumbwheel located on the Control Panel.
Low to Moderate Viscosity Media:
1. Start by setting the Fil l Time to the value that corr esponds to the Volum e Setting in the
table below.
2. Run a Test Cycle (see Se ction 7 – “Test Cycle”) while observing the m easure vessels
during the Fill Cycle to see where the fill level is with respect to the Fill Tube slot. The test
media must have the sam e approximate viscosit y as the Dissolution Media that w ill be
used.
3. If the actual Fill Leve l is too hig h, reduc e the Fil l Tim e. If the actual F ill Level is too low ,
increase the Fill Time.
4. Repeat Steps 2 and 3 until the desired characteristics are achieved.
High Viscosity Media:
For high viscosit y media it may be necessary to set the Volume Adjustm ent to one half the
desired delivery volume and run two cycles.
1. Set Volume Adjustment to one half the des ired del i ver y volume.
2. Set the Fill Time to two times the value that corresponds to the Volume Setting in the table
above.
3. Run a Test Cycle (see Se ction 7 – “Test Cycle”) while observing the m easure vessels
during the Fill Cycle to s ee wher e the Fill Level is with respec t to the Fill T ube slot . The
test media must have the s ame approxim ate viscosity as the Dissoluti on Media that will
be used.
4. If the actual Fill Leve l is too hig h, reduc e the Fil l Tim e. If the actual F ill Level is too low ,
increase the Fill Time.
5. Repeat Steps 3 and 4 until the desired characteristics are achieved.
Section 7 Operating Instructions25
Media-Mate Plus Operation Manual 25-710-800-O
3+3 Configuration
4+2 Configuration
4+3 Configuration
4+3 Configuration
Configuring the Dispense Head
The Media-Mate Plus Dis p ens e He ad has b een designed to accommodate the Hans on SR -6,
SR-8 and SR8-Plus D issolution T est Stations and most T est Stations m anufactured b y other
manufacturers. The Dispense Head is connected to the Dispense Harness by quick
disconnects which ha v e b e en ide ntif ie d by the numbers 1 through 7. T he D isp en s e Hea d will
accommodate six or seven Disso lution Vessels b y enabling or dis abling #7 Meas ure Vessel
(see Figures 7.1 and 7.2). The configuration is achieved by connecting the quick disconnects
so that the pattern f ormed m atches the test s tation ves sel pattern. C ommon ves sel patterns
are shown below:
Media-Mate Plus Interface with Distek 2100 and 2100B
Filling Six Vessels:
1. Remove the two fittings labeled “not used” in Figure 7-1 below.
2. Close the two sh ut-off valves to the seventh vess el at the Media-Mate Plus D ispense
Assembly (see Figure 7-2).
Figure 7-1
Filling Seven Vessels:
1. Remove the two fittings labeled “not used” in Figure 7-1 above.
2. Connect the Single Flask Filling Assembly (p/n 25-710-415) to the Media-Mate Plus
Dispense Harness, #7 Quick Disconnect.
3. Open the two shut-off valves to the seventh vessel at the Media-Mate Plus Dispense
Assembly (see Figure 7-3).
Section 7 Operating Instructions27
Media-Mate Plus Operation Manual 25-710-800-O
To Configure the Dispense Bar:
1. For Six Vessels: Clos e th e Ball Val ve and P inch Va lve at Vess el 7 (see Figure 7-2):
Figure 7-2
For Seven Vessels: Open the Ball Valve and Pinch Valve at Vessel 7 (see Figure 7-3):
Figure 7-3
2. Observe the Dissolution Test Station Vessel Pattern.
3. Arrange the quick disconnects at the Dispense Head to match the observed pattern.
NOTE: For six dis solution vessels, the # 7 disconnec t mus t be con nected to an inact ive
location.
Section 7 Operating Instructions28
Media-Mate Plus Operation Manual 25-710-800-O
Test Cycle
Test Cycles are accom plished with the Dispense He ad positioned on the Med ia Tank Cover
docking position. T his arrangement provides for media return back to the Tank during an
instrument cycle. Test Cycles are useful for observation of instrument performance.
Running a Test Cycle:
1. Set all user inputs (s ee Section 7 – “Volume Selection,” “Temperatur e Setting,” and “Fill
Time Setting”).
2. Position the Dispense Head in the docking position on the Media Tank Cover.
3. Fill the Media Tank with media.
4. Plug the retractab le power cord into an appro priate A C power r eceptacle (see Section 5 – “Electrical” for retracting requirements of cordage).
5. Turn on Air Pump power at the Control Panel.
6. Press the start button on the Control Panel.
Filling Dissolution Vessels
1. Set all user inputs (s ee Section 7 – “Volume Selection,” “Temperatur e Setting,” and “Fill
Time Setting”).
2. Fill the Media Tank with media.
3. Plug the retractab le power cord into an appro priate A C power r eceptacle (see Section 5 – “Electrical” for retracting requirements of cordage).
4. Turn on the main power switch, located on the pump panel next to the power cord outlet.
5. Turn on the Air Pump and Heater power switches, loc ated on the C ontrol Panel.
6. Configure the Dispense Head (see Section 7 – “Configuring the Dispense Head”).
7. Place the Dispense Head over the dissolution vessels on the Test Station.
8. Verify that the active output ports on the Dispense Bar engage appropriate vessels on the
Dissolution Test Station.
9. Verify the media temperature at the Control Panel.
10. Press the start button at the Control Panel.
11. When the c ycle is f inished, rem ove the Disp ense H ead from the Diss olution T est Stat ion
and return to the docking position on the Media Tank Cover.
Section 7 Operating Instructions29
Media-Mate Plus Operation Manual 25-710-800-O
Check and correct all electrical
connections.
Replace fuse (see S ecti on 9).
Contact Service if fuse blows again.
Section Eight – Troubleshooting
Volume Delivery Problems
1. Dispense Volume is too high or too low.
Cause Solution
Improper Volume Setting
Improper Volume Adjustment
Improper Fill Time Setting
Pressure or Vacuum Leak
Clogged Inlet Filter
Restricted Passage Visually check tubing for kinks.
High Media Viscosity
Pinch Valve Leaks
2. Fails to completely dispense (media left in measure vessels).
Cause Solution
High Media Viscosity
Fill Time too High
Reset (see Section 7).
Reset (see Section 6).
Reset (see Section 7).
Check and correct (see Section 8).
Replace Element (see Section 9).
Run two cycles (see Section 7).
Check and correct (see Section 8).
Run two cycles (see Section 7).
Reset (see Section 7).
Temperature Control Problems
1. Does not heat media (media remains at ambient temperature).
Power Source Connection
Low Water Level Fill Tank to at least the 18-liter mark.
Blown Fuse
Set Point too Low Adjust Set Point higher.
Defective Heater Assembly Check and replace if necessary.
Defective Temperature Controller Check and replace if necessary.
Section 8 Troubleshooting30
Cause Solution
Media-Mate Plus Operation Manual 25-710-800-O
Temperature Control Program
Changed
Perform Calibration Procedure (see
Section 6).
Increase to 2°C above Test
Temperature.
2. Temperature fluctuates more than ± 0.5°C with the Tank filled to at least the 20-liter mark.
Note that lower liquid levels may cause readings to fluctuate more than 0.5°C.
Cause Solution
Defective Heater Assembly Check and replace if necessary.
Defective Temperature Controller Check and replace if necessary.
Check program and fix.
3. Temperature reading does not match calibrated thermometer.
Cause Solution
Unit Not Calibrated
Deaeration Problem s
Delivered Media exceeds 95% saturation.
Cause Solution
Improper Fill Time Setting
Low Media Temperature
Reset (see Section 7).
Service Procedures
Pressure or Vacuum Leak:
1. Disconnect Fill Hose at upper hose connection and connect hose to Tank side port.
2. Plug manifold port with hose cap fitting.
3. Connect power cord to power source and turn on power to Air Pump at Control Panel.
4. Apply leak test compound (p/n 91-951-025) to all accessible, sealed connections such as
vessel covers and tube fittings.
5. Foaming compound indicates a leak.
6. Turn power off and disconnect instrument from power source.
7. Correct all points of le akage and retest per above St eps 1 - 6 until the System has no
leaks.
8. Remove hose fitting cap from Fill Manifold and reconnect Fill Hose.
Section 8 Troubleshooting31
Media-Mate Plus Operation Manual 25-710-800-O
Pinch Valve Leaks:
1. Set-up and run a Test Cycle (see Section 7 – “Test Cycle”).
2. Remove Tank Cover and observe Inlet Filter Element during the Dispense Cycle.
NOTE: Dispense LED on the Control Panel is energized during the Dispense Cycle.
3. Bubbles emitting f rom the filter indicate a leaking Pinch Valve Assem bly. Call Hanson
Research for service (see Section 12).
Liquid in Vessels
If the Instrument is tur ned off in the middle of a c ycle and/or media is left in the vessels, it is
important not to start another cycle before emptying the vessels as overfilling can occur.
Emptying the vessels is do ne by setting the Fill Time to 1 seco nd, placing the Dispense Head
back on the Tank, and starting a cycle. The material in the vessels will be dispensed back into
the Tank without overfilling the vessels. Remember to reset the Fill Time.
Section 8 Troubleshooting32
Media-Mate Plus Operation Manual 25-710-800-O
Section Nine – Maintenance
Media-Mate Plus has been designed to be a low m aintenance instrument. In general, th e
instrument is maintained by proper cleaning after use, periodic replacement of the filter element
and periodic lubrication of fill tubes.
The Media-Mate Plus has type 3 16 stainless steel i n the liquid flow path. HCl ca n effect the
316 stainless steel, especially when the solution is left to dry.
When using HCl, rinse the Media-Mate Plus with D.I. water when finished. Do not allow the HCl
to set in the unit for long periods of time (4 hours or more). Rinse off an y external spillage
immediately.
General Cleaning
See Section 5 for identification of parts.
The exterior of the Instrument should be periodically wiped down with a damp cloth. Particular
attention should be given to the Volume Adjust Components located on the Dispense
Assembly. Frequency of cleaning depends on Instrument usage and operating environment.
Cleaning the Media Tank and Fluid Lines
NOTE: Always unplug the Heater Assembly.
The Media Tank s hould alwa ys be c leaned prior to f illing the T ank with new media, or if it will
not be used within 36 hours.
Cleaning Method:
1. Disconnect the Fill Tube Assembly at the Fill Manifold and drain the Tank out the Fill Tube.
The side of the Tank housing the Filter Assembly may be shifted off of the Support Rail in
order to facilitate more complete draining.
2. Remove the Tank and pour out any remaining media and wipe dry.
3. Replace the Tank and reconnect the Fill Tube Assembly at the Fill Manifold.
4. Fill the Tank with c lean DI water and ru n a coup le of T est C ycles (see Sec tion 7 – “Test Cycle”).
5. Repeat Steps 1 - 3.
6. With the Tank em pty, run two dry Test Cycles (s ee Section 7 – “Test Cycle”). This will
help dry the fluid passages and leave the Instrument ready for the next usage.
7. If the Instrument is not going to be used within 15 days, it shou ld be covere d and moved
to an appropriate storage location.
Section 9 Maintenance33
Media-Mate Plus Operation Manual 25-710-800-O
Lubrication
The Fill Tubes (see Figure 6-1) should be lubricated every six-months to maintain easy
movement and to facilitate easy adjustment of the Volume Setting.
To Lubricate:
1. Adjust the Volume Delivery Setting to 1000 mL (see Section 7 – “ Volu me Sel ec tion”).
2. Apply a small amount of sili cone gr eas e (p/n 91-951-004) to the exterior of the Fi ll T ubes
between the Pointer and the vessel cover.
3. Loosen the upper lock screw and rotate the Pointer in order to disengage the incremental
standard.
4. Move the Fill Tube up and do wn several tim es between the upper and lower extreme
positions.
5. Raise the Fill Tube to the upper position and remove excess grease.
A clogged Filter Element will restrict media flow and impair Instrument performance. The Filter
Element should be replaced eve ry 90 -days or whenever the Fill Level is reduced by 25 mL (this
may be observed during the Fill Cycle). Also, since the Filter Element will retain a small volume
of media, it must be replaced whenever the Tank is to be filled with a media that is diff erent
than the media that was previously used.
Replacing the element for units without a filter housing:
1. Unscrew the Filter Core Assembly and remove it fr om the Tank along with the Elem ent
and Washers (see Figure 9-1).
2. Discard the Element and replace with a new Element (p/n 91-500-099).
Figure: 9-1
Section 9 Maintenance34
Media-Mate Plus Operation Manual 25-710-800-O
For systems with a f ilter housing used to reduc e dead volume in the Me dia-Mate Plus tank ,
follow the procedure below.
Replacing the element for units with a filter ho using:
1. Unscrew the Filter Core As sem bly and rem ove it f rom the T ank along with the f ilter, f ilter
element, and filter housing end caps (see Figure 9-2).
2. Remove the filter housing end caps and slide the filter off the filter core.
3. Discard the old element and replace with a new element (p/n 91-500-099)
4. Slide the new element into the housing and secure with the end caps.
5. Slide the filter core through the assembly.
6. Reinstall the assem bly into the Media-Mate Plus tank with the slots of the filter housing
facing down.
Figure: 9-2
Note: Removed from tank to provide clear view. Clear Filter housing shown only to provide
clarification on function.
Fuse Replacement
The fuses are located o n the Inter fac e Pane l of the C ontr ol. Each S ystem has four (4) fus es.
The amperage is labeled next to the fuse. Notice that the amperage of three of the four fuses
is dependent upon the voltage of the System.
CAUTION
For continued protection against risk of fire, replace the fuse(s) with the same type and current
rating. Do not over-tighten the fuse holder.
To check the fuses and replace a defective fuse:
1. For fuse holders with slo t knobs, insert the end of a standard (flat) screwdriver into the
slot, push in and slightly turn counter-clockwise to remove the holder.
Section 9 Maintenance35
Media-Mate Plus Operation Manual 25-710-800-O
2. For fuse holders with finger grip knobs, push in and slightly turn counter-clockwise to
remove the holder.
3. Visually inspect the fuse to see if it is defective. If you are not sure, use an Ohm meter to
confirm.
4. If it is defective, remove the fuse from the holder by pulling it straight out. Replace with a
fuse of the same type and rating.
5. Push the fuse bac k into the C ontrol. Secure the fuse ho lder by pressin g in and sligh tly
turning clockwise.
NOTE: Use a standard (flat) screwdriver for fuse holders with slot knobs.
Section 9 Maintenance36
Media-Mate Plus Operation Manual 25-710-800-O
Section Ten – Moving and Storage
Storage
If the Media-Mate Plus will not be us ed f or an ex tend ed p erio d of t im e (15-da ys o r m ore) , the
power should be turned of f and disconnec ted fr om the power sour ce. The Ins trum ent should
be cleaned (see Secti on 9), covered, and moved to an appropriate storage location.
Moving
The Media-Mate Plus is a portable System and therefore does not require special consideration
when being moved within the sam e laborator y or building. F or shipm ent to anot her location,
the Instrument should be repackaged in its original shipping container.
Section 10 Moving and Storage37
Media-Mate Plus Operation Manual 25-710-800-O
Section Eleven – Parts, Supplies, and Accessories
Spare Parts and Kits
25-710-701 Two-Year Spare Parts Kit, 115/ 230 V
25-710-125 Stand Alone Temperature Control, 115V
25-710-126 Stand Alone Temperature Control, 230V
25-710-400 Extra 40-liter Tank Assembly with Heater, 115V
25-710-401 Extra 40-liter Tank Assembly with Heater, 230V
25-710-723 Filter Element, 5-micron (pack of 5)
25-710-404 Fill Hose Assembly
25-710-706 Fuse Kit, 115V
25-710-707 Fuse Kit, 230V
91-601-219 Female Quick Disconnect Fitting
91-601-220 Male Quick Disconnect Fitting
25-710-507 Connector
25-710-569 Nipple Fitting, Dispense Head, Gray PVC
25-710-511 Incremental Standard
25-710-514 Pointer
25-710-408 Standoff Assembly, ¾” (1 per clamp; requires 7 per system)
25-710-409 Standoff Assembly, 3/8” (1 per clamp; requires 7 per system)
25-710-515 Fill Tube (0.025” gap)
25-710-577 Fill Tube (0.007” gap)
25-710-524 Dispense Tube
25-710-556 Support
25-710-130 Heater Replacement Kit, 115V
25-710-131 Heater Replacement Kit, 230V
91-601-237 Fitting, ¼” Male x ¼” Female, Stem Elbow
91-425-004 O-Ring, ¼”
91-212-059 Water Level Switch
91-217-021 Over-protec t ion Se nsor
91-600-014 Tygon Tubing, 1/8” x ¼” (sold per foot; 70 ft per unit)
91-600-020 Tygon Tubing, 3/16” x 5/16” (sold per foot; 40 ft per unit)
91-601-230 Fitting, 1/8-MPT x 1/8-B, St r aight
91-601-231 Fitting, 1/8-MPT x 1/8-B, El bo w
93-670-018 Nut, Acorn, ¼-20, Stainless Steel
25-710-725 Tubing Replacement Kit, Media-Mate Plus
Tools and Accessories
25-710-449 Flask Holding Stand for 8 Vessels
91-902-020 Electro-Mechanical Tool Kit
91-902-013 Tool, Allen Key Wrench, 7/56”
91-902-037 Tool, Wrench, ¼”
91-951-004 Silicone Grease (1 tube)
91-951-025 Leak Test Compound
91-030-003 Vessel, P las tic
65-233-401 Certified Calibrated Thermometer
65-233-402 Certified Calibrated Digit al T hermometer
25-710-415 Single Flask Filling Assembly
91-902-045 Calibration Gauge Set
Section 11 Parts, Supplies, and Accessories38
Media-Mate Plus Operation Manual 25-710-800-O
Section Twelve – Sales and Support
The Media-Mate Plus is sold and s erviced b y a worldwide network of dealers and dis tributors. If
you need additional accessories, replacement parts, or require service information, you may either
contact your local agent, or you can contact Hanson Research Corporation at our worldwide
headquarters:
Hanson Research Corporation
Corporate
Headquarters
Web Site
Sales Support
Customer Support
Technical Support
9810 Variel Avenue
Chatsworth, CA 91311 USA
P: 818.882.7266 or 800.821.8165 (toll-free)
F: 818.882.9470
www.hansonresearch.com
For quotes, literature, and sales assistance in the USA
and worldwide, please email:
sales@hansonresearch.com
To place an order, obtain an order’s status, or request a
return authorization, please email:
orders@hansonresearch.com
For assistance with applica tions and oth er techn ical
support and service questions, please email:
techsupport@hansonresearch.com
or fill out a Technical Support Request form:
www.hansonresearch.com/tsr.htm
.
.
,
.
When contacting Hanson Research, please help us eliminate duplication of effort amongst
personnel and departments by directing your inquiry to one department or representative.
Section 12 Sales and Support39
Media-Mate Plus Operation Manual 25-710-800-O
Section Thirteen – General Warranty
Hanson Research Cor p oration (HRC) products are warr ant ed f or one full year including parts an d
labor. Service contrac ts and Preventative Ma intenance contr acts are available for post-warranty
support. International dealer warranties may vary. HRC makes no warranty, expressed or implied,
for glassware, consumables or products not manufactured by HRC, as evidenced by nameplate on
the item or other designat ion. H RC will g ive r es pons ib l e as s istanc e to b u yer in o bt ain ing f r om the
respective manufacturer whatever adjustment is reasonable in light of manufacturer’s own
warranty. HRC shall be released from any and all obligations under any warranty , either expressed
or implied, if the product c o vered is repaired or modified by other than its own personnel, or made
without written authori zation of HRC. There are no other warrant ies, expressed or implied, and
HRC shall not be liable under any circumstances for consequential damages.
Section 13 General Warranty40
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