SERVICE-MANUAL

VAPODEST 50
VAPODEST 50 CAROUSEL

DATE: 23.09.2003
C. Gerhardt GmbH & Co. KG
Service manual Vap 50 1.2. Heating Control
The basic functions as well as most of the parts used are identical with The control of the heating has been adapted in regard to the
those used in the Vapodest Distillation Systems without titration (Vap electromagnetic compatibility. The stand-by pressure is set at 0,2 bar
20, Vap 30, and Vap40). (20 kPa). Should the pressure drop below this value, the heating will
The Service Manual for those systems has to be used as the major start at maximum capacity with 1500 W. Even though the heating impulse
source of information. Thus, only differences, as well as additional is only very short, the pressure in the steam generator raises to up to
functions and spare parts will be mentioned in the present manual. approx. 0.26 bar over pressure. The result is a hysteresis, the pressure
fluctuates between about 0.19 to 0.26 bar over pressure. However, this
has no effect on the reproducibility of the analysis. During stand-by, the
1. General Information heating operates on a continuous basis with 1% power, thus an analog
measuring device for the determination of the current consumption is
1.1. Special Tools better suited than a digital one.
- Battery operated voltage tester to check, respectively calibrate the The paramenter for standby (20kPa/0.2 bar and overpressure (40kPa/
amplifier of the electrode. The voltages needed are +/- 500 mV 0.4 bar)) as well as the calibrated values for offset and amplification
and 0V. are stored in the file "settings.dat".
- Philips screwdriver PH2 with a minimum length of the blade of
30 cm.
- Any instrument to generate pressure for the calibration and test of
the pressure sensor. Range between 0 ...and about 1 bar.
- Manometer for the calibration and check of the setting of the pres-
sure sensor.
- Service bangle

Plug 25-pol.
Sub-D Male
13 12 11 10 9 8 7 6 5 4 3 2 1

25 24 23 22 21 20 19 18 17 16 15 14

- For some work it is helpful to connect a VGA monitor to the corre-

sponding VGA-interace of the Vapodest (also see instruction ma-
nual).

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1.3. Titration cell
Here, the titration is done in a to the wago-micro connector plug. The entire receiver platform has to
special receiving vessel, be dismounted to set the wiring of the new sensor. The fastening screw
contrary to the distillation is located behind the pump crosshead. Thus access is only possible if
systems without titration, the later is unscrewed as well.
where the distillate is collected After termination of the analysis, the receiving vessel has to be emptied
in an Erlenmeyer-tube for the and refilled. The hose pump necessary for the sucction is exactly below
external titration. During the the PCB module. Prior to any work on the pump either the PCB module
titration the special so called has to be taken out in order to have access from above or the entire
'free working stirrer', operated pump crosshead has to be dismounted.
by a small d.c. motor ensures
a sufficient mixing of the
distillate. The speed of the
mixing can be reduced by the
only potentiometer, located on the power-board. It is set on maximum
speed by the manufacturer. In case of exchanging the motor, the mixer
has to be taken off the motor shaft and the polypropylene screw has to
be unscrewed using a coin or anything similar. Then, separate the
electric connections at the motor with a copper bit. Please be careful to
observe the polarity at the voltage supply of the motor when
reassembling. Should it be exchanged, the sense of the rotation would
be opposite which might achieve an insufficient mixing result and thus,
analytical problems.
The distillate has an optical sensor to prevent spill over. If the conical
part of the sensor is completely immersed in the receiving solution, the
distillation is terminated with a time delay of 5 seconds. The sensor
works without delay if the boric acid is added manually in the analysis
start image. To exchange the sensor, unscrew the polypropylene-cover,
separate the three wires with a side cutter, and unscrew the sensor.
Cover the new soldered joints with a shrink down plastic tubing. This is
not the most beautiful but the easiest way to do it. For a more profes-
sional exchange, the PCB module has to be taken out to have access

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1.4. PCB Module 2. Service
Any work at the PCB module should be reduced to the check or the The following repairs can only be done when using the dangle; the LPT1
exchange of the fine-wire fuse on the power board, the semi-conductor or LPT2 have to be used.
relay and the battery on the Card-presso-board. The overview as well
as the wiring can be found on the support CD ROM. For ANY other
2.1. Calibration of the Pressure Sensor
defects the entire module has to be returned to C.Gerhardt for the repair.
You can order an exchange PCB module using the order number 5/ Any fluctuations of the components of the pressure sensor and various
40885. other electronic components are compensated by the manufacturer by
To take out the module the 3-pin plug of the heating of the steam calibration. Should the standby pressure not reach around 0.2 bar then
generator, the internal electrode connection cable, the outlet tubing for the calibration has to be repeated.
the titration acid, as well as the grounded wire connection have to be
dismounted. Unscrew the three screws fastening the module, the one In PRESS.CALIBRATION the value for Offset and the amplification can
at the front can only be loosened using a special Phillips screwdriver be corrected. The three pin flat plug of the steam generator should be
(minimum length of the blade 30cm). The location of the front screw is separated from the PCB module as a precaution.
identical at the Vap 20/30/40. The length of all electrical wires is chosen
so that the module can be taken out without unplugging it. The only Pull off the silicone tube 4x7 that connects the pressure sensor to steam
exception is the cable to the level sensor of the steam generator. This generator. Empty the tubing (if there is any water) and store the Offset
cable has to be unplugged at the sensor. After taking off the cap nut, the value. For the amplification, the pressure generator and the manometer
module can be opened and all cables unplugged. have to be connected to the pressure sensor. Build a pressure of 0.2
bar (20kPa) as precisely as possible and store the value. Run a check
Attention: with overpressure; when 0.4bar (40kPa) are reached there should be
It is absolutely necessary to avoid that any force is put on the micro the error message: 'Overpressure Steam Generator'. Turn down again
dosing pump. The throw of the piston might be changed and thus, the and by using the manometer check whether the standby pressure is in
calibrated volume per turn might change. the anticipated range.
The micro dosing pump is a spare part. It is not available in single parts.
Version 5.01
Since version 5.01, the calibration points of the pressure sensor are
. set to 0.15bar and 0.4 bar. The calibration procedure is not changed.
The values shown on the display after successful calibration
are recalculated to offset (0 bar) and stand-by (0.2 bar =20 kPa=2.9
PSI

Page 4
2.2. Calibration of the Electrode Amplifier Input the beaker on the balance. In the menu follow the instructions to start
the the pump. The pump is controlled to run exactly 400 cycles, for
The Electrode Amplifier Input is calibrated by the manufacturer with +/-
approx. 80sec. When finished, weigh the beaker and note the readout.
500 mV. Another calibration is not necessary. To check whether the
Divide the value by 0.9982063, write the result into the box in the
calibration is correct a voltage supplier operated by a battery is needed.
calibration menu and confirm. The display shows the calculated value
In order to test it, the voltage supplier has to be connected instead of
for one rotation in µl. Due to the size of the pump chamber, the value
the electrode. During the calibration of the electrode the voltage
must be about 50µl. Bigger deviations may derive from bad tube
generated by the electrode is shown in mV and is not calculated in pH.
connections or defective pump.
If mV values are displayed the various voltages of the voltage supplier
have to be compared to the mV display of the Vapodest. The function
Verification
of the voltage supplier should be checked with a precise measuring
Restart the Vapodest. The actual values for volume are read via
device first.
GerBus©, every time the Vapodest is turned on.
If the value shown deviates more than 2 mV from the voltage needed,
Tare the beaker on the balance. Go to "special functions/dosing pump"
the entry has to be calibrated again. Go into AMPL.CALIBRATION and
set volume to 10ml and confirm. When the pump stops, weigh the beaker.
by following the instructions on the display, start the Vapodest again.
Multiply the readout on the balance with 0,9982063. Repeat this step
The new start is absolutely necessary, as the new values for the pH-
several times, the results must be the same as shown in the Vapodest´s
measurement and the control of the micro dosing pump are stored in
display, within a range of +/- 0,2%. Otherwise repeat the calibration.
the microprocessor. At each new start they are entered via GerBus.
After the calibration, another test is done, as previously described.

2.3. Calibration and verification of the micro-dosing pump

Calibration
This calibration procedure determines the pump´s really delivered
volume per rotation. The necessary utilities are one small beaker
(approx. 50ml) and a laboratory balance. The calibration and its
verification are based on the fact that distilled water has a density of
998.2063 kg/m3 at 20°C (68°F), so that 1ml equals 0.9982063 g.
Before starting the calibration/verification, the pump must be rinsed
with sufficient amount of distilled or demineralized water (approx. 100
ml). This procedure is performed in the menu "special functions/
dosing pump".
Move to the menu "special functions"/"service"/"vol.calibration". Tare

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2.4. Data Communication Attention!
If the data transfer has been faulty or incomplete, then the Vapodest
In order to update the software, the dangle has to be inserted in LPT2.
cannot load the program and thus, the data communication in Special
LPT 1 is reserved for the parallel data transfer cable.
Functions is not available any more.
The following hardware is needed:
Should this happen, plug in an external keyboard and a screen and
interrupt the booting process with Strg + C (Ctrl + C) during the acoustic
signal. When TERMINATE BATCH JOB Y/N comes up, confirm with Y.
1x Parallel Connection Cable for the PC-direct connection
The German keyboard driver has not been installed yet, thus the keys
1x PC with DMS-DOS and the file Iinterlnk.exe as well as the current
don't always correspond to the functions.
software version.
Important differences are: Y=Z, ':' is generated by pressing Shift+ö.
The following steps have to be observed to update the software:
To start the interserver, change to drive D: The data communication
- Connect the parallel cable from the LPT 1 of the Vapodest to the
between the Vapodest and the external PC can be started again with
LPT port of the PC
'intersvr' in the folder DOS. During the communication the Vapodest
- The file 'interlnk.exe' has to be stored in the file config.sys. Then
gives an acoustic signal.
restart the PC.
- At the Vapodest go to 'SPECIAL FUNCTIONS/DATA COMMUNI-
Since Version 5.01
CAATION, the interserver-screen will come up. The screen will
Due to technical changes, the harddisk is replaced by a Compact-Flash
only show part, the entire screen can be made available on an ex-
card. The OS, previously located in the flashROM, is now integrated in
ternal VGA monitor. To check the connection, run the command
the Compact-Flash card. Please note the following:
'interlnk'. Delete the data stored on the Vapodest from the PC,
· Software-updates must be copied to the vapodest, without dele-
enter dos-order 'Deltree/Y (if necessary, you might want to save
ting the old software before, using the command: xcopy *.* /s e: (in
the .tbl-files previously, they have all the customer relevant data as
most cases the drive´s name on the vapodest).
well as programs and results stored.
· All previously existing *.bat -files must be saved first and then co-
- Copy the files of the present version from the PC to the Vapodest
pied to the new software. Any existing bat-files of the new softwa-
(Dos-Order: "xcopy *.*/s e:". In case that the .tbl files have not
re must be deleted.
been saved, execute the file 'buildfile.exe'.
· If the bat-files get lost, you can recover them out of the directories
- Then, execute the file 'settings.exe' in order to generate the file
"Start\Disk", resp. "Start\Flash".
'settings.dat'. After that, the pressure amplifier has to be calibra-
· If incorrect bat-files were copied, the data communication with the
ted again (see 2.1.Calibration of the pressure sensor).
PC fails to work. Because of incorrect paths, the responsible files
can´t be found.

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3. Vapodest 50 carousel The display contains the following information:

The distillation unit Vapodest 50 carousel is identical with the Vapo- 1. The Autosampler has 4 different modes:
dest 50. All further information given below is only valid for the auto-
sampler. The communication between the two parts is via GerBus® - L - The autosampler works independently, the Vapodest 50 does
not yet control it. The proximity switch makes the carousel turn for
3.1. Special To about 120 °. This mode allows the insertion of the tubes.
- A - The program of the Vapodest 50 controls all functions of the
- Wrench 5.5 mm with small head, maximum outer diameter 8 mm, autosampler, the analysis has started.
for dismounting glass guide cage - T - For a simple test of the autosampler a test program can be
- Inbus wrench 1.5 mm, to set the relay of the z-axis called up during which the chosen carousel simulates an entire
work process
- S - To calibrate position 1 of the carousel in distillation position as
3.2. Servicedisplay well as the deactivation of certain inputs or the activation of certain
outputs, the service program can be called up by using a special
All conditions (input-output) of the autosampler are shown on the ac- key combination. For further details see Chapter Service.
cessory display. The lights of the display are only turned on when it is
pulled out. 2. 20, 16, 12 - The size of the chosen carousel is displayed. In the
Service mode there is the additional option of 'cal'. For further de-
tails also see Chapter 3.3 Service Mode.

3. An ultrasound sensor checks whether there is a sample tube in the

chosen position. If there is a glass in the area covered by the sen-
 ! " #
sor, number 1 is shown; alternatively, 0 shows that there is no
+ E n te r
sample tube.
A 2 0 1 = 1 7 1 2 3 4 5
4 5 0 1 1 0 0 0 B X - E s c

$
4. =, >, < - The position of the carousel is permanently checked by an
$ % &    
angle transmitter. Thus, the 360 ° of the carousel can be divided in
1024 positions. The lift of the z-axis can only be activated if a = is
C a ro u s e l
shown on the display, meaning that the carousel is in the correct
position.

Page 7
5. The level of the chemical reservoir is continuously checked during 11.The status of the stepping motor of the carousel is shown. The fol-
the analysis. A stable number display shows that all containers are lowing modes are possible:
in perfect condition. If a ! is shown instead of a number, the mini- S = Stop, the motor is not active, the carousel can be turned ma-
mum level (or the maximum level in the sample-waste container) is nually.
reached. If '_' is shown, then this entry has been deactivated in the B = Break, the motor is kept in the actual position.
service mode. For further details see Chapter Service. L, R = left, right, way of turning the motor. During the distillation the
motor is stopped to hold the carousel in place.
6. The z-axis is driven pneumatically. A maximum pressure of
600kPa, a minimum pressure of 300 kPa, as well as a sufficient
pressure for the start of the analysis is checked continuously.

7. For safety reasons the stepping motor for the turning of the ca-
rousel is only put into action when the protection hood is closed.
'1' shows closed, '0' shows open. If '_' is shown, then this entry has
been deactivated. For further details see chapter Service.

8. The position of the lift on the z-axis is monitored by 2 reed relays.

The lower relay should give contact if the lift has reached the lo-
west position. The upper relay sets the upper height of the lift du-
ring the distillation. Furthermore, both relays have an LED, which
shows the status. Should both displays show '1' then a technical
defect is likely. During the upward movement, both relays are not
active.

9. The status of the compressed air valves is shown with '0' (arrow).
Only one valve at a time can be addressed.

10. As mentioned earlier, the carousel is brought into loading position

by turning about 120 ° via a proximity switch. If one of the determi-
ned positions for loading is reached, this is shown by 'A', 'B', or
'C'. A non-defined position e.g. during turning is shown by 'X'.

Page 8
3.3. Access to the Service Mode Set position 1 of the carousel exactly into distillation position. Should
the values shown be not identical you have to enter the new values by
Access to the Service Mode pushing the keys "+" and "-" simultaneously. To abandon this pro-
gramming procedure, press Esc. The calibration is valid for all types of
- With the key "+" or "-" the selected carousel and the load mode carousels.
have to be shown on the display. Depending on the selected lan-
guage, the following display is shown: 3.4. Access to the Electronic

Karussell 20 Carousel 20 Should work become necessary at the

Lade-Modus Load Mode
electronic of the autosampler or at the
Caroussel 20 Carrousel 20 compressed air valves, then the cap nut
Mode Caroussel Laad - modus has to be released first.
The PCB module can be pulled out com-
- Gently touch the sensor switch for carousel and then within 2 se- pletely.
conds push "+" and "-" simultaneously. The Service Mode will Cap nut
come up.
- With "+" or "-" change to main menu. The cursor can be moved
into all relevant positions with the keys "+" and "-". To activate a
command, confirm cursor position with "Enter".

3.3.1. Calibration of the Angle Transmitter 3.5. Exchange of Round Belts

The calibration has to be done if the control board or the angle transmit- In order to exchange the round belts, the
ter have been exchanged. carousel has to be taken out and the VA-
To do the calibration for the angle transmitter, set the cursor on the ca- retainer for the carousel has to be uns-
rousel position (Pos.2 in service display), activate with Enter and by crewed. The tension of the belt as such
pushing "+" go till "Cal" is reached, confirm with "Enter". has no important significance; even if the
belt should move, the angle transmitter
Pos1 Offset-XXXX can position the carousel exactly.
ist=XXXX Cal=Ent
Round belts carousel

Page 9
3.6. Setting of the Ultrasound Sensors 3.8. Upgrade of Vapodest 50OT to Vapodest 50carousel

Turning the screw located on the sensor can vary the settings of the 1. Carefully clean the surface of the Vap 50 upper part and lower
sensor. It is advisable to check the setting by loading the carousel with part. Take off the adjustable feet of the upper part.
some glasses only. The sensor should then be able to detect empty 2. Put the OT on the carousel and make sure that it is positioned
spaces. If different sizes of tubes are used, make sure that the test is centrally. Use the hole for the tubes as a guideline.
done with each size of glasses. 3. Draw the outline of the OT with a pencil on the carousel.
4. Put silicone at a 1 cm distance of the marked outline.
3.7. Settings of the Sensors of the Z-Axis 5. Mount fastening rails on the right and left side of the floor of the OT
6. Take off cover on the right side and the protective cap of the ca-
Unscrew the inbus-screw and move the contact. The lower relay has to rousel
be set that way so that a contact is guaranteed, if the lift is in a lower 7. Mount the OT on the carousel using Befestigungsstreifen and
position. The upper relay has to be set in such a way that a contact is bolts.
guaranteed, if the sample tube has been brought up. However, it should 8. Remove excess silicone using a sharp knife
also be able to leave the working position if no sample tube is present. 9. Put the GER-Bus cable from the carousel through the rubber duct
Thus, an indirect sample tube recognition is made possible. and attach it to the dosing pump.
10.Guide the power cord through the same opening and connect it to
the power plug at the power board
11.Close the back of the instrument and connect tubings.
12.Prior to first usage calibrate dosing pump and carousel (also see
Gerhardt Support CD-ROM)

Sensors

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