Vibro -LE Manual Please be sure to read this entire user manual prior to use of the equipment. Please read all safety instructions carefully. This user manual is part of the product. Keep it in a safe place for future reference. Replacement manuals can be downloaded from our Webpage at: www.sanimembranes.com 1
1. Description a. Introduction b. Validity c. Symbols 2. System 3. Safety a. Parts list b. System description a. Intended use b. Personnel Qualification c. Media d. Pressurized Components e. Leaking fluids f. Sharp objects g. Moving parts h. Personal protective equipment i. Accessories and spare parts 4. Operation a. Introduction b. General Guidelines - Process c. Batch operation with the SANI Membranes Standard Batch Feed System d. Continuous operation with the SANI Membranes Standard Continuous Feed System e. CIP operation f. Homogenization of viscous/high concentration media in the retentate chamber 5. Assembly a. Assembly of batch production system with SANI Membranes Standard Batch Feed System b. Assembly of continuous production system with SANI Membranes Standard Continuous Feed System c. Assembly and removal of the Vibration Motor 6. Membrane Exchange a. Disassembly of the Membrane Assembly b. Assembly of the Membrane Assembly 7. Technical Data 8. Conformity 2
1. Description Please be sure to read this entire user manual prior to use of the equipment. Please read all safety instructions carefully. This user manual is part of the product. Keep it in a safe place for future reference. a. Introduction The Vibro -LE is a portable benchtop filtration system for continuous microfiltration and ultrafiltration applications. The Vibro -LE holds 0,35 m 2 membrane area in a rigid Free Flow Plate element. The patented Vibro -LE vibrates the rigid Free Flow Plate membrane element relative to the media. Thus, creating turbulence in the media on the membrane surface. The turbulence created on the membrane surface ensures a fast and low fouling filtration process without the need of conventional tangential crossflow. The Vibro -LE is perfect for process development, small batch production and other applications where traditional dead-end filtration devices gives up and tangential crossflow solutions are few and expensive. Disruptive in size, simplicity and process allowing full observation of media and membrane surfaces at all times, no dead volumes, easy to clean, easy to service and simple to operate. The Vibro -LE is exceptional for gaining insight into the filtration process, for selecting the right membranes and for filtering almost any media with continuous membrane filtration in a laboratory or even small production scale. The Vibro -LE can filtrate the most demanding media with high viscosity, high solid loads and even high particulates with unpreceded results less fouling, higher flux, higher degree of up-concentration. The Vibro -LE can be operated as vibration driven deadend filtration, where the media is concentrated in the retentate chamber and discharged at end of operations. The vibrating membrane will keep fouling levels to a minimum and give you unimpeded fluxes and retentate concentrations. The Vibro -LE can also be operated as continuous filtration, with a feed pump feeding in media and continuously discharging of permeate and retentate. The vibrating membrane will diminish fouling and create a higher flux than conventional cross flow filtration. A slow circulation pump with minimum shear can be mounted for homogenization of the retentate if necessary. The membrane is fused to the surface of the Free Flow Plates by welding. The Free Flow Plates are then welded together forming the Free Flow Plate Laboratory Element (HPL) with all its functionalities. The HPL configuration with 1.7 mm free flow channels allows for filtration with no need for pre-filtration even for high solids loading and high viscosity media. The HPL has an integrated and open permeate channel design. Thus, the retentate as well as the permeate can be drained completely - no product loss. The HPL can be configured with virtually any commercially available MF or UF membrane. The pressure chamber is made in clear polymeric material and operates at up to 4 bar at room temperature. The clear plastic gives excellent visibility of the membrane during operation and cleaning. All media contacting parts are in durable polymeric materials or stainless steel. The Vibro -LE can conform to FDA materials if required. b. Validity This manual applies to the Vibro-L in the following versions: Vibro-LE This manual applies to the Vibro-LE in combination with the following components: Free Flow Plate Laboratory Elements (HPL) from SANI Membranes with all MF and UF membranes available at any time. Standard Batch Feed System from SANI Membranes Standard Continuous Feed System from SANI Membranes 3
c. Symbols As warning of danger, all text statements in these instructions to be noted will be marked as follows: WARNING This symbol denotes a possible danger with medium risk that death or (severe) injury may result if it is not avoided. CAUTION This symbol denotes a possible danger with a low risk that moderate or minor injury may result if it is not avoided. ATTENTION This symbol denotes a danger with low risk of damage to property if not avoided. 4
2. System a. Parts list Base plate Membrane Assembly including mechanic Vibration Motor, Membrane Chamber, Permeate Outlets and Chamber Sides Leaf Spring Set Rubber Gasket Set 1 set of fittings for the air cushion chambers 1 Free Flow Plate Laboratory Element (HPL) b. System description The Membrane Chamber has 2 media inlets at the top and 2 media outlets at the bottom, all with 1/8 thread for mounting fittings. The Membrane Chamber has 2 circular holes running through it for mounting the membrane element rigidly with the Permeate Outlets. 1 permeate outlet has a ¼ thread for fittings and the other Permeate Outlet is a blind with no fluid connection to the permeate. The Membrane Chamber also have two rectangular openings in each end, where impermeable rubber gaskets are placed to divide the media from the Air Cushions in the Chamber Sides. The Chamber Sides are mounted on the Membrane Chamber ends with impermeable rubber gaskets in-between the Chamber Sides and the Membrane Chamber. The Air Cushions are made up by the rubber gaskets and the cavities in the Chamber Sides. The Air Cushions should be filled with pressurized air of the same pressure as the media in the Membrane Chamber (e.g. by using one of SANI Membranes Vibro-LP feed systems). The Chamber Sides are fitted with push-in fittings for 6mm flexible tubing for pressurized air supply. The Chamber Sides also have slits for the leaf springs connecting them with the base plate. 5
The mechanic Vibration Motor is mounted on Chamber Side 2 with 4 bolts running through the chamber side. The Membrane Assembly is defined as the entire vibrating unit mounted to the base plate through the Leaf Springs. The Vibration Motor delivers the vibrating motion of the entire Membrane Assembly and the pressure balanced Air Cushions makes the media stationary inside the Membrane Assembly. The turbulence created on the membrane surfaces is optimal for low fouling filtration applications. The standard way to run the Vibro-LE is to feed media in through one of the feed inlets in the top of the Membrane Chamber, the other inlet is only used to vent the air out of the system when it is filled with media. The permeate is taken out through the bottom permeate outlet and the retentate is bleeded out of the retentate outlet in the bottom opposite the feed inlet used. The other retentate outlet is usually not used and therefor plugged. SANI Membranes have made feed systems dedicated for use with the Vibro-LE, but you can also make your own feed system for your specific application. The most important things to remember when designing a feed system, is that it should deliver an air pressure for the Air Cushions at the same pressure as in the media in the Membrane Chamber, and that it should have a CE approved safety valve of maximum 4 bars. When You operate under 1 bar you can use a special balloon gasket (not included) instead of the polymer gasket and plug the Air Cushion inlet. See more examples of use in the Operation section. 6
3. Safety Please be sure to read this entire user manual prior to use of the equipment. Please read all safety instructions carefully. This user manual is part of the product. Keep it in a safe place for future reference. a. Intended use The Vibro-LE is a manually operated benchtop filtration system for MF and UF filtration. The user should read and understand this manual before use. The Vibro-LP is intended for use in a laboratory setting in an industrial, research or teaching facility. The Vibro-LE is intended to filter media and can only be used with a 0,35 m 2 HPL membrane element from SANI Membranes. The Vibro-LE can only be used together with a feed system with a CE approved safety valve set to maximum 4 bars. The feed system could be the Standard Batch Feed System or the Standard Continuous Feed System from SANI Membranes. Other feed systems can be used if they have a CE approved safety valve of maximum 4 bars. The Vibro-LE is NOT suited for use in explosive environments. WARNING This instruction manual is part of the Vibro-LE. The Vibro-LE is intended exclusively for use in accordance with this instruction manual. The Vibro-LE must only be used for intended use, the following are examples of improper use WARNING: Unauthorized modifications and technical changes to the Vibro-LE are improper use. Operation outside the permissible physical conditions given in this document (e.g. temperature, pressure, chemical vapors etc.) and given in the specification sheet for the HPL membrane element used. Installation of unauthorized items on the Vibro-LE. Connection of unsuited devices to the Vibro-LE (e.g. unsuited feed systems). Use of media with biological materials in Safety Classes 2 and 3. Use of flammable or potentially explosive substances. Filtration of unstable media. Use of media which are incompatible with PP, PVC, Stainless Steel, PDMS or other materials in the Vibro-LP, HPL membrane element or feed system used. b. Personnel Qualification All personnel operating the Vibro-LE must have read this instruction manual thoroughly and be skilled in the art of pressurized filtration. All personnel operating the Vibro-LE should be used to conduct themselves in a laboratory environment and have passed mandatory safety courses etc. Students operating the Vibro-LE must be instructed thoroughly by skilled teachers or other skilled personnel in proper use of the Vibro-LE. c. Media The media used in the system can be dangerous to handle and cause personnel injuries or equipment damage when not handled correctly. The operator should always seek the applicable safety information for the media to be filtered (e.g. handling and storage and conduct in emergency situations). WARNING Personal safety equipment should always be worn when applicable (e.g. safety googles, safety gloves etc.). WARNING Do Not use media with biological materials in Safety Classes 2 and 3. WARNING 7
Do Not use flammable or potentially explosive substances. WARNING Do Not use unstable media where concentration changes might start chemical reactions within the media. WARNING The operator should always make sure that the media to be filtered is compatible with the materials in fluid connection in the Vibro-LE (PP, PVC, Stainless Steel and PDMS) and the feed system used. ATTENTION d. Pressurized Components If the pressure needed for the Membrane Assembly is generated by an external feed system (not included), then the Membrane Assembly, the external feed system and the tubing and fittings between the external feed system and the Membrane Assembly are a separate pressurized system. The system must be operated at maximum 4 bar and the external feed system must have a CE approved safety valve set at maximum 4 bar. Parts of the system can burst if they are subjected to pressures over 4 bar. WARNING e. Leaking fluids If the fluid system is leaking, liquid spill can cause a serious health danger depending on media. The operator should always seek the applicable safety information for the media to be filtered (e.g. handling and storage and conduct in emergency situations). Personal safety equipment should always be worn when applicable (e.g. safety googles, safety gloves etc.). WARNING If the fluid system is leaking, liquid spill to the floor can cause a slipping hazard. CAUTION f. Sharp objects The leaf springs are sharp objects. Be very careful not to get in contact with the leaf springs when assembling or disassembling the system. CAUTION g. Moving parts Body parts can be crushed when they come into contact with moving parts, e.g. the Membrane Assembly. This can lead to injuries. WARNING Lose hair or lose clothing parts can be caught in moving parts and cause injuries. CAUTION The Vibro-LE must be placed on a horizontal non-slippery surface as the vibrating movement can otherwise make the Vibro-LE move doing operation and cause injuries if it falls to the floor. CAUTION h. Personal protective equipment Mandatory personal protective equipment to protect against risks arising from the equipment or the material being processed: Tight-fitting work clothing - Protects against being caught by moving parts. CAUTION Head covering - Protects hair from being pulled into moving parts. CAUTION Safety glasses - Protects against substances leaking under high pressure, splashing liquids etc. WARNING Safety shoes - Protects against injuries to the feet caused by mechanical effects. CAUTION i. Accessories and spare parts The Vibro-LE can only be used together with a feed system with a CE approved safety valve set to maximum 4 bars. The feed system could be the Standard Batch Feed System or the Standard Continuous Feed System from SANI Membranes. Other feed systems can only be used if they have a CE approved safety valve of maximum 4 bars. 8
The use of unsuitable accessories, consumables and spare parts can be hazardous and have the following consequences: Severe personnel injury WARNING Damage to the device WARNING Malfunctions of the device ATTENTION Device failure ATTENTION Only use accessories, consumables and spare parts that are in technically perfect condition. The use of accessories, consumables and spare parts not approved by SANI Membranes is the sole responsibility of the operator. 9
4. Operation a. Introduction The Vibro-LE is simple to operate and gives you a perfect continuous filtration, if you remember to feed in air to the air cushions with the same pressure as the feed media has. Sani Membranes has developed feed systems for this purpose, but you can also make your own feed system for the Vibro-LE. When You operate under 1 bar you can use a special balloon gasket (not included) instead of the polymer gasket and plug the Air Cushion inlet. The chamber is filled by feeding media carefully through the Feed inlet (4) with the Retentate Outlet (7) closed and the Airvent (6) and Permeate Outlet (5) open. Close the Airvent (6) when the media has covered the membrane completely. Air pockets in top of the chamber has no effect on the filtration if the entire membrane is covered by media. Start the Vibration Motor at 4 bar just after filling the chamber with media and turn it off just after emptying the chamber for media. Severe fouling will occur if you stop the vibration motor with pressurized media in the chamber. The pressure is regulated up to the operating pressure and retentate is bleeded out through the Retentate Outlet (7). The amount of retentate to bleed out is calculated from your desired up-concentration degree and the amount of permeate produced (e.g. to up-concentrate your feed to double concentration you need to bleed out the same amount of retentate as the amount of permeate produced). When the filtration process is finished, take of the feed pressure and empty the system for retentate and permeate. Clean the system with the appropriate CIP protocol for your membrane and application and finish the CIP by filling the system with an appropriate storing solution for your membrane and application. Attention: Organic membranes must never be allowed to dry out after initial wetting. See storage after CIP. Attention: Always maintain a positive trans membrane pressure when operating Your Vibro-LE. Permeate Outlet (5) must be kept open when the unit is in operation. Pressure guidelines during operation: a) Avoid operating the unit at excessive flux leading to fast and high fouling of the membranes. b) Recommended trans membrane pressure for microfiltration is 0.05-1 bar. c) Recommended trans membrane pressure for ultrafiltration is 1-3 bar. 10
b. General Guidelines Process 1. Maintain a positive trans membrane pressure (min 0,02 bar) when vibration mode is on and keep the permeate drain open at all times. 2. Maintain a retentate flow to avoid dead-end type filtration. A suitable retentate flow is normally +3 L/h but it is application dependent. 3. When filtering media with high viscosity or high solids load a mix flow of 200-1000 l/h should be established from corner to corner to avoid severe fouling. 4. When MF filtering media with high solids load, the mix flow and vibration must be initiated as soon as the unit is filled to avoid severe fouling. Microfiltration (0 1 bar) 1. Keep a very low trans membrane pressure: 0,02 to 0.2 bar often gives the best long-time results. 2. The flux can be very high and easily result in severely fouled areas in the vibro unit. Reduce the flux by lowering the trans membrane pressure and let more retentate out to avoid severe fouling. 3. Air Cushion exits can be plugged off or their pressure can be balanced with the feed pressure as in UF Filtration. Examples of Microfiltration Process Configurations: MF batch mode with Standard Batch Feed System plug flow Simple configuration for viscosities up to cream level Feed flow and trans membrane pressure is regulated with the air pressure The concentration factor is regulated with the retentate valve (flow of permeate measured against flow of retentate) MF batch mode with Standard Batch Feed System and mix pump high solids or high viscosity Configuration for high viscosity or high solids load; retentate must be kept fluid. Feed flow and trans membrane pressure is regulated with air pressure The concentration factor is regulated with the retentate valve (flow of permeate measured against flow of retentate) 11
Continuous MF mode with feed pump plug flow Configuration for viscosities up to cream level Feed flow and trans membrane pressure is regulated with the speed of the feed pump. The concentration factor is regulated with the retentate valve (flow of permeate measured against flow of retentate) Continuous MF mode with feed and mix pump high solids or high viscosity Configuration for high viscosity or high solids load; retentate must be kept fluid. Feed flow and trans membrane pressure is regulated with the speed of the feed pump. The concentration factor is regulated with the retentate valve (flow of permeate measured against flow of retentate) Continuous MF mode Concentration in tank - high solids or high viscosity possible Configuration for high viscosity or high solids load with concentration in feed tank; retentate must be kept fluid. Feed flow and trans membrane pressure is regulated with the speed of the mix flow pump and retentate valve The concentration factor in the retentate is calculated from the amount of permeate collected and the initial feed volume 12
Ultrafiltration (1 4 bar) 1. Make sure that the system pressure does not exceed 4 bar (3 bar at temperatures above 35 C) a 4 bar safety valve is required! The batch tank from Sani Membranes Standard Batch Feed System is equipped with a 4 bar safety valve. Examples of Ultrafiltration Process Configurations: UF batch mode with Standard Batch Feed System plug flow Simple configuration for viscosity up to cream level Feed flow and trans membrane pressure is regulated with air pressure Vibro cushion pressure is regulated with the air pressure in the feed tank The concentration factor is regulated with the retentate valve (flow of permeate measured against flow of retentate) UF batch mode with Standard Batch Feed System and mix pump high solids or high viscosity Configuration for high viscosity or high solids load; retentate must be kept fluid. Vibro cushion pressure is regulated with the air pressure in feed tank Feed flow and trans membrane pressure is regulated with air pressure The concentration factor is regulated with the retentate valve (flow of permeate measured against flow of retentate) Continuous UF mode with feed pump plug flow Configuration for viscosity up to cream level Feed flow and trans membrane pressure is regulated with the speed of the feed pump. The Vibro cushion pressure is regulated by a hydrophore The concentration factor is regulated with the retentate valve (flow of permeate measured against flow of retentate) 13
Continuous UF mode with feed and mix pump high solids or high viscosity Configuration for high viscosity or high solids load; retentate must be kept fluid. The Vibro cushion pressure is regulated by a hydrophore Feed flow and trans membrane pressure is regulated with the speed of the feed pump The concentration factor is regulated with the retentate valve (flow of permeate measured against flow of retentate) Normal CIP for all Process Configurations (MF and UF): Water flushes, buffer flushes or CIP cleaning must be performed after each run with media in the Vibro -LE. The appropriate cleaning method must be found for each membrane and membrane application by the user. A typical CIP routine for operation with organic material could consist of: Drain Flush through with warm water Drain Lye, max 55 C at ph 11.5 for 20-25 min. Drain Flush with water for 10 min. Drain Acid at ph 1.5 for 15-20 min. Drain Flush with water for 10 min. Drain Leave filled with water or water + preservation or 20% alcohol. To adjust timing adjust flow, adjust trans membrane pressure and retentate flow. Ensure around 50/50 flow through the permeate and the retentate outlet. 14
c. Batch Operation with the SANI Membranes Standard Batch Feed System 1. Start with a fully assembled and drained Vibro -LE system as shown above with all valves and regulators closed. 2. Fill the feed tank with your feed solution (maximum 7 L). 3. Open the Airvent (6), the Feed Inlet valve (4) and the Permeate Outlet valve (5). 4. Fill the retentate chamber by opening the Feed Pressure Regulator (1) slightly. Follow the filling of the retentate chamber visually and close the Airvent (6) when the retentate chamber is full. 5. Start the vibration motor. 6. Regulate the feed pressure to the desired operation pressure and start collecting permeate in a suitable measuring vial. 7. If a given up-concentration degree is desired, the correct amount of retentate relative to the measured amount of permeate must continuously be taken out through the Retentate Outlet valve (7) by adjusting the valve carefully during operation. 8. When the feed tank is nearly empty you can choose to refill it: a. Downregulate the feed pressure to 0 bar on the Feed Pressure Regulator (1) b. Close the Retentate Outlet valve (7) and the Feed Inlet valve (4) c. Ensure that tank is not pressurized, Refill the feed tank and close it securely d. Open the Feed Inlet valve (4) e. Regulate the feed pressure to the operating pressure on the Feed Pressure Regulator (1) f. Start adjusting the retentate flow on the Retentate Outlet valve (7) as before the refilling 9. When the feed tank is empty, air will enter the retentate chamber and the filtration process must be stopped. It is possible to run the filtration process until air reaches the Permeate Outlet (approx. 75ml of retentate left in the chamber). a. Downregulate the feed pressure on the Feed Pressure Regulator (1) to approx. 0,1 bar b. Stop the vibration motor c. Open the Retentate Outlet valve (7) completely to drain out the remaining retentate at low feed pressure 10. Clean the system with the appropriate CIP protocol for your membrane and application and finish the CIP by filling the system with an appropriate storing solution for your membrane and application. 11. Close all valves to the retentate chamber (Airvent (6), Permeate Outlet valve (5), Retentate Outlet valve (7) and Feed Inlet valve (4)). The Vibro -LE is now ready for storage. 15
d. Continues Operation with the SANI Membranes Standard Continuous Feed System 1. Start with a fully assembled and drained Vibro -LE system as shown above with all valves and regulators closed. 2. Fill the feed reservoir (not shown) with your feed solution. 3. Open the Airvent (6), the Feed Inlet valve (4) and the Permeate Outlet valve (5). 4. Fill the retentate chamber by slowly starting your Feed Pump (1). Follow the filling of the retentate chamber visually and close the Airvent (6) when the retentate chamber is full. 5. Start the vibration motor. 6. Adjust the feed pressure with your Feed Pump (1) to the desired operation pressure and start collecting permeate in a suitable measuring vial. 7. If a given up-concentration degree is desired the correct amount of retentate relative to the measured amount of permeate must continuously be taken out through the Retentate Outlet valve (7) by adjusting the valve carefully during operation. 8. When the feed reservoir is empty, the feed pump will take in air and the pressure will drop. Stop the pump and the vibration motor. Empty out the retentate by closing the Feed Inlet valve (4), open the Airvent (6) and open the Retentate Outlet valve (7). 9. Empty the remaining feed out the Feed Chamber (2) and the connected tubing. 10. Clean the system with the appropriate CIP protocol for your membrane and application and finish the CIP by filling the system with an appropriate storing solution for your membrane and application. 11. Close all valves to the retentate chamber (Airvent (6), Permeate Outlet valve (5), Retentate Outlet valve (7) and Feed Inlet valve (4)). The Vibro -LE is now ready for storage. 16
e. CIP Operation The following procedure is a general guideline for the cleaning/sanitation of Vibro-LE for most normal applications with a Standard Batch Feed System. Depending on individual process streams, equipment, and process time, some variations in cleaning procedures may be required for optimal cleaning results. Please consult a qualified chemical supplier for application specific cleaning regimes. Water flushes, buffer flushes or CIP cleaning must be performed after each run with media in the Vibro -LE. The appropriate cleaning method must be found for each membrane and membrane application by the user. A typical CIP routine for operation with organic material could consist of: 1. A 7L hot water flush at 0,5 bar with the retentate valve slightly open 2. A 30min 55 C caustic wash at ph 11 and 0,5 bar with an appropriate CIP chemical and the retentate valve slightly open 3. A 7L water flush at 0,5 bar with the retentate valve slightly open 4. A 15min 55 C acid wash at ph 2 and 0,5 bar with an appropriate CIP chemical and the retentate valve slightly open 5. 2 times 7L water flush at 0,5 bar with the retentate valve slightly open 6. Filling of the retentate chamber with an appropriate storage solution (e.g. 20% Ethanol or 1% Sodium metabisulfite) 7. Closing of all valves to the retentate chamber (Airvent (6), Permeate Outlet valve (5), Retentate Outlet valve (7) and Feed Inlet valve (4)) 8. The Vibro -LE is now ready for storage f. Homogenization of viscous/high concentration media in the retentate chamber At high viscosity / high concentrated media mix/homogenization of the retentate in the retentate chamber can be necessary. A Mix Pump (9) can be fitted between the Airvent (4) and the 2 nd Retentate Outlet valve to mix/homogenize the retentate in the chamber during operation. 17
5. Assembly a. Assembly of batch production system with the SANI Membranes Standard Batch Feed System 1. Close the Feed Pressure Regulator (1) completely. 2. Connect all pressurized air connections with flexible tubing: a) Connect the external pressurized air (minimum 4 bar) to the Feed Regulator (1) on the Feed Chamber b) Connect the Feed Chamber (2) with the Feed Pressure Regulator (1) on the Feed Chamber c) Connect Air Cushion Inlet 1 with the Feed Pressure Regulator (1) on the Feed Chamber d) Connect Air Cushion Inlet 1 with Air Cushion Inlet 2 3. Connect all fluid connections with flexible tubing: a) Connect the Feed Chamber (2) to the Feed Inlet (4), include an on/off valve with in towards the Feed Inlet (4) b) Connect an on/off valve to the Airvent (6) with in towards the Airvent (6) c) Mount a plug in the Retentate Outlet under the Feed Inlet (4) d) Connect the Retentate Outlet (7) with a hose to your retentate collection vial, include a regulation valve or an on/off valve with in towards the Retentate Outlet (7) e) Connect the Permeate Outlet (5) with a hose to your permeate collection vial include an on/off valve with in towards the Permeate Outlet (5) (the valve should only be in off position during storage) 18
b. Assembly of continuous production system with the SANI Membranes Continuous Feed System 1. Close the Feed Pressure Regulator (1) completely. 2. Connect all air connections with flexible tubing: a) Connect the Feed Hydrophore (2) with the Air Cushion Inlet 1 b) Connect Air Cushion Inlet 1 with Air Cushion Inlet 2 3. Connect all fluid connections with flexible tubing: a) Connect the Feed Pump (1) with the Feed Hydrophore (2) b) Connect the Feed Hydrophore (2) to the Feed Inlet (4), include an on/off valve with in towards the Feed Inlet (4) c) Connect an on/off valve to the Airvent (6) with in towards the Airvent (6) d) Mount a plug in the Retentate Outlet under the Feed Inlet (4) e) Connect the Retentate Outlet (7) with a hose to your retentate collection vial include a regulation valve or an on/off valve with in towards the Retentate Outlet (7) f) Connect the Permeate Outlet (5) with to your permeate collection vial, include an on/off valve with in towards the Permeate Outlet (5) (the valve should only be in off position during storage) c. Assembly and removal of the Vibration Motor 1. Assembly of the Vibration Motor a) Place and align the Vibration Motor on Chamber side 2 b) Put the 4 bolts in and tighten them c) Tighten the unbrako bolt between the 2 ball bearings 2. Removal of the Vibration Motor a) Loosen the unbrako bolt between the 2 ball bearings b) Remove the 4 bolts connecting the motor to Chamber Side 2 c) Remove the Vibration Motor 19
6. Membrane exchange a. Disassembly of the Membrane Assembly Attention: The membrane surface is extremely fragile. Do not touch the membrane surface at any time. 1. Start with a drained system with all tubing s disconnected. 2. Carefully release the Membrane Assembly from the base plate. Preferably with the leaf springs left in the base plate. 3. Empty out any remaining permeate and retentate from the Membrane Assembly. 4. Place the Membrane Assembly with the vibration motor between your thighs sitting down and start the disassembly. 5. Remove the 8 M8 unbrako bolts from Chamber Side 1. 6. Remove Chamber Side 1 from the Membrane Assembly. 7. Remove the rubber gasket between Chamber Side 1 and the Membrane Chamber. 8. Slide the Membrane Chamber out of Chamber Side 2. 9. Remove the rubber gasket between Chamber Side 2 and the Membrane Chamber. 20
10. Take of the two M10 nuts from the Permeate Outlets. 11. Press half of the Permeate Outlets out of the Membrane Chamber by pressing the bolt ends with your finger. 12. Remove the Permeate Outlet ends from the Membrane Chamber with a M8 bolt and a rubber hammer (gentle knocks in an exactly 90 angle from the chamber). 13. Remove any remaining gaskets from the permeate outlet holes in the Membrane Chamber. 14. Slide the Free Flow Plate laboratory element (HPL) out of the Membrane Chamber without touching the membrane with your fingers or the Membrane Chamber. 15. Store the membrane element in an appropriate storing solution without the membrane touching the vial. 16. Clean the parts with 50% EtOH before storing or re-assembly. 21
b. Assembly of the Membrane Assembly 1. Clean the parts with 50% EtOH if necessary and check that all gaskets and O-rings are intact. 2. Press the Permeate Outlet ends (with gasket and O-rings) into the holes in the Membrane Chamber after lubricating the O-rings with water. The first O- ring should be covered by the chamber (make sure that the orientation of the chamber is correct for where you want your bottom Permeate Outlet). 3. Place the Membrane Chamber upright on a table with the holes in the bottom and slide the HPL element into the Membrane Chamber from the top, without touching the membrane with your fingers or the Membrane Chamber. 4. Press in the other half of the Permeate Outlets (with gasket and O-rings) after lubricating the O- rings with water. The first O-ring should be covered by the Membrane Chamber (make sure that the orientation of the Membrane Chamber is correct for where you want your bottom Permeate Outlet). 5. Put on the M10 nuts and tighten them carefully until the second O-rings are covered completely by the Membrane Chamber. 6. Check that the HPL is mounted straight. If the HPL is crocked, you should align it by knocking on the permeate exits with a rubber hammer (gentle knocks in an exactly 90 angle from the chamber). 7. Check that all the gaskets are visible within the membrane chamber. If not, then tighten the nuts and realign the HPL with a rubber hammer until the gaskets are all visible and the HPL is aligned in the middle of the Membrane Chamber. 22
8. Place Membrane Side 2 with the motor between your thighs sitting down and start the assembly of the Membrane Assembly. 9. Put a rubber gasket in Chamber Side 2 and carefully slide in the Membrane Chamber in the correct orientation. 10. Press the Membrane Chamber into Chamber Side 2 while making sure that the rubber gasket is in place. 11. Place a rubber gasket on top of the Membrane Chamber and carefully press on Chamber Side 1 in the correct orientation, while making sure that the rubber gasket is in place. 12. Put in the 8 M8 unbrako bolts and cross tighten them very carefully (1 st corner,3 rd corner, 2 nd corner, 4 th corner, etc.) until they are all finger tight (It is very hard to tighten with only your little finger 5 cm out on a standard unbrako wrench). 13. Carefully place the Membrane Assembly onto the leaf springs on the base plate. Be careful to center the Membrane Assembly correctly on the leaf springs and press the leaf springs all the way into the slits in the Chamber Sides. 23
7. Technical Data Vibro -LE Data Weight Dimensions (L x W x H) Membrane Internal Retentate volume Internal Permeate volume Operating Pressure Temperature Range Vibration Motor Power Consumption Noise Level 10 kg 515 mm x 160 mm x 332 mm 0,35 m 2 HPL element 500 ml, Fully drainable 50 ml, Fully drainable 0-4 bar 5-85 C Electric 240V, 40W excl. feed system 50-65 dba Vibro -LE Accessories and Spare Parts Standard Batch Feed System 9L Stainless Steel tank with feed pressure regulator and all necessary fittings and tubing s Standard Continuous Feed System Feed pump and Feed Chamber (hydrophore) with all necessary fittings and tubing s Homogenization Pump System Homogenization Pump with all necessary fittings and tubing s Rubber Gasket Set 2 Rubber gaskets for the Air Cushions Ballon Rubber Gasket Set for operation under 1 bar 2 Balloon rubber gaskets for the Air Cushions and 2 plugs for the Air Cushion Inlets Permeate Outlet Set including O-rings and Gaskets 2 Permeate Outlets with gaskets and O-rings (one plugged and one with 8 mm outlet) O-ring / Gasket Set for the permeate outlets 8 gaskets 16 big O-rings and 4 small O-rings for the permeate outlets Leaf Spring Set 2 polymer leaf springs and 2 steel leaf springs Membrane Chamber 1 PVC Membrane Chamber Free Flow Plate Laboratory Element (HPL) Data Generic Design Free Flow Plate. Fused Polypropylenes Membrane Type Most organic membranes (MF, UF, and other filter types) Membrane Area 0,35 m 2 Dimensions (L x W x H) 242 mm x 30 mm x 202 mm Viscosity Range, Apparent 1-1000 cp (e.g. Cream Cheese+) Temperature Range 5-85 C ph Range 1-14 Free Chlorine Membrane dependent Free Flow Plate Laboratory Element (HPL) Standard Membranes Membrane type Cut-off Membrane Material UF 5 kda PES UF 5 kda PESH UF 30 kda PESH UF 100 kda PVDF UF 300 kda PES UF 400 kda PAN MF 800 kda / 0,08 µm PVDF MF 0,2 µm PVDF MF/Filter 1 µm PET (Woven) MF/Filter 5 µm PET (Woven) MF/Filter 10 µm PET (Woven) The HPL can be equipped with your membrane of choice. SANI Membranes have a line of standard MF and UF membranes from Synder, Microdyn-Nadir and others on stock. Most commercial available membranes can however also be used with the HPL. Please, do not hesitate to contact us with your membrane wishes. 24
8. Conformity The Vibro-LE system is CE marked to demonstrate compliance with relevant regulations including the European Machine, Electrical and Pressure Directives. 25