Guidelines on correct operation of AutoLab dispensers to

AutoLab

Laboratory Dispensers

and

Solution Makers

Guidelines on correct operation ofAutoLab dispensers to ensure best

dyeing results

July 15th, 2003Revision 10.0

Guidelines for customer maintenance of AutoLab systems ALMAINT / Rev 10.0 / July 15th 2003 Page 3 of 30

Guidelines for customer maintenance of AutoLab dispensers

Any mechanical system requires regular maintenance to ensure correct, accurate and reliable operation.The AutoLab Laboratory Dispenser is no exception to this, and as such it is imperative that regularmaintenance is carried out. It is suggested that one person within the laboratory is nominated to beresponsible to check that this maintenance is carried out, to ensure it is done correctly and on a regularbasis.

The following pages outline the general guidelines, recommended regular routine maintenance, andpreventative maintenance procedures that should be carried out, in order to keep the system runningefficiently and effectively.

It is recommended to make up a checklist and sign off each item to show when maintenance is done andby whom. You should also keep a logbook of all problems encountered by any operator. The personresponsible for the system can then regularly check to see if a particular problem occurs frequently and, ifso, take the necessary steps to resolve the problem.

At the end of this document are some sample checklists, which may be used as the basis of the internalmaintenance procedures.

Time and effort dedicated to simple routine maintenance will be rewarded in thetime saved by the precision of the results.


General guidelines for ensuring good repeatable dyeing results

Water quality

The quality of the water used to dispense recipes, and used to make the dye solutions is important inensuring good repeatability of dyeing.

Poor quality water can lead to poor stability of solutions, and also poor repeatability of dyeing. Therefore itis essential that the water be filtered before it is supplied to the dispenser and solution maker.

If the water filter supplied with the system is not sufficient (the filter supplied is a general-purpose 5micron filter, designed only to remove large dirt particles), then it may be necessary to install a specialisedwater filter, specifically designed to eliminate whatever problem the water used has. For example it maybe necessary to install a 2-micron water filter if algae is present, or where very small particles exist in thewater, or for example a de-ionising filter, a de-aerating filter, to reduce the amount of air in aerated water.

Stability and lifetime of the dye solutions can also be affected by water quality. It is important to makesure that high levels of algae are removed or neutralised, to ensure long shelf life, and reduce anypossibility of algae build up within the dispense tubes.

If it is not possible to remove the algae from source of the water, it is possible to add chemical additiveswithin the dyestuff solutions, to kill of any algae present. Dyestuff manufacturers will giverecommendations on what type of chemicals to use.

Biocides such as PROXEL GXL (Zeneca) can be added within the dyestuff solutions themselves, toreduce the build-up of algae within the solutions bottles, and ensuring better quality and accuratesolutions, and reducing the build-up of algae in the tubes.

Typically something like Hydrogen Peroxide can be used to clean out dispense tubes etc to kill anybacteria that may have already formed.

It is important also to use water for laboratory work that is similar to the water used in production. This willensure that correlation between laboratory and production is as close as possible.

Dyestuff solution strength

Each dyestuff available on the market has a maximum solubility level, up to which the solutions willremain stable. It is important not to use the dyestuffs at solution strength higher than the dyestuffmanufacturer’s recommendations, since this may cause problems of poor repeatability.

Dyestuff solution shelf life

Each dyestuff available on the market has a recommended shelf life when made up into a solution. It isimportant not to use any solutions once they have passed their shelf life, but should be thrown away, anda new solution made up.

The software automatically controls the lifetime of the solutions, and will give a warning when any solutionis out of lifetime. It is important, however, that system operators heed and follow these warnings.



Stability of dyestuffs solutions

In addition to the recommendations on quality of water used to make solutions, certain dyestuffs alsoneed chemical additives to ensure stability and long shelf life.

For example, it is recommended that a dispersing agent such as Irgasol DA or Dispersan DAN, at 3g/l, isadded to certain heavy disperse dye solutions, acid dyes should have a level of acid added to thesolutions to ensure correct pH and stability of solution, etc.

The dyestuff manufacturers for the different specific ranges of dyestuffs will give recommendations onwhat procedures to use.

Preparation methods of solutions

It is important that the method of actually preparing dyestuff solutions is correct, and in line with themanufacturer’s recommendations. Incorrect procedures can lead to unstable solutions and incorrectsolution strengths.

For example acid dye solutions should be made up by first adding a small amount of very hot water, thenadd the dyestuff, then mix for about 5 minutes, prior to completing the solution to the required volume byadding warm water.

For disperse dyes, it is important that the water used to make the solutions is not too hot, about 50-60’C,since hot water can actually damage the dyestuff, and reduce the capability of correct dyeing.

Standard procedures can be programmed into the system, ensuring that the operators always make upeach solution correctly. However it is important that initially the correct procedures for each dyestuff type,as recommended by the dyestuff manufacturers, are inputted into the system.

Dyestuff bottles

If light sensitive dyes are being used, it is recommended to use brown solution bottles, and not clearbottles, since this will reduce the possibility of the dyestuffs degrading.

Physical positioning of dyestuff solutions on the dispenser

Due to the nature of disperse dyes not being a true solution but a dispersion, they may therefore settleout over time. It is recommended that all disperse dye and dyestuff solutions be positioned on thedispenser where the shortest length of dispense tube are. In other words, disperse dyes should bepositioned just above the dispense heads, and not at each end of the dispenser, where tube lengths arelonger.

Cleaning of dispense tubes

To ensure that results of dispensing are as accurate as possible, it is important that the dispense tubesare kept as clean as possible. Regular refreshing and cleaning of the tubes with solution and water, asexplained in the daily and weekly maintenance guidelines, will ensure tubes are kept clean for most typesof dyestuffs. However some dyestuffs, such as heavy disperse dyes, by nature of the fact that they arenot a solution but a dispersion, are more difficult to keep clean.It is, however, possible to get very good repeatability, and possible to keep the dispense tubes clean, witha few additional procedures.



Cleaning of dispense tubes (cont…)

The dispense tubes should be regularly checked, and if they are not clean, refreshing with water shouldbe done. If this, however, does not fully clean them, then it may be necessary to maybe once a month orperhaps every 2 weeks, clean them with a chemical solution, which has a better cleaning effect comparedto water. Dyestuff manufacturers will recommend what chemical mixtures to use for cleaning of the tubes.

For example, Clariant recommend to use the following chemical formula for cleaning of dispense tubesused when dispensing their disperse dye solutions:

Ekaline F liq. 10 g / L.Na2S2O4 Natriumhydrosulphite 20 g/LNaOH Sodium Hydroxide 36°C 30 cc/L.

Warm up chemical solution mixture up to about 40°/50°, and then clean the valve for about 120 secondsusing this mixture. Neutralise by cleaning through with a 2 cc/l solution of CH3COOH at about 98 °C.Clean through with water, then refresh the tube with the original dyestuff solution, until the tube iscompletely full of solution.

Also using a standard reduction clear solution can be used for cleaning the tubes, and again should becleaned out with water after using the reduction clean solution.

Recommended frequency dependent on type and concentration of dyestuff used.

If the tubes are still not clean after refreshing with water and chemical, it may be necessary to use thedispense tube cleaning brush, which is supplied with every system, to more thoroughly clean thedispense tubes.

Replacing dispense tubes

From time to time, it may be necessary to replace the dispense tubes on AutoLab dispenser systems, forexample, when a new dyestuff is to be used in a particular valve position, which is different to the originaldyestuff used in that position, or for example when a dispense tube has become too dirty to manuallyclean.

It is important when dispense tubes are replaced, that the correct procedure is used, and ensure thatwhen replaced, all other tubes are correctly positioned. This will ensure that no dripping may occurafterwards. Enclosed are the recommended procedures for replacing the dispense tubes.

Cutting of dispense tube (4mm outer diameter, 3mm inner diameter)

When replacing dispense tubes on AutoLab systems it is important that the ends of the tubes are cutcleanly and straight.

If the tube ends are not cut straight, this will create a poor connection between the tube and the dispensevalve, which may cause dripping of the valve.

To help achieve a clean cut of the tubes, a set of tube cutters is supplied with each system, which shouldalways be used to cut the dispense tubes.

Extra sets of these cutters can be obtained by contacting you local Datacolor International spare partsupply office. Part number for this item is 101-MFC-01.

It is not recommended to use scissors or other such cutting devices, as this can cause the tube to bebent, and also will not create a straight cut.



Replacing dispense tubes (cont..)

Length of tube end nozzle (3 mm inner diameter, 2mm inner diameter)

It is important that the tube end nozzle is of the correct length; if it is too short, then solutions beingdispensed may form on the bottom of the dispense head, with the potential of causing contamination ofrecipes. If the tube end is too long, then this may then catch on the dispense head drain when the headmoves in and out, therefore bending the tube ends, which may cause dispensing to occur out of the dyepot.

Also supplied with each system is a measuring block, to be able to measure the correct length ofdispense tube end nozzle, required to correctly fit into the dispense head. The measuring block makes iteasier to determine the correct tube end length.Extra sets of these measuring blocks can be obtained by contacting you local Datacolor Internationalspare part supply office. Part number for this item is AP-M011.

The tube end should be first placed inside the 4*3 dispense tube, with at least 5 mm of the narrow 2*3tube end nozzle inside the dispense tube, ensuing a good fit.

The diagram below shows this in more detail:

Dispense tube

Tube endnozzle

Secondly, place the tube end inside the measuring block

Thirdly, cut the tube end at the position at which it exits the bottom of the measuring block, ensuring thecut is clean and straight.

5mm




Inserting a dispense tube into the dispense head

It is important that when replacing a dispense tube, that the tube end is correctly fitted into the head.

The dispense head consists of two plates, an upper and lower plate. These are held together by screws.Holding these two plates together, and slightly mis-aligned with each other, ensures that the tubes areheld tight into the dispense head. If the tubes are not held tight in the head, then they may come looseafter a period of time, which may cause dyestuff solution to form inside the head, or on the bottom of thehead, therefore causing dripping from the head and contamination of recipes.

You may find it easier to completely remove the dispense head from the head-moving cylinder beforecarrying out this procedure, if you need to replace more than one dispense tube, or replace a tube whichis situated in the middle of the dispense head. To do this, slacken and remove the nut which holds thedispense head to moving air cylinder piston shaft. Then remove the dispense head from the shaft.

To slacken the dispense head, the two screws B1 and B2 underneath the head must first be slackenedoff slightly, by turning the screws only one or two rotations. This makes the bottom plate come loose fromthe top plate.

Then the screw A at the front should be rotated slightly so that the top plate is moved such that the holesin the top plate are in line with the holes in the top plate, therefore loosening the tubes. Make sure that allthe tubes do not fall out when performing this operation.




Inserting a dispense tube into the dispense head

Once the tubes are easy to remove, remove the tube required to be replaced, and put the new tube backin the same hole, making sure that the tube is pushed right down, so that the 4*3 dispense tube goesright through to the bottom plate, and so that the 2*3 tube end comes through the bottom of the dispensehead. See diagram below.

When this has been done, check that none of the other tubes have come out of its respective hole, andthen gradually and slightly tighten up the front screw, so that the holes in the two plates becomemisaligned again, and the tubes are gripped within the head. Note that it is not necessary to adjust thefront screw very firmly, just enough that the tubes are gripped within the dispense head. Test this bygently lifting one tube from the head. If resistance can be felt, then the screw has been sufficientlytightened. If the tube comes out easily, then the screw has not been tightened sufficiently.

Next, tighten the two screws underneath, so that the two plates are firmly held together.

If the dispense head was removed from the moving air cylinder shaft, place the head back on the shaft,and reconnect the nut, making sure the dispense head is horizontal.




Amounts of tubing required to replace all dispense tube, for each model of dispenser.

Below is a table which shows the amount of dispense tube, nozzle end tube, and protector tube requiredto replace all the dispense tubes, for each model of dispenser.

AutoLab32

1&2Litre

AutoLab40

1&2Litre

AutoLab64

1 Litre

AutoLab64

2 Litre

AutoLab72

1 Litre

AutoLab72

2 Litre

AutoLab96

1 Litre

AutoLab96

2 Litre

AutoLab96T1&2Litre

AutoLab100 plus1 Litre

PI-H010 3x4 PFA tube 100m 100m 150m 150m 150m 200m 200m 250m 500m 200m

PI-H001 2x3 Teflon tube 1m 2m 2m 2m 2m 2m 3m 3m 6m 3m

PI-D003 4.5x6.5 PU tube 30pcs(15m)

38pcs(20m)

64pcs(30m)

64pcs(30m)

72pcs(30m)

72pcs(30m)

96pcs(40m)

96pcs(40m)

192pcs(80m)

100pcs(40m)

APP-C003 Sticker for tube 1-32 1-40 1-64 1-64 1-72 1-72 1-96 1-96 1-962 Sets

1-100

EG-B002 Cable tie(150mm x 3.6mm)

1pack 1pack 1pack 1pack 1pack 1pack 1pack 1pack 1pack 1pack

AutoLab100 plus2 Litre

AutoLab104

2 Litre

AutoLab104T

2 Litre

AutoLab108

1 Litre

AutoLab 108T1 Litre

AutoLab128

1 Litre

AutoLab128

2 Litre

AutoLab128T

1 Litre

AutoLab128T

2 LitrePI-H010 3x4 FFA tube 250m 250m 500m 250m 500m 300m 350m 600m 700m

PI-H001 2x3 Teflon tube 3m 3m 6m 3m 6m 4m 4m 8m 8m


104pcs(40m)

208pcs(80m)

107pcs(45m)

214pcs(90m)

127pcs(50m)

127pcs(50m)

254pcs(100m)

254pcs(100m)

APP-C003 Sticker for tube 1-100 1-104 1-1042 Sets

1-108 1-1082 Sets

1-128 1-128 1-1282 Sets

1-1282 Sets


1pack 1pack 1pack 1pack 1pack 1pack 1pack 1pack 1pack

ModuloGT 36/48

1L/1L

ModuloGT 36/48

1L/2L

ModuloGT 36/72

1L/1L

ModuloGT 36/72

1L/2L

ModuloGT 36/102

1L/1L

ModuloGT 36/102

1L/2L

ModuloGT 36/126

1L/1L

ModuloGT 36/126

1L/2LPI-H010 3x4 FFA tube 100m 100m 150m 200m 250m 300m 300m 350m

PI-H001 2x3 Teflon tube 2m 2m 2m 2m 3m 3m 4m 4m


48pcs(20m)

72pcs(30m)

72pcs(30m)

102pcs(40m)

102pcs(40m)

126pcs(50m)

126pcs(50m)

APP-C003 Sticker for tube 1-48 1-48 1-72 1-72 1-102 1-102 1-126 1-126EG-B002 Cable tie(150mm x 3.6mm)

1pack 1pack 1pack 1pack 1pack 1pack 1pack 1pack

CADS100 plus1 Litre

CADS40M

1 Litre

CADS72

1 Litre

CADS108

1 Litre

CADS108T

1 Litre

CADS128

1 Litre

CADS128T

1 LitrePI-H010 3x4 FFA tube 200m 100m 150m 250m 500m 300m 600m

PI-H001 2x3 Teflon tube 3m 2m 2m 3m 6m 4m 8m


38pcs(20m)

72pcs(30m)

106pcs(45m)

214pcs(90m)

127pcs(50m)

254pcs(100m)

APP-C003 Sticker for tube 1-100 1-40 1-72 1-108 1-1082 Sets

1-128 1-1282 Sets


1pack 1pack 1pack 1pack 1pack 1pack 1pack

PI-H010 3*4 PFA tube Dispense tubing made of Teflon PFAPI-H001 2*3 Teflon tube Dispense tube end nozzle tubingPI-D003 4.5*6.5 PU Tube Protector tubing that goes over the dispense tube at the valve endAPP-C003 Sticker for tube Used to number the tubing to know which tube goes to which valve numberEG-B002 Cable tie Used to tie all the dispense tubing together at the dispense head



Recommendations on dispense tube automatic refresh times and intervals

Within the AutoLab software are a number of configuration settings to allow automatic cleaning of thedyestuff tubes, to ensure no build up of sedimentation occurs.

The methods of cleaning are three types.

1. Pre dispense refresh.

This function automatically refreshes the dispense tubes of the dyestuff to be used in a recipe, prior todispensing the recipe, therefore ensuring that good clean solution is transferred into the tubes from thesolution bottles, and ensures that any sedimentation is dropped into the drain.

Within the program CPTSDUTL, dispensing utility, there is an option “Pre-Dispense Refresh”.

Each valve can be individually set with its own refresh time and refresh interval setting.

Pre dispense refresh time

Depending on the type of solution being used in a particular valve position depends on the settings thatshould be made. Firstly, the time should be set so that the system will dispense around one tube full ofsolution into the drain, prior to dispensing the recipe. The time to do this depends on where the valve isphysically positioned on the dispenser, and also what model of dispenser the system is. For example, onan AutoLab 128, it takes about 10 seconds to dispense one tube of solution for valves that are positionedon the far left-hand side and far right-hand side of the system. Valves positioned in the middle of thedispenser need about 4 seconds to dispense one tube full. On an AutoLab 108, extreme left and rightrequire about 7 seconds, and 4 seconds for the centrally positioned valves.

Pre dispense refresh interval

The interval that each valve should be set to again depends on the type of solution being used. Typicallyfor disperse dyes this should be set to 30 minutes, or maybe 15 minutes for more difficult dispersions.

For true solutions that do not sediment, this can be set to 60 or 120 minutes, since it is not necessary torefresh the tubes often.

N.B the frequency that it refreshes the tubes with an interval set to for example 30 minutes, does notmean that it will always refresh every 30 minutes, but will depend on how often recipes are dispense.Prior to dispensing a recipe, it will check the valves needed to dispense. If the valve needed to dispensehas not been used for more than 30 minutes, it will refresh into the drain. This means the pre dispenserefresh will only take place just before dispensing a recipe, and will only occur if the interval the valve wasused is greater than the value set.

It is important to experiment with different settings, to ensure the optimum interval has been sent for thedifferent type of dyestuffs, i.e. the system is refreshing frequently enough to ensure no sedimentation, butnot too often, that solutions are running out too quickly.



Recommendations on dispense tube automatic refresh times and intervals (cont…)

1. Smart refresh

Smart refresh is implemented when the dispenser is not being used. The purpose of this is to keep thesolutions moving in the tube, so that sedimentation does not build up on top of existing sedimentation,therefore causing a build up of dye which is difficult to remove when the system does a pre dispenserefresh.

This setting is not needed for true solutions such as acid dyes, and should be disabled, but is required fordispersions such as for disperse dyes.In CPTSDUTL, Dispenser Utility program, setting for smart refresh can be made.

It is recommended for disperse dyes to set the refresh time for 1 second (it is not necessary to set anyhigher since the purpose of this setting is to just keep the solution moving within the tube), and interval of30 minutes, or higher for more difficult disperse dyes. Ensure that the smart refresh is enabled (makesure “Auto” is ticked) for those valves that require smart refresh to operate.

For true solutions, such as acid dyes, smart refresh can be disabled.

1. Tick refresh prior to dispensing

Within the dispense control, there is an option within the Menu option Parameters.When this is enabled, the system will automatically quickly open and close each valve together,dispensing one single drop of solutions into the drain, prior to starting to dispense a batch of recipes.This function should be enabled on systems where the dyestuffs being used dry out easily, and can formsolid deposits on the ends of the dispense tubes. Ensuring that tick refresh is done prior to dispensingevery recipe ensures that the tube ends do not dry out, and maybe block.

The function also ensures that any drops that may have formed on the tube ends due to expansion of theliquid in the tubes are removed prior to starting to dispense. This can occur especially if the water used tomake the solutions has a high content of dissolved air, or if there are large temperature changes withinthe laboratory during operation of the system.

Strength and quantity of dyestuff solution dispensed in each recipe

The weaker the dyestuff strength, and the more dyestuff solution that is dispensed in a recipe, the higherthe accuracy of the results. There are, however, other considerations to take into account, such as theliquor ratio and total volume of the recipes, and speed of dispense.

It is therefore important to organise the strengths of the dyestuff solutions that are used in such a way thataround 10 g of each solution is dispensed within each recipe. Considering the system is capable ofdispensing to an accuracy of 0.02g, dispensing around 10 grams of solution will ensure the tolerance ofdispense accuracy is negligible, and therefore will not affect final dyeing results.

To achieve this may require the use of 2 or 3 solution strengths. The AutoLab software will alwaysautomatically select the most suitable solution strength of each product to use, when saving a recipe,based on the different solution strengths available on the system, and based on the standard dispenseweight defined for that recipe. It is recommended to set the standard dispense weight to 11g for mostrecipes, with the exception of very light shades, where even higher accuracy may be required, and assuch it may be necessary to increase the standard dispense weight to, for example, 20, so that thesystem will try to select the solution strength which will give a target weight of around 20g to dispense.

More details and explanation of this subject can be found in the AutoLab Operation Manual, under thesection Recipe Queue Manager.



Fabric weight used to dye samples

Whilst the AutoLab system will automatically accurately weigh each piece of fabric to be dyed, if a Fabricweigh scale is connected to the dispenser PC, and calculate the amount of dyestuff solution, chemicalsand water to dispense based on the weight of fabric used, it is important when dyeing a number ofrecipes in the same dye machine at the same time, that the difference in weights between different piecesof fabric is minimal.

If the weights of the pieces of fabric vary by a large amount, this will mean that each dyepot will contain adifferent volume of dye liquor. This will cause the rate of absorption of heat from the dye machine to varyfrom dyepot to dyepot, therefore potentially causing differences in dyeing time/temperature gradient.

It is important to always standardise to a fixed weight of fabric for each class of dyestuffs andfabric/material to be dyed, and always ensure that the actual weight of each sample is within a tighttolerance.

It is advised that the actual weight of sample used is within 1% of the target standard sample weight, toensure no significant variation in dyeing result.

For example, if using a sample weight of 10 grams, the amount of fabric used should always be between9.9 and 10.1 grams.


ROUTINE MAINTENANCE

Daily maintenance

The following maintenance tasks and procedures should be carried out on a daily basis:

Refresh the solutions in the dispense tubes every morning for at least 10 seconds, using theRefresh function from the Utility option in the Dispenser Control program, to ensure that anysedimentation formed in the tubes overnight is cleaned out.

Ensure all tubes are full of liquid at all times. Even if a bottle is not being used, it must be primedwith water. If a tube is only partially full, then this can cause dripping, therefore affecting thedispense results.

Make sure at all times that none of the bottles are low on solution: this will ensure that you do notrun out of solution during the day, and therefore also eliminate the possibility of dripping due toempty tubes.

Ensure the dispense heads have no dripping tubes, or any dried sedimentation. If there are,check valve and tube for leaks and remove any dried sedimentation. Blocked or dirty valves,holes in tubes or poor connection of tubes to the valves may cause dripping.

Make sure that beakers are positioned on the turntable and that they are placed centrally on theadapter, otherwise the readings from the scale will not be accurate.

Ensure that the dispense scale is placed centrally to the beaker holder position, to ensure correctweighing.

Ensure that there is a magnetic stirrer bar in every solution bottle.

Ensure that both agitation blocks are activated, and all positions are working well.

Ensure that agitation speed is set correctly. The speed should be such that there is sufficientagitation within the bottle to allow homogenous movement of the solution within the bottle,ensuring that the solutions do not settle out.

Ensure that the agitation speed is not too fast such that the dyestuff particles are broken downdue to excessive movement, or a centrifugal effect caused such that the dyestuff particles areforced to the outside edges of the bottle.

Ensure there is no spillage around the dyestuff bottles or auxiliary bottles or on the dispenseturntable. Clean all liquids immediately after the spillage occurs. Liquid on the turntable can droponto the scale below and therefore create incorrect weighing.


ROUTINE MAINTENANCE

Daily maintenance (cont…)

If any valve gives a tube error during dispensing, first ensure that the tube is full of solution. If it is,then it is probable that the valve is blocked. Open the valve, clean inside and replace the valvediaphragm if necessary. If the valve diaphragm is stuck onto the metal base, clean them boththoroughly and rub the valve metal cylinder and rubber membrane with a small quantity oflubricating oil or lubrication jelly. Remove any excess lubricant, refit the valve and re-test it. If thetube error persists, check the electric connections: if they are all correct, contact your localDatacolor International representative.

After cleaning or replacing a valve at any time, always perform a valve calibration after toensure that the valve is correctly calibrated.

If any valve is found to be constantly over dispensing or takes too many attempts in opening thevalve to achieve the target weight, then re-calibrate that valve.

If water and auxiliaries are set to volumetrically dispensed, there is no 'closed loop' control ofcorrect operation of these valves. Dispensing is done on a time basis, based on the lastcalibration done on that valve. Therefore, if there is a blocked valve, or for some reason the flowrate of the valve has altered since the last calibration, the system will not be aware of thedifference. It is suggested that every morning the volumetric dispense valves be checked foroperation using the Refresh option. Ensure visually that the valves operate and the solution isdispensed in a smooth flow. If tighter control is required, then pre-loaded test recipes should bedispensed every morning, each recipe being a fixed quantity of one auxiliary. If the weight of thebeaker before and after dispensing is checked then the actual dispensed amount can be checkedagainst the target weight to ensure the valve is dispensing accurately.

If greater precision is required for the auxiliaries and water, then these can be set togravimetric dispensing. However this will reduce the speed of dispense.

If you change a solution, ensure that the correct valves are placed in the correct bottles.

When making up a new solution, it is suggested to refresh the corresponding dispense valve withwater before putting on the new solution, and then refresh the valve again once the new solutionhas been placed on the dispenser. This will enable the tube to be visually checked for anysedimentation, and will also improve the regular cleaning of the tube. Ensure that all the water inthe tube is replaced with solution, before starting to dispense.


ROUTINE MAINTENANCE

Daily maintenance (cont…)

Checking reliability and repeatability of dispensing and dyeing:

To ensure good operation of the system, it is suggested to carry out a control dyeing every day. Thisdyeing should be exactly the same recipe dispensed every day, dyed on the same fabric, in the samemachine using the same dyeing procedure. It is suggested that the recipe used is a light to mediumgrey, using a combination of the three most used dyestuffs.

By doing this dyeing, a daily check can be made to ensure that the recipe is within tolerance andcontinuity can be checked. If a problem is found, it can be identified before it creates problems inproduction.

However, before this can be done, the accuracy of the laboratory in other areas has to beestablished, to determine the true level of achievable repeatability of dyeing, regardless of theoperation of the dispenser.

The system is only capable of dispensing and producing results as good as the repeatability of dyeingin the laboratory. It is important to realise that it cannot be expected for the dispenser to produceresults any better than repeatability of dyeing.

To determine the repeatability of dyeing, certain tests can be made. This can be done by dispensinga large quantity of the same recipe in one dispense, splitting this into six or so equal parts, thendyeing three parts together in the same machine at the same time on the same material. This willdemonstrate the repeatability of dyeing for that machine. The same dyeing should be done the dayafter or a week after with the three remaining split recipe solutions. This will then allow checking ofrepeatability of the same machine over a period of time. The maximum difference between thesesamples is the minimum accuracy that can be expected from the daily control dyeing.


ROUTINE MAINTENANCE

Weekly maintenance

Check the condition of the water filter: if it is dirty, remove it and clean it, or replace it with a newfilter.

Check the air filter: if it is filled with water, remove it by pressing the button switch on the filter.

Check that the main input air pressure is around 4.0 kg/cm2; the input pressure for the air gunshould be less than 1.5 kg/cm2; the input pressure for the refill function should be 1 kg/cm2.

Ensure no tube has permanent sedimentation inside the tube especially disperse dyes. Checkthis by refreshing the valve with water instead of solution, and then visually check the tube. If anysedimentation remains, then this should be removed using the tube cleaning brush. Ifsedimentation persists, replace the tube. If the tube is replaced, then the valve should be re-calibrated.

Check that the ends of the tubes are not blocked. If they are, then the small end tube insertshould be replaced.

Ensure the turntable is free running.

Ensure the dispense scale is placed centrally below the dispense area and ensure the scale ishorizontally balanced.

Ensure all tubes are fitted well into the solenoid valves. Leakage or entry of air at the joint willcause dripping.

Ensure that all dispense tubes are well positioned on the top of the dispenser and are notwrapped around each other or cross each other. Well-organised tubes will ensure easier andquicker replacement of solution bottles.

Ensure all auxiliary refill bottles refill correctly. Check the float sensors are free running and thatthe refill tubes are not blocked.

Ensure the water refill is not set at too high pressure. This may cause varying dispensing of waterdue to air bubbles forming in the water tank. If the water refill pressure is too high, then adjust itand re-calibrate the water valves.

Ensure that all tubes are correctly fitted into the dispense heads. Every dispense tube must havethe small end tube fitted completely through the head. If any tube is not fitted correctly, thensolution may form on the lower surface of the head during dispensing, which may drop into otherbeakers, and so causing contamination.

A backup of all recipes that may be needed in the future should be made onto floppy diskette, forsafety. A backup of the solution data should be made for security reasons.


ROUTINE MAINTENANCE

Monthly maintenance

You should carry out the following maintenance tasks on a monthly basis:

Keep the fan filters free from dust.

Clean out all valves with water, and check all tubes for permanent sedimentation. Clean all tubeswith a wire brush to clear out sedimentation and if sedimentation persists, replace the tube. Seealso section on cleaning of dispense tubes in General Maintenance section.

Ensure that the dispense scale is calibrated. Details of the procedure on how this is achieved canbe found in the manufacturer’s operation manual, as supplied with the electronic scale.


ROUTINE MAINTENANCE

Periodic maintenance

The following options should be used whenever you:

Add a new solution to the system. Change an existing solution concentration. Install a new valve or tube:

1. Use the Start Up option to make sure that the tubes between the bottles and the valves arefully primed, and ready for dispensing.

2. Use the Refresh option to ensure the tubes are completely full of solution.

3. Calibrate the valve using the Calibration option.

If a valve repeatedly over-dispenses, calibrate the valve.If a solution runs out during dispensing, refill the bottle and use the Start Up option to prime the valve.If very strong solutions or heavy disperse/direct dye solutions are used on the system, leave thedispenser and computer on overnight. This will ensure that the automatic tick Refresh function operatesthroughout the day and night. This will ensure that the dispense tube ends do not dry out, and will reducethe chances of sedimentation forming inside the dispense tubes.

All valves should be kept in good condition, i.e. valve diaphragms must be free from blockages orsticking, and any spillage of solutions onto the valve wiring connectors must be cleaned off immediately.

All auxiliary refill bottles must continually be kept filled up. Ensure that the tops of the refill bottles are notblocked with crystallised solution.

All tubing must be free of holes or cracks. Any such damage will cause dripping at the dispense head.

Whenever a new make of a solution is put on the system:

1. Before putting on the new solution, refresh the valve with water using the Refresh option.

2. Place the new bottle on the system and use the Refresh option again, ensuring that the new solution fillsthe whole length of the tube.

This will ensure that tubes are cleaned more thoroughly to ensure no sedimentation forms.

If at any time a dye/auxiliary valve or tubing is changed, then that valve must be re-calibrated using theCalibration option. Whenever a valve is re-calibrated, it must be done with the bottle full of solution, andnot with the bottle half-empty. If a valve is calibrated with the bottle half empty, and the bottle is then laterfilled up, this will cause the flow rate to increase, which will cause a greater possibility of over dispensing.If the valve is calibrated with the bottle full then, as the bottle empties, the flow rate will decrease slightlyand therefore not over dispense.

If at any time a solution is substituted for a different type or different concentration of solution at any bottleposition, then that valve must be re-calibrated with the new solution, to ensure that the dispenser is usingthe correct flow. It is not necessary for a valve to be calibrated if a new make of the same solution isplaced on the system. The flow rate of the new make should be the same as when using the old bottle,and therefore there should be no change in dispensing.


ROUTINE MAINTENANCE

Periodic maintenance (cont..)

We recommend that, on a regular basis, old recipes on the system are checked and any recipes notneeded are backed up onto floppy diskette and deleted from the system.

Automatic tube refresh time and intervals should be set in the Utility Program to permit sufficient cleaningfor each valve. Stronger solutions, or more difficult solutions such as disperse dyes, may require longerrefresh time and shorter interval than weak solutions.

If the system is left unused for a long period of time, such as during holidays, or if the system is not beingused daily or weekly, we suggest you remove all solutions from the system and refresh all the tubes withwater. This will ensure that the tubes do not get dirty and the valves do not get blocked. When the systemis to be used again, refresh all the tubes with water prior to replacing the solutions on the system, andthen refresh the tubes again with the solutions in place.


AutoLab Dispenser CHECKLIST 1

Daily maintenance/housekeeping check list

ACTION DATECHECKED

BYACTION TAKEN

1.

2.

3.

4.

5.

6.

7.

8.

Check that all the agitation blocks are activatedturned to maximum and are working well.

Check the dispensing heads are free from drips.

Check the dispensing heads are free from dyecontamination/sedimentation.

Check that none of the tubes are partly empty asmay result in drips of dye.

Check the current level of dye stock solutions. Makeup any low solutions as necessary.

Check there are no spillages around the dye andauxiliary bottles and on the dispenser turntable.Clean any spillage IMMEDIATELY.

Check the dispenser scale is placed centrally belowthe dispense area, enabling the dyepot holders to belifted completely clear of the turntable when thescale moves to it’s weighing position.

Check that the water is being dispensed accurately.

If the machine fails any of the above checks inform the Lab Manager and take the corrective/containmentaction described in the appropriate SOP.



Weekly maintenance/housekeeping check list

ACTION DATECHECKED

BYACTION TAKEN

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Check the condition of the water filter. If dirty takethe appropriate action.

Check the condition of the air filter. If contaminatedtake the appropriate action.

Check that the main input air pressure is 4.0kg/cm3.

Check the input air pressure for the air gun is lessthan 1.5 kg/cm3.

Check the input air pressure for enabling theautomatic refilling of the auxiliary bottles is 1kg/cm3.

Check the dispenser scale is horizontally balanced(bubble gauge).

Ensure all the dispensing tubes are fitted well on tothe solenoid valves.

Ensure all the auxiliary refill bottles are refillingcorrectly.

Check that all the dispenser tubes are correctly fittedinto each dispensing head. Each tube must have asmall end tube fitted completely through the head.

Backup the week’s recipes and then delete any thatare no longer required.

If the machine fails any of the above checks inform the Lab Manager as soon as possible and take thecorrective/containment action described in the S.O.P.



Monthly maintenance/housekeeping checklist

ACTION DATECHECKED

BYACTIONTAKEN

1.

2.

3.

4.

5.

6.

Check that the fan filters are free from dust.

Drain the two water reservoirs on top of thedispenser. Clean them and then refill them.

Dismantle a sixth of the valves, clean then withdistilled water and replace faulty diaphragms.

Check all the dispensing tubes are free fromsedimentation/staining.

Check all the tubing is free from holes &/or cracks.

Check that the rotation speed of the magneticstirrers is 190rpm on all four agitation blocks using atachometer.

* Check the next sixth of the valves in the following month. Hence, all the valves will have been checked atleast every six months.

If the machine fails any of the above checks inform the Lab Manager as soon as possible and take thecorrective/containment action described in the appropriate S.O.P.

Documents

Guidelines on correct operation of AutoLab dispensers to