Hydro Series Wet Dispersion Units (MAN0479-05-En-00)

Malvern Instruments Limited
Grovewood Road, Malvern

Worcestershire, WR14 1XZ, UK
Tel +44 1684 892456

Fax +44 1684 892789
www.malvern.com
PARTICLE SIZE
MASTERSIZER 3000
HYDRO SERIES
WET DISPERSION UNITS
MAN0479
MRK1955-01
MRK1955-01_HYDRO_dry_disp_units_cover_86pp.indd 1 28/08/2013 12:49:10

Hydro series wet
dispersion units
MAN0479-05-EN-00 March 2015
Copyright © 2011, 2015 Malvern Instruments Ltd.
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Table of contents
Introduction and Hardware
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Hydro dispersion units - overview . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hydro MV and LV dispersion units . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Hydro EV dispersion unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Hydro SM dispersion unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Hydro SV dispersion unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Hydro series wet cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
Connecting the dispersion units . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47
External dispersant pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51
Software and Control

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Making a measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control of a Dispersion unit via an SOP . . . . . . . . . . . . . . . . . . . . . 2-2
Manually controlling the dispersion unit . . . . . . . . . . . . . . . . . . . . 2-10
Manual control accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Maintenance
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Consumable kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Appendix
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Chemical compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Regulatory Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Hydro series wet dispersion units Page i

Table of Contents Hydro series wet dispersion units
Page ii Hydro series wet dispersion units

1
Introduction
and Hardware
Introduction
This manual details the important features of the Mastersizer 3000 Hydro series
wet sampling dispersion units.
Dispersion unit Description Model number

Hydro SV Small volume (SV) automatic wet dis- MAZ3100
persion unit
Hydro SM Small volume manual (SM) wet disper- MAZ3150
sion unit
Hydro MV Medium volume (MV) automatic wet MAZ3200 /
dispersion unit MAZ3210
Hydro LV Large volume (LV) automatic wet dis- MAZ3300 /
persion unit MAZ3310
Hydro EV Extended volume (EV) user-interactive MAZ3400
wet dispersion unit
Note
The Hydro MV/LV (MAZ3210/3310) dispersion units are fitted with an
analogue level sensor and a manual drain button. These additions to the
Hydro MV/LV (MAZ3200/3300) dispersion units are identified in the rele-
vant manual sections.
This manual is a supplement to the following manuals:

 Mastersizer 3000 User Manual
 Mastersizer 3000 Basic Guide
Hydro series wet dispersion units Page 1-1

1 Chapter 1 Introduction and Hardware
Warning!
The dispersion units or the samples to be measured may be hazardous if
misused. Users must read the Health and Safety information in the
Basic guide before operating the system.
This manual focuses on specific issues of the Hydro series wet dispersion units that
are not covered by the above manuals. Within the following chapters the manual
will detail:
Introduction and Hardware

This chapter serves as the introduction to the dispersion units and describes what
the Hydro dispersion units are and explains in simple terms how they work. It also
identifies the physical features of each model of the dispersion units and how to
connect each one to the Mastersizer optical unit.

This chapter describes the Hydro software controls identified in the Mastersizer
3000 user manual and explains how to use the dispersion units to make measure-
ments on the system.
Maintenance
This chapter covers all the user maintenance procedures for the dispersion units.
This includes a maintenance schedule and associated maintenance procedures for
inspecting and cleaning each dispersion unit and its respective components. Spe-
cific procedures for inspecting and cleaning the flow cell windows are described.
Appendices
This chapter details the useful specifications of each dispersion unit and identifies
the chemical compatibility of the dispersion unit components that may come into
contact with the sample. Additionally it provides the important regulatory informa-
tion to which the dispersion units are compliant.
Page 1-2 MAN 0479

Introduction and Hardware Chapter 1
Hydro dispersion units - overview

What do the Hydro dispersion units do
The sole purpose of any sample dispersion unit is to prepare the sample and then
deliver it to the optical unit so that it can be measured.
The Hydro dispersion units allow the Mastersizer to be used for particle-in-liquid
particle sizing of both aqueous and non-aqueous samples.
Many materials need to be measured as wet dispersions. Typically these are materi-
als that are used or produced wet in the manufacturing process. The Hydro LV,
MV, EV, SV and SM dispersion units are designed to create a suspension of parti-
cles in water or other liquid media, which can be optimized through the use of
ultrasonics and surfactants where necessary. In the mineral, chemical, metal pow-
der refining and cement industries, measurements of larger sample volumes are
often most appropriate for Quality control (QC) of the manufacturing process and
finished product.
ill 8760
The materials used in the manufacture of the dispersion units maximise the range
of materials that can subsequently be handled. Variable pump/stirrer speeds allow a
wide range of particle sizes and densities to be suspended and circulated enabling

Chapter 1 Introduction and Hardware
adequate dispersion and representative sampling prior to a measurement being per-

formed.
Additionally a variable power ultrasonic system enables particle agglomerates to be
dispersed.
Hydro MV and LV dispersion units

Except for a couple of functional differences, the Hydro MV and LV dispersion
units are virtually identical. The Hydro LV can circulate 600ml of liquid while the
Hydro MV has a smaller capacity of 120ml.
The large capacity of the Hydro LV makes it ideally suited for the measurement of
larger sample quantities as well as larger materials having broad size distributions.
In some cases, sample materials are not plentiful and the MV's smaller volume sam-
ple dispersion unit is a sensible choice to minimize sample consumption while
retaining the benefits of totally automated sample dispersion and measurement.
Additionally the small volume of the Hydro MV is ideal when using solvent disper-
sants or when samples and dispersants are either expensive or hazardous.
Hydro EV dispersion units

Whilst the Hydro MV and LV dispersion units will have dispersant added and
drained automatically, in the EV the sample and dispersant are added to and meas-
ured in a standard laboratory beaker of 600ml or 1000ml capacity.
Hydro SV
The Hydro SV enables the Mastersizer to be used for particle-in-liquid particle siz-
ing, where the amount of sample available limits the amount of dispersant that can
be used to dilute it, or where just a small volume of dispersant is available. This is
ideal when the sample or dispersant is toxic or expensive.
The Hydro SV manual dispersion unit is designed for the measurement of small
amounts of a sample with a particle size typically less than 200μm.
The dispersion unit comprises a sampling cuvette that holds the sample and disper-
sant liquid together, the Hydro SV can contain a maximum volume of 7ml.
Hydro SM dispersion units

The Hydro SM is designed for use where the amount of sample available limits the
amount of dispersant that can be used to dilute it, or where just a small volume of
dispersant is available.
Depending on the length of sample tubing used to connect to the cell, a Hydro SM
will require a maximum dispersant volume of 120ml.
Page 1-4 MAN 0479

Additional accessories: Heater/chiller unit (not shown)

A facility exists to alter the temperature of the sample by connecting a heater/chiller
circulator unit to the water jacket connections at the front of the wet cell.
The heater/chiller circulator unit is not compatible with the Hydro SV.
Control of the Hydro dispersion units

The Hydro dispersion units can be controlled by two methods - via the Mastersizer
application software or manually.
 Automatically, as part of measurement protocol when controlled through a
Standard Operating Procedure (SOP). The software tells the user what they
need to do as the measurement progresses.
 Alternatively the dispersion unit can be controlled by a separate manual acces-
sory control dialogue. This will enable simple control of the dispersion unit,
allowing individual selection and operation of the units functionality. This is
useful for performing evaluation methodology before constructing a SOP.
 If a fully manual accessory is connected to the optical unit, this will not have an
automated or manual software control, but will be controlled directly.

Hydro MV and LV dispersion units

The following section explains the important aspects of the Hydro MV and LV dis-
persion units:
 How the sample dispersion is performed.
 The main features of the dispersion units.
 How to connect the dispersion unit to the Mastersizer optical unit and other
accessories.
How is the dispersion performed

The Hydro MV and LV operate in essentially the same way. The basic operation is
described below; a Hydro LV dispersion unit is shown.
1 2
ill 8696
The dispersion unit comprises a tank  that holds the sample and dispersant liq-
uid; up to 120ml for a Hydro MV, 600ml for a Hydro LV.
Page 1-6 MAN 0479

Aqueous or non-aqueous dispersant is added to the tank via either the standard
lower internally regulated inlet port (commonly used for aqueous samples) or the
upper externally regulated inlet port (commonly used for non-aqueous samples).
Alternatively the dispersant can be manually added directly into the tank.
A light positioned in the dispersion unit body above the tank will flash briefly
when the tank is filled to the correct level.
With the tank filled, a pump within the tank, controlled using the Mastersizer soft-
ware, circulates the dispersant from the ‘to cell’ port of the dispersion unit to the
wet cell  located in the optical unit, via the sample tubing. The dispersant is
pumped through the wet cell and then returns to the tank via the sample tubing
and the ‘from cell’ port.
Sample is added to the tank and dispersant as required. A stirrer within the tank
agitates the sample to stop it from settling or separating out; the pump then circu-
lates it through the system and wet cell to be measured using the optical unit and
software. Refer to the Mastersizer 3000 User Manual for advice on adding sam-
ple.
An ultrasonic transducer is provided to aid sample dispersion and can also be
used to remove bubbles from the flow path.
Note
The lower ‘to cell’ sample tubing has yellow identifier markings, whilst
the upper ‘from cell’ sample tubing has blue identifier markings.
Once the sample has been measured using the Mastersizer optical unit, it can be
disposed of using the drain outlet. The drain outlet is compatible with most aque-
ous and non-aqueous dispersants.
The Hydro MV and LV dispersion units contain two fluid handling valves con-
trolled from the application software:
 A internally regulated dispersant valve that opens to allow clean aqueous dis-
persant into the tank.
 A motor-driven drain valve that allows the tank to be drained.

Features of the Hydro MV / LV dispersion units.

This section identifies the main features of the Hydro MV (medium volume) and
LV (Large volume) dispersion units.
A Hydro LV dispersion unit is shown in the following illustration.
4
8
9
1
7
3 6
11
5 10 12
ill 8668
 Sampling tank  Lower Internally regulated disper-

sant inlet port
- for aqueous dispersants
 Sampling pump and stirrer  Upper Externally regulated disper-
sant inlet port
- for non-aqueous dispersants
 Ultrasonic transducer  To cell / From cell connections
 Tank cover  CAN connection
 Status indicator  Auxiliary connection
 Drain port  Drain button (MAZ3210/3310 only)
Sampling tank
The tank holds the sample and dispersant. The tank can hold up to 120ml (Hydro
MV) or 600ml (Hydro LV) of sample and dispersant prior for circulation through
the wet cell situated in the measurement area of the optical bench.
Page 1-8 MAN 0479

The sampling tank is normally filled using the dispersant inlet ports, though sam-
ple and dispersant can be poured directly into the tank if required. A light posi-
tioned in the dispersion unit body above the tank will flash briefly when the tank is
filled to the correct level.
Additionally the tank contains the pump and stirrer assembly, described in the
next section, whilst an ultrasonic transducer attached to the tank also helps to dis-
perse the sample.
Once a measurement has finished, the tank can be emptied automatically using a
drain valve in the base of the tank. The sampling fluid is emptied through the drain
pipe out to a sink or other waste container.
All functions of the tank area are controlled by the Mastersizer application software.
Sampling Tank features
The tank assembly incorporates these important additional features.
B D A C
 Tank light  Breather holes

 Over-flow (castellations)  Baffles
 Over-flow system and drain

An over-flow system exists underneath the metal shield on the top of the sam-
pling tank - this is indicated by castellations at the bottom edge of the shield.
If too much fluid is filled into the tank, any excess will overflow into here and
subsequently out of the drain pipe at the rear of the unit. Overfilling of the tank

may lead to particles being lost via the over-flow system, leading to an incorrect
particle size distribution being reported.
Caution!
If manually filling the tank, ensure that the tank does not overflow by fill-
ing it too quickly. Never overfill the tank as spillage may occur once the
pump starts. Clean any spillage off the covers immediately to prevent dam-
age.
 Breather hole
A breather hole is incorporated into the metal shield on the top of the sampling
tank. This is used to enable a sufficient draining rate for the tank when empty-
ing. Note that under filling of the tank may lead to air being entrained into
the liquid, again leading to an incorrect particle size being reported.
 Baffles
The tank incorporates additional baffles; these help interrupt the sample flow
and aid mixing.
Note
The level sensor in the dispersion unit stops the tank being overfilled
above a certain level. This level, when the dispersant is detected and the
tank light flashes, depends upon the liquid that has been used in the tank. A
threshold value needs to be applied to the level sensor for all liquids other
than water, so if the tank fails to fill properly then this threshold, for the
dispersant being used, may need adjusting. Refer to the Sample - Disper-
sant and accessory controls sections in the software chapter.
Notes on manually filling the tank:

 The tank should be filled slowly until the tank light flashes - this will indi-
cate the correct level for adding sample and running measurements. If the
tank is filled higher than this, sample and particles may be lost via the over-flow
system (drain), leading to an incorrect particle size distribution being reported.
 The tank fill indicator in the software provides the same function - refer to the
software chapter for description.
 Visibly the maximum fill level is just below the top of the tank baffle.
 The light is additionally used to illuminate both the tank and the sampling
fluid within.
Page 1-10 MAN 0479

Sampling pump and stirrer

The pump and stirrer keep the sample in suspension and continually circulate the
sample and dispersant through the wet cell.
The stirrer, located in the middle of the tank, agitates the sample/dispersant mix-
ture ensuring it is adequately dispersed prior to a measurement. The pump in the
base of the tank circulates the sample through the wet cell located in the measure-
ment area of the optical bench.
The pump and stirrer speed is controlled by the Mastersizer application software.
Warning!
Never put fingers into the tank when the pump/stirrer shaft is rotating.
Caution!
Never operate the pump/stirrer at more than half speed with the tank
empty.
Ultrasonic transducer
The ultrasonic transducer (not shown) is used to help disperse samples. The power
of the transducer is controlled through the Mastersizer application software.
Warning!
Due to the possible risk of sonication of the blood and its unknown effects,
never put fingers in the tank when the ultrasonic transducer is in opera-
tion.
Ultrasonic transducers have a recommended lifetime; this is with respect to the

amount usage they have been subjected to during any sample preparation. The
Mastersizer application software monitors this usage and will indicate, in the notifi-
cation field, when the ultrasonic transducer is reaching, and has reached, its recom-
mended usage time. When an ultrasonic transducer warning appears contact your
Malvern representative for information on ordering a replacement transducer.
Note
The Ultrasonics will switch off automatically after 20 minutes continuous
use.

Tank cover
The tank cover is there to protect the operator from splashes from the tank. Always
replace the cover after adding sample to the tank.
The tank cover is removed and replaced by holding on to the raised portions of the
cover.
Status indicator
A status indicator illuminates to indicate the operating condition when the disper-
sion unit is powered up:
 Blue - full intensity
The dispersion unit is functioning correctly and the cell has been loaded into
the optical bench, (i.e. the dispersion unit is “active”).
 Blue - pulsing
The dispersion unit is functioning correctly but its cell has not been loaded
into the optical bench, (i.e. the dispersion unit is at “standby”).
If communication has failed with the optical unit the status indicator will also
be on standby, but the optical unit indicator will be off.
Drain port
The drain port is the exit point where sample/dispersant leaves the dispersion unit.
A warning triangle warns that the contents of the tank are drained from this pipe.
The risk depends on the hazardous nature of the dispersants/samples being meas-
ured.
Refer to the connecting the dispersion units section, and the site requirements
section in the Basic guide, for advice on the drain/waste positioning.
Connecting the drain pipe
To connect the drain pipe:
1. Insert the pipe into the drain port fitting.
2. Tighten the collar nut until fully secure.
 Removal is the reverse of the procedure.
A 90 degree support bracket can be fitted to the drain tube to direct the waste fluid
into the drain. Replacement drain pipes are available direct from Malvern Instru-
ments.
Note
It is important that the draining end of the drain pipe is above the level of
the waste liquid at all times. It must not be under the surface of the liquid
otherwise the dispersion unit will not drain efficiently.
Page 1-12 MAN 0479

Lower internally regulated dispersant inlet port

 For aqueous dispersants
The lower dispersant input is the inlet port which is connected to a clean source of
dispersant. For most sample applications the dispersant will be water (aqueous).
The lower dispersant inlet port is not chemically compatible due to the presence
of an internal pressure regulator. This controls the dispersant input flow.
In the software this is referred to as Auto-
matic Fill (Internal). This is explained fully
later in the manual.
The valve will be in a closed state when in
standby or when power is supplied to the
accessory.
 Refer to the Mastersizer 3000 User manual and Basic guide for the site
requirements of the dispersant input.
Connecting the lower/aqueous dispersant tubing.
To connect the supplied aqueous dispersant tubing:
1. Press the lock down on the connection to open (if closed).
2. Insert the aqueous dispersant tubing into the connection until the lock is
engaged.
3. Pull the dispersant tubing gently to ensure it is secure.
 To remove, Press the lock down on the connection and pull tubing to
remove.
Suitable aqueous tubing is available direct from Malvern Instruments.
Note
Using the Accessory controls in the SOP, the inlet ports can be used for
both tank filling, and cleaning. Refer to the Sample Dispersion-Acces-
sory SOP description.
Upper externally regulated dispersant inlet port

 For non-aqueous dispersants
For non-aqueous samples a direct input is available. This will be connected to a
separately enabled dispersant supply.
The upper dispersant inlet port is chemically compatible - refer to the chemical
compatibility chart in the Appendix.

In the software this is referred to as Auto-

matic Fill (External). This is explained fully
later in the manual.
The valve will be in a closed state when in
standby or when power is supplied to the
accessory.
 Refer to the Mastersizer 3000 User manual and Basic guide for the site
requirements of the dispersant input.
Note
The upper dispersant inlet has no internal regulator controlling the disper-
sant input. It is therefore recommended that the supply to this inlet is ena-
bled and controlled through the use of an external pump and cable.
Connecting the upper/non-aqueous dispersant tubing

To connect the non-aqueous dispersant tubing:
1. The non-aqueous dispersant tubing is simply pushed onto the non-aqueous
inlet port.
2. Ensure it is pushed on as fully as possible to prevent any leaking risk.
Suitably compatible tubing must be used for any non-aqueous solvent used.
The inlet pipe has an outside diameter of 1/4 inch (6.35mm).
Suitable non-aqueous tubing is available direct from Malvern Instruments.
Note
Using the Accessory controls in the SOP, the inlet ports can be used for
both tank filling, and cleaning. Refer to the Sample Dispersion -Accessory
SOP description.
To cell / From cell connections

The sample from the dispersion unit is circulated through the cell via ‘to cell’ and
‘from cell’ connections and connected sample tubing.
To cell connection
The bottom connection is for connecting the wet cell sample outward tubing;
where the sample leaves the dispersion unit for the bottom connection of the wet
cell (yellow collar) in the optical unit.
The ‘to cell’ connection has yellow identifier markings.
Page 1-14 MAN 0479

From cell connection

The top connection is for connecting the wet cell sample return tubing; where the
sample returns to the dispersion unit from the top connection of the wet cell (blue
collar) in the optical unit.
The ‘from cell’ connection has blue identifier markings.
Connecting the wet cell sample tubing.
To connect the wet cell tubing:
1. Unscrew the tubing connection cap.
2. Insert the cap over the wet cell tubing.
3. Push the sample tubing onto the connection.
4. Screw the tubing connection cap back to the connection, until secure.
5. Repeat for all other wet cell connections on the dispersion units and the wet
cell.
 Removal is the reverse of the procedure. Stop the stirrer and ensure the cell
and dispersion unit are empty before removing.
Suitable aqueous and non-aqueous wet cell tubing is available direct from Malvern
Instrument.
CAN connection
The CAN connection provides both the communications and power to operate the
dispersion unit.
The CAN cable is connected from the CAN connection to one of the CAN con-
nections on the side of the optical unit.
Auxiliary connector
When required, the auxiliary connector (AUX) is used for connecting any acces-
sory that can be used with the dispersion unit.
Drain Button (MAZ3210/3310 only)

Press this button to drain the sample from the dispersion unit. The drain function
only works while the button is pressed; releasing the button will stop the draining
operation.
Note
The drain operation will not function when the dispersion unit is per-
forming a measurement. The function will only work when in standby
mode.

Hydro EV dispersion unit

The following section explains the important aspects of the Hydro EV (extended
volume) dispersion units:
accessories.

3
1
2
ill 8763
The Hydro EV dispersion unit uses a standard laboratory beaker  to hold the
sample and dispersant liquid. Standard beaker sizes recommended are 600ml and
1000ml.
The pump head is tilted back, and a beaker containing an aqueous or non-aqueous
dispersant is then placed onto the beaker holder at the front of the unit. The pump
head is then tilted forward, lowering the pump arm into the beaker, and allowing
Page 1-16 MAN 0479

the sample to be pumped. Raising the pump head at any time will automatically
stop the pumping action.
The pump , controlled using the Mastersizer application software, circulates the
dispersant from the ‘to cell’ port of the dispersion unit to the wet cell  located in
the optical bench, via the sample tubing. The dispersant is pumped through the
wet cell and then returns to the tank via the sample tubing and the ‘from cell’
port.
Sample is then added manually to the beaker by the user, as required. The stirrer
 then agitates the sample, to stop it from settling or separating out, and then cir-
culates it through the system and wet cell to be measured using the optical unit and
software. Refer to the Mastersizer 3000 User Manual for advice on adding sam-
ple.
An ultrasonic transducer is provided to aid sample dispersion and can also be used
to remove bubbles from the flow path.
Once the sample has been measured using the Mastersizer optical unit, the pump
arm can be raised and the sampling beaker withdrawn, and the sample disposed of.
Features of the Hydro EV dispersion unit

This section identifies the main features of the Hydro EV dispersion units
The features are:
Sampling area / beaker

The sampling beaker holds the sample and dispersant. A beaker of 600ml or
1000ml capacity is used to contain the sample and dispersant prior for circulation
through the wet cell situated in the measurement area of the optical bench. The
beaker should be no taller than 15cm.
Dispersant is added directly into the beaker by the user, and then placed onto the
sampling area drip tray; sample is then added as required.
Caution!
Do not overfill the beaker as spillage may occur once the pump starts.
Clean any spillage off the covers immediately to prevent damage.
The tank contains the pump and stirrer assembly, described below, whilst an ultra-
sonic transducer (not shown) within the sample flow path also helps to disperse the
sample.
All functions of the tank area are controlled by the Mastersizer application software.

Once a measurement has finished, the pump head can be raised and the beaker
removed and emptied in to a sink or other waste container.
3 7
6 8 9
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 Sampling area / beaker  Status indicator

 Drip tray / beaker holder  To cell / From cell connections
 Pump head  CAN connection
 Sampling pump and stirrer  Auxiliary connection
 Ultrasonic transducer
Drip tray / beaker holder

The beaker holder supports the chosen sample beaker under the pump head. By
flipping the holder over it can be used to support a standard 1000ml laboratory
beaker on one side, and 600ml or smaller beakers on the other.
The drip tray under the beaker holder collects any minor spillages from the pump/
stirrer head. The tray can be removed to allow easy cleaning by lifting it up by the
cut-out on the left hand side.
Page 1-18 MAN 0479

Pump head
By holding the pump head by the indent and front face, the pump head can be
raised and lowered into the beaker of sample. When the pump head is lifted, the
pumping action automatically stops and the cell and sample pipes are drained of the
sample and dispersant.
A light, positioned in the base of the pump head above the tank, is used to illumi-
nate both the beaker and the sampling fluid within.
The sampling pump and stirrer (described below) is attached to the bottom of the
pump head, whilst an ultrasonic transducer (not shown) within the sample flow
path also helps to disperse the sample.

The sampling pump and stirrer keep the sample in suspension and continually cir-
culate the sample and dispersant through the wet cell.
ill 8762
The stirrer, located at the base the sampling pump, agitates the sample/dispersant
mixture ensuring it is adequately dispersed prior to a measurement. The central
sampling pump (in the middle of the assembly) circulates the sample through the
wet cell located in the measurement area of the optical bench.
The pump and stirrer speed is controlled by the Mastersizer application software.
Warning!
Never run the pump/stirrer without the beaker in place.

Warning!
Never put fingers into the beaker when the pump/stirrer shaft is rotating.
Caution!
empty.
 Ultrasonic transducer
The ultrasonic transducer (not shown) within the pump head is used to help dis-
perse samples. The power of the transducer and the ultrasonic timer are controlled
sing the Mastersizer Application software.
Warning!
Due to the possible risk of sonication of the blood and its unknown effects,
never place fingers in the beaker when the ultrasonic transducer is in oper-
ation.
Ultrasonic transducers have a recommended lifetime; this is with respect to the

amount usage they have been subjected to during any sample preparation. The
Mastersizer application software monitors this usage and will indicate, in the notifi-
cation field, when the ultrasonic transducer is reaching, and has reached, its recom-
mended usage time. When an ultrasonic transducer warning appears contact your
Malvern representative for information on ordering a replacement transducer.
Note
use.
Status indicator
A status indicator illuminates to indicate the operating condition when the disper-
sion unit is powered up:
 Blue - full intensity
The dispersion unit is functioning correctly and the cell has been loaded into
the optical bench, (i.e. the dispersion unit is “active”).
 Blue - pulsing
The dispersion unit is functioning correctly but its cell has not been loaded
into the optical bench, (i.e. the dispersion unit is at “standby”).
Page 1-20 MAN 0479

If communication has failed with the optical unit the status indicator will also
be on standby, but the optical unit indicator will be off.

ill 8898
To cell connection
The ‘to cell’ connection has yellow identifier markings.
The ‘from cell’ connection has blue identifier markings.
Connecting the wet cell sample tubing
1. Push the wet cell tubing onto the connection. Ensure it is pushed on fully to
prevent any leaking risk.
2. Place a retaining clip over the connected tubing and compress using pliers to
provide a secure connection.

3. Follow the Hydro MV/LV wet cell connection procedure for connection to the
wet cell.
 Removal is the reverse of the procedure. Ensure the cell is empty before
removing.
The retaining clips are removed by twisting apart using pliers - this will sepa-
rate the teeth allowing the clip to be removed.
Instruments.
CAN connection
dispersion unit.
Auxiliary connector
When required, the auxiliary connector (AUX) is used for connecting any acces-
sory that can be used with the dispersion unit.
Hydro SM dispersion unit

The following section explains the important aspects of the Hydro SM dispersion
units:
accessories.

The Hydro SM enables the Mastersizer to be used for particle-in-liquid particle
sizing, where the amount of sample available limits the amount of dispersant that
can be used to dilute it, or where just a small volume of dispersant is available. This
is ideal when the sample or dispersant is toxic or expensive.
Page 1-22 MAN 0479

1 3 2
ill 8764
The dispersion unit comprises a tank  that holds the sample and dispersant liq-
uid; depending on the length of tubing used, the Hydro SM will require a maxi-
mum volume of 120ml.
Aqueous or non-aqueous dispersant is manually added into the tank. A pump
within the tank, its speed controlled using the dispersion unit controller , circu-
lates the dispersant from the ‘to cell’ port of the dispersion unit to the wet cell 
located in the optical unit, via the sample tubing. The dispersant is pumped
through the wet cell and then returns to the tank via the sample tubing and the
‘from cell’ port.
Using a pipette or spatula, sample is added to the tank and dispersant as required. A
stirrer within the tank then agitates the sample, to stop it from settling or separat-
ing out, and then circulates it through the system and wet cell to be measured using
the optical unit and software. Refer to the Mastersizer 3000 User Manual for
advice on adding sample
disposed of using the drain outlet. The drain outlet is compatible with most aque-
ous and non-aqueous dispersants.

Features of the dispersion unit

This section identifies the main features of the Hydro SM dispersion unit.
The features are:
1
5
2
4
ill 8765
Page 1-24 MAN 0479

 Dispersion unit and sampling tank  Drain port and lever

 Sampling pump and stirrer  To cell / From cell connections
 Tank cover  Dispersion unit controller
Dispersion unit and sampling tank

The dispersion unit is where the sample and the dispersant is mixed and then
pumped to the flow cell of the optical bench.
The sampling tank holds the sample and dispersant. The tank can hold a maximum
of 120ml of sample and dispersant prior for circulation through the wet cell situ-
ated in the measurement area of the optical bench. Sample and dispersant are
poured directly into the tank as required.
Caution!
Do not overfill the beaker as spillage may occur once the pump starts.
Clean any spillage off the covers immediately to prevent damage.
The tank contains the pump and stirrer assembly, described below.
Once a measurement has finished, the tank can be emptied using the drain valve
lever in the base of the dispersion unit. The sampling fluid is emptied through the
drain pipe out to a sink or other waste container.

The pump and stirrer keep the sample in suspension and continually circulate the
sample and dispersant through the wet cell.
The stirrer, located in the middle of the tank, agitates the sample/dispersant mix-
ture ensuring it is adequately dispersed prior to a measurement. The pump in the
base of the tank circulates the sample through the wet cell located in the measure-
ment area of the optical bench.
The pump and stirrer speed is controlled by the Dispersion unit controller.
Warning!
Never put fingers into the tank when the pump/stirrer shaft is rotating.
Caution!
empty.

Tank cover
The tank cover is used to protect the operator from splashes from the tank and pre-
vent any ingress of dust when the system is left for extended periods. It also pre-
vents evaporation or the release of fumes when the system is in use (e.g. when
using a noxious solvent or sample).
Always replace the cover after adding sample to the tank.
Drain port and lever

The drain port is the exit point where sample/dispersant leaves the dispersion unit.
A warning triangle warns that the contents of the tank are drained from this pipe.
The risk depends on the hazardous nature of the dispersants/samples being meas-
ured.
Refer to the connection the dispersion units section, and the site requirements
section in the Basic guide, for advice on the drain/waste positioning.
The drain port is operated using the drain lever. The drain is closed when the lever
is fully back, and opened by moving the lever forward.
Connecting the drain pipe
To connect the drain pipe:
1. Place the jubilee clip over the drain pipe.
1. Push the pipe over the drain port fitting.
2. Tighten the jubilee clip until fully secure.
Replacement drain pipes are available direct from Malvern Instruments.

To cell connection
On the Hydro wet cell, the ‘to cell’ connection has yellow identifier markings.
On the Hydro wet cell, the ‘from cell’ connection has blue identifier markings.
Page 1-26 MAN 0479

Connecting the wet cell sample tubing

1. Push the wet cell tubing onto the connection.
2. Ensure it is pushed on as fully as possible to prevent any leaking risk.
3. Follow the Hydro MV/LV wet cell connection procedure for connection to the
wet cell.
removing.
Instruments.
Dispersion unit controller

The Dispersion unit controller is used to power and control the dispersion unit.
B A C D E
ill 8766
 Pump/stirrer speed control  Power and CAN connection

 Pump speed display  Dispersion unit connection
 Power switch
Pump/stirrer speed control

This control alters the speed of the stirrer/pump and thus the flow rate of sample/
dispersant through the cell. When it is turned fully anti-clockwise the pump speed
is zero. When it’s turned fully clockwise, the pump speed is at its maximum.

Pump speed display

Indicates the speed of the pump stirrer in rpm.
Power switch
Press once to power on the unit, press again to power off.
Power and CAN connection
The CAN connection provides the power to operate the dispersion unit.
Dispersion unit connection
The dispersion unit connection provides both the control signals and power to the
dispersion unit from the dispersion unit controller.
Page 1-28 MAN 0479

Hydro SV dispersion unit

The following section explains the important aspects of the Hydro SV (small vol-
ume) manual dispersion unit:
accessories.

The Hydro SV dispersion unit enables the Mastersizer to be used for particle-in-
liquid particle sizing, where the amount of sample available limits the amount of
dispersant that can be used to dilute it, or where just a small volume of dispersant is
available. This is ideal when the sample or dispersant is toxic or expensive.
The Hydro SV manual dispersion unit is designed for the measurement of small
amounts of a sample with a particle size typically less than 200μm.
2 1
ill 8855
 Hydro SV dispersion unit  CAN connection to Optical unit

The dispersion unit comprises a sampling cuvette that holds the sample and disper-
sant liquid together, the Hydro SV can contain a maximum volume of 7ml.
Aqueous or non-aqueous dispersant is manually added into the sampling cuvette. A
stirrer bar is added into the cuvette, and the cuvette then inserted into the cuvette
holder within the Hydro SV cell.
The complete cell is inserted into the cell bay of the optical unit. With the cell in
position, a motor within the cell rotates the stirrer bar continually circulating the
dispersant around the cuvette ensuring it is adequately dispersed prior to a meas-
urement. The stirrer speed is controlled using the Mastersizer software or front
panel dial. Refer to the Mastersizer 3000 User Manual for advice on adding sample.
disposed of by first removing the SV cell, and then removing the cuvette.
Note
As the Hydro SV incorporates a magnetic stirrer for dispersing the sample,
it is recommended that the Mastersizer 3000 is not used anywhere near
external magnetic fields, or used where stationary magnets may impact.
These may affect the effectiveness of the stirrer bar sample dispersion.
Recommended sample criteria

 Size typically less than 200μm
(sample and dispersant dependent)
 Non-magnetic samples only
 Non-abrasive samples
Page 1-30 MAN 0479

Features of the dispersion unit

This section identifies the main features of the Hydro SV dispersion unit. The fea-
tures are:
10
5 7 3
ill 8856
 Cell shroud  Pipette entry

 Shutter activation arm  Stirrer bar motor
 Sampling cuvette and cuvette lid  Stirrer speed display
 Cell handle and unlocking button  Stirrer speed control / On/off
 Drip tray  Power and CAN connection
Note
The Hydro SV dispersion unit will generally be referred to as the "Hydro
SV" or "SV cell" or just "cell".

Cell shroud
The cell shroud prevents stray light entering the measurement area that may affect
a measurement. More importantly, the cell shroud stops human access to laser
radiation.
The cell shroud incorporates an arm that will open a mechanical shutter when
inserted into the cell bay of the optical unit. With the shutter open laser light is
allowed into the sample area. When the SV cell is withdrawn the shutter will move
back into position to prevent the emission of any laser light.
The system should never be used if the cell shroud or shutter arm is damaged.
Sampling cuvette assembly

The sampling cuvette is where the measurement of the sample is performed. The
cuvette windows allow the analyzer beam of the optical unit to pass through the
cuvette and hence the particle field. For optimum measurement analysis it is vital
that the cuvette and cuvette windows are kept clean of all residue.
A cuvette lid can be fitted to prevent any dust ingress into the cuvette, before plac-
ing the cuvette into the SV cell.
For details on how to fill the cuvette with dispersant and then sample, refer to the
Filling the cuvette section.
The sampling cuvette can be removed to allow cleaning; the cuvette locks are
rotated and the complete cuvette can be removed. The cuvette windows are deli-
cate and should be treated with caution; refer to the Maintenance chapter for
details on removing the cuvette and cleaning the cuvette windows.
The cuvette has a maximum capacity of 7ml in total:
Max. (7ml)
Min. (6ml)
ill 8857
Page 1-32 MAN 0479

 This corresponding to a minimum volume of 6ml dispersant + 1ml maximum

of sample. If more than 7ml of sample/dispersant is inserted the cuvette will
overflow.
 The maximum volume when filled to the bottom of the window chamfer is
7ml.
 The minimum volume when filled to the marks on the metal work as shown
below is 6ml. This is the amount of dispersant that the cuvette must be filled
with to ensure the background measurements are suitable.
Cell handle and unlocking button

When the SV cell is inserted into the sample area of the optical unit, a locking
motor will pull the cell down and lock it into a defined measurement position. This
ensures that the cell is always optimally located before any measurements are per-
formed. To remove the cell, press the button on the cell handle. This will release
the locking motor and raise the cell slightly ready to be withdrawn from the optical
unit.
Warning!
Never attempt to lift the optical unit by the locking handle of the cell. Read
the Health and Safety section in the Mastersizer 3000 Basic Guide for
details of correct moving techniques.
Drip tray
Any overspills will be captured within the drip tray and drained through a drain
port at the front of the cell and optical unit. If any liquid is noticed in the drip tray,
remove the cell and tip the contents away.
Pipette entry
Note
The pipette must be inserted fully before injecting the sample. Do not
drip sample into the top of the pipette entry hole.
The pipette entry is used for adding the sample into the cuvette once the SV cell has
been inserted into the cell bay of the optical unit. This enables sample addition to
be performed within the required obscuration range. The cuvette lid must be
removed first to allow this.
Sample is added by inserting the pipette until it stops. A guide within the pipette
entry ensures the pipette is positioned above the cuvette opening. Sample is then
injected as required. Take care not to overfill the cuvette.

Note
The internal pipette guide is curved to prevent any laser light escaping dur-
ing the sample addition.
The pipette must be removed once the sample is added. Refer to the Filling the
cuvette section.
Stirrer speed control, display and motor

Turning on:
With the Power and CAN cable connected, power the unit ON by pressing on the
speed control dial; pressing again will turn the unit OFF.
The Hydro SV does not need to be located into the cell bay of the optical unit
before it can be turned on. This is to allow the cuvette to be filled, the sample agi-
tated and any extra actions such as checking for bubbles, liquid levels, or adding
more sample/dispersant before being inserted into the cell bay.
Stirring the sample
In the SV cell a stirrer bar is placed into the cuvette, and this is used to the keep
the sample in suspension, continually circulating the sample/dispersant mixture
around the cuvette mixture ensuring it is adequately dispersed prior to a measure-
ment. The stirrer bar has a magnetic core which couples to the magnets on the stir-
rer motor head. The stirrer motor then rotates the stirrer bar at a speed determined
by the SOP or the speed control dial on the front of the unit.
 The speed range is 500 to 1800 rpm.
 Pressing the dial turns the stirrer on and off.
Note
The software stirrer slider bar, and the SV front panel manual control dial
are synchronized. Altering the slider bar will alter the front panel display;
and vice-versa
Stirrer bar care

Refer to the maintenance chapter for details of inspecting, handling and cleaning
the stirrer bar
Power and CAN connection

dispersion unit.
Page 1-34 MAN 0479

Filling the cuvette
Note
The cuvette and stirrer bar must be cleaned thoroughly before first use
and before performing any subsequent measurements. Refer to the main-
tenance chapter for details.
The technique for filling the cuvette used with the Hydro SV is the same as for any
cuvette, ensuing that the dispersant is carefully injected into the cuvette with the
minimum of bubbles produced.
The cuvette is filled and inserted into the SV cell while the cell is out of the optical
unit.
Note
It is recommend to not use dispersants with too high a viscosity. The
greater the viscosity of the dispersant, the less effective the stirrer bar sam-
ple dispersion will be.
Note
Any aqueous dispersant must be degassed fully before use. For aqueous
use only correctly degassed DI water (negligible dissolved C02), or signifi-
cant bubbles will form on the windows and stirrer and will affect the qual-
ity of the measurement.
Filling the syringe:

 If using an aqueous dispersant, a plastic syringe is sufficient
 A glass syringe may be required for any non-aqueous dispersants
On the end of the syringe fit the syringe tip,
Place the syringe tip into the dispersant, then pull the plunger back to draw the dis-
persant into the syringe; to a minimum of 6ml.
Note
The maximum volume of the cuvette is 7ml. This corresponding to a min-
imum volume of 6ml dispersant + 1ml maximum of sample. If more than
7ml of sample/dispersant is inserted the cuvette will overflow.

ill 8858
To fill the cuvette:
Hold the cuvette at an angle, and with the syringe tip placed along an inner side of
cuvette, carefully inject the sample. The sample will flow along the side of the
cuvette slowly filling it up.
Rotate the cuvette while it is being filled, to prevent any spillage when as the maxi-
mum fill level is reached.
Continue filling until the minimum volume fill mark is reached (minimum 6ml).
ill 8859
Page 1-36 MAN 0479

Place a stirrer bar into the filled cuvette.
Note
The stirrer bar must first be washed in the dispersant being used in the
measurement before inserted into the cuvette.
ill 8860
Place the cuvette lid on to the cuvette and place into the SV cell. Datum/position-
ing points in the corners of the cuvette holder aid correct insertion. The spout on
the top of the cuvette must be facing the front of the cell once inserted.
Secure with the cuvette clamps – ensure both clamps are fully in place after loading
the cuvette into the SV cell. Failure to secure the clamps may cause alignment and
measurement problems
You will note that the stirrer bar, will attach to the stirrer motor.
Press the speed dial to turn the SV cell on and test the SV operates correctly; the
stirrer bar should spin.
ill 8861

Place the SV cell into the Cell bay of the optical unit and Start the measurement.
Adding sample:
Take a pipette and draw the sample into it; filling until the maximum fill mark is
reached (maximum 1ml).
Note
The cuvette can hold a maximum total volume of 7ml of sample and dis-
persant. If the amount of dispersant in the cuvette is more than 6ml then
the amount of sample used must be less than 1ml, otherwise the cuvette
will overflow.
ill 8862
When in optical unit:
Note
To perform this action the cuvette lid must not be fitted.
Specific pipettes are required for use in the optical unit. When the measurement
requests the sample to be added, take the pipette and insert into the pipette access
until it stops and cannot be inserted anymore. While monitoring the live display,
add sample until the obscuration is in range.
Remove the pipette once the sample has been added.
Page 1-38 MAN 0479

ill 8863
Press Start to continue and complete the measurement.
When not in optical unit:
When the measurement requests the sample to be added, press the unlock button
on the cell handle and remove the cell.
Unlock the cuvette locks and place the cuvette alongside the SV cell. Ensure the
cuvette is kept vertical at all times.
Take a pipette and draw the sample into it; filling until the maximum fill mark is
reached (maximum 1ml), then insert the sample into the top of the cuvette.
ill 8864

Take the cuvette and place into the SV cell. Secure with the cuvette locks.
You will note that the stirrer bar, will attach to the stirrer motor.
Press the speed dial to turn the Hydro SV on and test the SV operates correctly; the
stirrer bar should spin
Insert the SV cell into the optical bench. The instrument will again align, and the
obscuration should then be checked.
If ok, continue with the measurement; if obscuration is not ok, repeat the sample
insertion.
Advanced measurement cuvette filling.

The cuvette has a maximum capacity of 7ml in total. This corresponds to a mini-
mum volume of 6ml dispersant + 1ml maximum of sample.
If more than 7ml of sample and dispersant is inserted the cuvette will overflow;
therefore if the amount of pre-dispersed sample required to achieve the correct
obscuration, will be greater than 1ml, then this can be achieved by folloing the
below actions:
 First fill the cuvette with dispersant (6ml minimum).
 Insert into SV cell and instrument, and perform a background and initial align-
ment.
 The SV cell can then be removed, and using the syringe (with syringe tip
attached) extract an amount of dispersant.
 Sample is then added back into the cuvette, again to a 6ml minimum level
 The SV cell is then reinserted into the instrument, the alignment redone, and
the obscuration checked.
 If the obscuration is incorrect, remove the cuvette and add either more sample
or dispersant as required.
 Repeat until the obscuration is correct, then continue with the measurement.
Page 1-40 MAN 0479

Hydro series wet cell

The Hydro series wet cell is used with the Hydro MV, LV, EV and SM wet disper-
sion units.
Caution!
The flow cell is an optical device. Scratches to the surfaces of the cell may
affect performance.
Each Hydro dispersion unit will be connected to a matching Hydro series wet cell.
Two wet cells are available, for use with aqueous or non-aqueous based samples.
A chemically compatible wet

A standard wet cell for use
cell for use with non-aqueous
with aqueous samples, identi-
samples, identified by a red
fied by a blue badge.
badge with an R.
The dispersion unit continually circulates the sample/dispersant from the disper-
sion unit to the wet cell and through the analyser beam of the optical unit so that a
measurement can be performed.
The cell windows in the wet cell are critical parts of the measurement optical path
of the system and should be kept clean and free from scratches at all times. Refer to
the Maintenance chapter for details on cleaning/maintaining the cell.
Note
If the cell is not used for short periods (up to 24 hours), leave the cell and
beaker full of clean dispersant so that the cell windows do not dry out,
leaving smears or water marks on the window surface. If the cell is not to
be used for longer periods, remove and dry the cell windows.
Features of the wet cell

Cell shroud
The cell shroud prevents stray light entering the measurement area that may affect
a measurement. More importantly, the cell shroud stops human access to laser
radiation.
The cell shroud incorporates an arm that will open a mechanical shutter when
inserted into the optical unit. With the shutter open laser light is allowed into the
sample area. When the cell is withdrawn the shutter will move back into position to
prevent the emission of any laser light.

The system should never be used if the cell shroud or shutter arm is damaged.
3 5
ill 8672
 Cell shroud  Drip tray

 Shutter activation arm  To cell / From cell connections
 Sampling wet cell, cell windows  Water jacket connections (Heat
and seals exchanger)
 Cell handle and unlocking button
Sampling wet cell, cell windows and seals

The sampling wet cell is where the measurement of the sample is performed. The
cell windows allow the analyser beam of the optical unit to pass through the cell
and hence the particle field. For optimum measurement analysis it is vital that the
cell and cell windows are kept clean of all residue.
Page 1-42 MAN 0479

The cell windows can be removed to allow cleaning; the cell lock handle is
rotated and the front plate of the cell, containing a cell window and seal pair,
removed. The cell windows are delicate and should be treated with caution; refer to
the Maintenance chapter for details on removing the front plate and cleaning the
cell windows.
The cell window seals prevent the windows from leaking. Inspect them regularly,
especially if aggressive solvents are used as a dispersant. Details on changing the
seals can be found in the Maintenance chapter.
 For the standard aqueous wet cell (blue badge) Fluoroelastomer (FKM)
seals are fitted.
 For the chemically compatible cell (red badge) Perfluoroelastomer (FFKM)
seals are fitted.
Cell handle and unlocking button

When the cell is inserted into the sample area of the optical unit, a locking motor
will pull the cell down and lock it into a defined measurement position. This
ensures that the cell is always optimally located before any measurements are per-
formed.
To remove the cell, press the button on the cell handle. This will release the lock-
ing motor and raise the cell slightly ready to be withdrawn from the optical unit.
Warning!
Never attempt to lift the optical unit by the locking handle of the cell. Read
the Health and Safety section in the Mastersizer 3000 Basic Guide for
details of correct moving techniques.
Drip tray
Any small leaks will be captured within the drip tray and drained through a drain
port at the front of the wet cell and optical unit. If any liquid is noticed in the drip
tray, remove the cell and tip the contents away. Locate and fix any leaks.

The sample from the dispersion unit is circulated through the cell via the ‘to cell’
and ‘from cell’ connections and connected sample tubing.
To cell connection
The bottom connection is for connecting the sample tube from the dispersion
unit. It is important that the sample flows up through the cell so that any bubbles in
the flow path can escape.
The incoming ‘to cell’ connection has yellow identifier markings.


sample/dispersant returns to the dispersion unit from the wet cell in the optical
unit.
The returning ‘from cell’ connection has blue identifier markings.
Connecting the wet cell sample tubing.
1. Using the supplied spanner or with fingers, unscrew the connection cap.
2. Insert the cap over the wet cell tubing.
3. Push the sample tubing onto the connection.
4. Screw the connection cap back to the connection, until secure.
5. Repeat for all other wet cell connections on the dispersion units and the wet
cell.
removing.
Instruments.
Warning!
Fully drain the cell and sample tube before attempting to disconnect the
cell.
Water jacket connections (Heat exchanger)

A facility exists to alter the temperature of the sample by connecting a heater/chiller
circulator unit to the water jacket connections  at the front of the cell.
 Maximum pressure for water jacket connections: 0.5 bar g.
Page 1-44 MAN 0479

ill 8673
 Water jacket connections (inlet /  Water jacket

outlet ports)
The Heat exchanger consists of a 'jacket’ that is wrapped around the flow cell input
and output pipes. Into this jacket cooling/heating liquid is fed to cool/heat the sam-
ple. The heat exchanger can be used for two functions:
 To heat or cool the sample so that sample measurements can be performed at
different temperatures.
 To eliminate temperature fluctuations after any sonication of the sample. This
can be important when working with some organic solvents, where tempera-
ture fluctuations can cause a slight misalignment of the system. This misalign-
ment is caused by the changes in refractive index that are observed in solvents
as the temperature changes. This may cause the presence of large particles to be
reported and thus affect the particle size distribution measured by the Master-
sizer system.
The water cooling would normally be provided by an external heater/chiller circu-
lator unit. This will be connected to the inlet  and outlet  ports on the front
of the wet cell.
Always fill from the bottom inlet connection . This is to prevent any air bub-
bles being caught in the heat exchanger arrangement.

For most applications the heater/chiller fluid will be water.

 Refer to the Mastersizer 3000 user manual and Basic guide for the site
requirements of the heater/chiller fluid connections.
Connecting the heater/chiller tubing
To connect the heater/chiller tubing:
1. Press the lock down on the connection to open.
2. Insert the heater / chiller tubing into the connection until the lock is engaged.
3. Pull the dispersant tubing gently to ensure it is secure.
Removal is the reverse of the procedure.
Page 1-46 MAN 0479

Connecting the dispersion units

Connection of the Hydro dispersion units is described in this section. The Mas-
tersizer 3000 User Manual details specific connections to the optical unit.
If using a peristaltic pump, refer to the connection diagram later in this chapter.
Hydro MV and LV connections
HYDRO
3
2
4
5
8
2m max
ill 8674
 Power cable from External PSU  Heater / chiller connections

(optional)
 CAN/Power cable  Dispersant input: aqueous
 Computer connection (USB)  Dispersant input: non-aqueous
 Sample tubing to and from cell  Drain pipe to waste

Note
The drain/waste must be within 2m of the dispersion unit and lower than
the bench surface, with the drain tube sloping gently downhill and have no
loops or kinks, so any liquid drains efficiently due to gravity. It can be a
normal sink, provided the sample and dispersant are non-hazardous.
Hydro SV connections
3
2
ill 8854
 Power cable from External PSU  Computer connection (USB)

 CAN cable
Page 1-48 MAN 0479

Hydro SM connections
HYDRO
3
2
4 5
ill 8767

 CAN cable  Controller unit connection
 Computer connection (USB)  Drain pipe to waste
 Sample tubing to and from cell
Note
The drain/waste must be within 2m of the dispersion unit and lower than
the bench surface, with the drain tube sloping gently downhill and have no
loops or kinks, so any liquid drains efficiently due to gravity. It can be a
normal sink, provided the sample and dispersant are non-hazardous.

Hydro EV connections
HYDRO
3
2
4 5
ill 8675

(optional)
 CAN/Power cable
 Computer connection (USB)
 Sample tubing to and from cell
Page 1-50 MAN 0479

External dispersant pump.

Using the auxiliary connector on the rear of the dispersion unit an externally ena-
bled pump can be connected to control the flow of dispersant from an external
source into the tank via the upper dispersant inlet port.
Note
The External dispersant pump and external triggering control is only com-
patible with later versions of software, please contact Malvern for details.
Malvern supplied peristaltic pump

Malvern supplies a peristaltic pump that can be connected and plumbed into the
Hydro LV and Hydro MV dispersion units. The pump will be used in conjunction
with the software to activate when a specific fill or clean routine is selected.
Supplied Pump
components Auxiliary Control cable
Tubing. For chemical compatibility of the tubing, refer to the
appendix.
Connection
The below illustration and paragraphs describe how to use the peristaltic pump
when connected into the Mastersizer 3000 system.
4
2
3
1
110
? 240
5
ill 8893
 Power cable to Pump  Dispersant inlet

 Pumphead  Auxiliary control cable
 Dispersant source  Retaining clip

Refer to the Connecting the Dispersion units section for connection of the
Hydro LV and MV to the Optical unit.
Pump setup
The information below on setting the pump is taken from the pump user manual.
Refer to this manual for complete information regarding the operation of the
pump.
1. The pump must be set for the voltage specific to the country it is installed into.
Set the mains voltage selector at the back of unit to the correct voltage for
the country you are in. Refer to the Peristaltic pump user manual.
2. Connect the power cable  into the back of the pump.
3. Connect the auxiliary control cable  from the dispersant unit into the
back of the pump.
4. The pump must be set for Analogue-Automatic operation mode using the
control cable and Malvern software (Auto restart mode). In this mode the
pump will automatically start in automatic mode when turned on. To do this:
Turn pump off using mains switch on back of unit.
Hold down the Start button on the front of the pump, and turn the mains
switch on. An exclamation mark ( ! ) will appear on the screen.
Put pump into Analogue-Automatic mode.
Press Mode until ANA is displayed on screen, with the word Auto appearing
in the corner to indicate that the pump is in analogue and automatic mode.
The pump is now set.
It will now always restart in Analogue-Automatic mode whenever the power is
connected.
Note
With the auxiliary control cable connected and the pump set to auto mode,
manual mode will not be available.
Warning!
If the auxiliary cable is disconnected when the power is still supplied the
pump will briefly rotate. This may deposit any dispersant present in the
tubing.
Tubing Connection
The pumphead  is uni-directional and travels anti-clockwise. The tubing must
be connected so that the flow travels from the right (the dispersant source) to the
left (the dispersant inlet).
Page 1-52 MAN 0479

Also refer to the pump manual for complete information on installing the tubing
into the pumphead.
1. Connect the tubing from the dispersant source  to the upper externally
regulated dispersant inlet . Tubing lengths upto 15m can be used.
2. Place a retaining clip  over the connected tubing at the dispersant inlet and
compress using pliers to provide a secure connection.
3. Open the top of the pumphead.
4. Set the tube clamps to the correct tube size.
Using the adjustment knobs on either side of the pumphead set the tube
clamps to 4.8mm as indicated on the pumphead scale (4.8mm is the inner
diameter of the supplied Tygon tubing).
5. Slide the tube into the open pumphead over the rollers. Ensure the tube is not
twisted or stretched.
6. The head can be loosened or tightened around tubing using the 2 adjustment
knobs on the sides of the pumphead. Ensure that the head height is tight
enough so that tubing cannot move forward or backward but loose enough that
flow is not restricted.
7. Close the top of the pumphead.
Control
Once setup the pump will always start in Automatic mode, with the Mastersizer
system automatically detecting the pump. Commands to activate the pump are pro-
vided using either the Sample dispersion - Accessory SOP window or the
Accessory control panel. Refer to the Software chapter for details.
Note
If the distance between the system and the liquid container is large, the
system may first need priming by performing a number of fills using the
accessory controls
Switching Box
A Switching box is available to allow a customers external pump to be controlled
from the Hydro LV and Hydro MV dispersion units. This allow dispersant to be
supplied from an unpressurised tank or flask.
Contact Malvern Instruments for more details

Setup and control

The switching box will activate the connected pump using the same software com-
mands as indicated above.
Page 1-54 MAN 0479

2

Introduction
This chapter describes the features of the software which are specific to the disper-
sion unit. It covers:
 Making a measurement – the basics of making a measurement using the dis-
persion unit.
 Controlling the dispersion unit via a Standard Operating Procedure (SOP).
 Manually controlling the dispersion unit.
Making a measurement
Making a measurement using the Hydro LV, MV, EV, SV and SM dispersion units
is fully documented in the Mastersizer User Manual. Refer to that manual for
details.
The dispersion units can be controlled in several ways;
 Manually or automatically by running an SOP. The system automatically
detects which dispersion unit and cell is connected. If more than one disper-
sion unit is connected, the system detects all dispersion units connected, but
only the dispersion unit that has its cell installed on the optical unit will be
“active”.
 Alternatively the dispersion unit can be controlled by a separate manual acces-
sory control dialogue. This will enable simple control of the dispersion unit,
allowing individual selection and operation of the unit’s functionality.
 If a fully manual accessory is connected to the optical unit, this will not have an
automated or manual software control, but will be controlled directly.
These are described in the following pages.

2 Chapter 2 Software and Control
Control of a Dispersion unit via an SOP

An SOP can be configured to control all settings for the dispersion unit automati-
cally. When an SOP is run, the software will (depending on how the SOP has been
set up) automatically fill the tank, set the pump, stirrer and ultrasound to prede-
fined settings, and once a measurement sequence is complete, flush the tank to
clean it.
The SOP Editor and setup is described in full in the Mastersizer User Manual.
Most of the SOP sections are common to all dispersion units, and these are
described in the above manual. Other SOP sections are specific to the Hydro dis-
persion unit being used; these are described below.
Creating or editing an SOP - Dispersant unit

selection
SOPs need to be specified and saved before they can be run. To create a new SOP:
1. On the Home ribbon, select New-SOP from within the Documents group.
ribbon. (To edit an existing SOP, choose Open-SOP instead.)
Page 2-2 MAN 0479

Software and Control Chapter 2
2. Select an SOP template from the list in the New SOP window or click the
From existing SOP... button to locate an SOP in the file system that fulfils
(or is close to) your required criteria.
3. The SOP Editor window is now displayed. This will be configured to apply to
the dispersion unit selected.
4. Complete the SOP Editor as described in the Mastersizer User Manual.
Sample - Dispersant
- Hydro MV/LV (MAZ3210/3310) units only
Please also refer to the Sample - Dispersion description in the Making
measurements chapter of the main Mastersizer user manual.
The Sample - Dispersion SOP window contains a level sensor threshold field
where a value can be inputted that is suitable for the level sensor to detect the
dispersant level when filled. The value will be different depending upon the
dispersant used.
The level sensor in the dispersion unit automatically stops the tank being overfilled
above a certain level. If the tank fails to fill properly then the level sensor threshold,
for the dispersant being used, may need adjusting. This value can be changed either
manually (for the current measurement only) or by using the dispersants
database, to store the new values for future use.
Configuring this threshold value will be done using the accessory controls
window described later in this chapter.
Sample Dispersion - Accessory

The Accessory control settings allow you to set up the behaviour of the currently
connected accessory during a manual or SOP measurement. Depending on the
accessory that is connected the settings presented differ accordingly.
Accessory control settings: Hydro LV/MV/EV/SV

This section describes the Hydro LV/MV/EV/SV Sample Dispersion - Accessory
control settings. There are no Accessory control settings for the Hydro SM.

Chapter 2 Software and Control
Section Description
Stirrer speed This Hydro dispersion units have a variable-rate stirrer allow-
ing flexible control of sample flow and agitation. The stirrer
speed may be controlled manually using the Wet Accessory
dialogue or by a predefined SOP for automatic operation.
Manual control would typically be used to determine the
optimum measurement setting prior to using an SOP proce-
dure or when doing one-off manual measurements.
To control the stirrer from an SOP, determine the optimum
stirrer speeds initially using manual control, ensuring that the
lowest setting to give satisfactory dispersion is obtained.
Page 2-4 MAN 0479

Section Description
Stirrer speed Make a note of the settings and enter these into the SOP
(continued) Accessory control settings. Click and drag the slider bar to
set the speed.
It is also possible to control the accessory manually by using
the Accessory Controls panel (from the manual measure-
ment window) or the from the Tools-Accessories option at
any other time.
Hydro SV only. The speed on the Hydro SV is also con-
trolled using the dial on the front panel of the SV accessory.
Note that the software stirrer slider bar, and the SV front
panel dial are synchronized. Altering the slider bar will alter
the front panel display; and vice-versa
Tank fill The tank can be filled with dispersant manually or automati-
behaviour cally. When set to Automatic the dispersant is plumbed into
(Hydro LV/MV) the lower dispersant inlet port at the rear of the accessory
and an internal regulator valve controls the flow of dispersant
into the tank.
However, if an organic dispersant is to be used, it is unlikely
that this dispersant will be plumbed into the accessory. In
these situations the filling of the tank can be set to Manual.
Under manual filling the solenoid valve is switched off (this
will mean that the dispersant inlet does not have to be dis-
connected during a manual fill) and the tank can be filled by
hand. The software will tell the operator when to fill the tank
during an SOP measurement.
The tank filling can be done by carefully pouring the disper-
sant directly into the tank, or by using the upper dispersant
inlet port. In this case the supply to this inlet is enabled either
through the use of an external pump and cable, or other reg-
ulation method.
Dispersant Source
This option enables the dispersant inlet to be switched
between the lower internally regulated inlet port (commonly
used for aqueous samples) and the upper externally regu-
lated inlet port (commonly used for non-aqueous samples) –
refer to the Features of the Hydro MV/LV dispersion units
section in the user manuals.
This is useful for instances after a measurement has been
performed using an expensive organic dispersant - supplied
via the upper externally regulated non-aqueous inlet. It may
be undesirable to then use this expensive dispersant for
cleaning, so the tank and cell can then be cleaned with a
cheaper comparable alternative - supplied via the lower
internally regulated aqueous inlet.

Section Description
Tank fill The Dispersant source options are:
behaviour Auto - Both inlets activated and can be used. This is the
(continued) default selection, and is the setting used for SOPs that were
(Hydro LV/MV) set up in previous software versions where this option did
not exist. This will activate both the lower regulated and
upper externally regulated inlets when required.
Note: If using this option, It is advised that only one supply is
connected to the accessory to prevent the two dispersant
supplies mixing inadvertently.
Internal - Will control and activate the lower internally regu-
lated dispersant inlet port (There is an internal regulated
valve rated to handle mains pressure).
External - Will control and activate the upper externally reg-
ulated dispersant inlet port (The upper dispersant inlet is
externally regulated.
There is no internal regulator controlling the dispersant. It is
therefore recommended that the supply to this inlet is ena-
bled through the use of an external pump and cable). Refer
to the Introduction and hardware chapter for details on
using an external pump.
Note: both valves will be in a closed state when in standby
or when power is supplied to the accessory.
Filling the tank manually:
Fill the tank slowly until the tank light flashes - this will indi-
cate the correct fluid level for adding sample and running
measurements. If the tank is filled higher than this, sample
and particles may be lost via the over-flow system (drain),
leading to an incorrect particle size distribution being
reported.
Degassing
If dispersant is stored under pressure or at low temperature,
consider de-gassing before use. The pressure release or
temperature rise reduces the solubility of gases, resulting in
possible bubble formation in the pipes and tank.
Select the Degas after fill check box to remove bubbles and
dissolved gases from the dispersant before use. Once the
tank is filled, this runs the stirrer briefly to dislodge any bub-
bles off the cell walls and out of cell, then stops the stirrer to
allow the bubbles to be released.
Note: It is preferable that all dispersants are degassed
before being added to the system. Degas by storing the dis-
persant at room temperature and pressure for before use.
Page 2-6 MAN 0479

Section Description
Ultrasonics This sample dispersion unit has an ultrasonic transducer
(Hydro LV/MV/EV) which can assist the dispersion of cohesive samples. The
level and duration of ultrasound may be set manually using
the Wet Accessory dialogue or may be set by a predefined
SOP for automatic operation.
To determine the correct ultrasonic level for an SOP, initially
determine the optimum ultrasound level and duration using
manual control, ensuring that the lowest setting giving satis-
factory dispersion is obtained. Record the settings and
transfer these to the SOP in the Sampler Settings page using
the slider controls. Click and drag the slider bar to set the
ultrasonics power level.
Set the Ultrasound mode to one of the following:
None - No ultrasound is applied.
Pre-Measurement - ultrasound is activated for a set time
prior to measurement. For pre-measurement mode, enter
the required duration in seconds in the Duration box.
Continuous (from Sample Addition) - ultrasound is acti-
vated after sample is added and will run continuously.
Continuous (from Measurement Start) - ultrasound is
active throughout the measurement. Ultrasound will start
after the electrical background is complete. The stabilising
period will add a delay between the electrical background
and the optical alignment - during this delay ultrasound will
be on allowing bubbles to be driven from the dispersant.
To manually control the ultrasonic level from the Wet Acces-
sory dialogue, either select and drag the Ultrasound slider
bar to set the level, or select the bar and use the keyboard
control up/down/left/right arrows; this will step the ultrasonic
level up or down in 10% divisions.
Alternatively, for an exact setting, double click on the dis-
played ultrasonic value and type in the required level.
Degas after ultrasound - select this check box to remove
any bubbles that may have occurred during ultrasound.
Align after ultrasound - select this check box to align the
cell once the ultrasound has completed.
Pulsed Enable pulsed ultrasonication - in this mode, ultrasonica-
Ultrasonics tion is applied in pulses (with fixed duration on and off
(Hydro LV/MV/EV) pulses). This option can be used in combination with both
continuous or timed ultrasonication mode. Specify the dura-
tion of on and off pulses by entering the required values
(seconds) into the corresponding boxes.

Note
use.
Sample Dispersion - Cleaning

This section describes the Hydro LV/MV/EV Sample Dispersion - Cleaning set-
tings. There are no Cleaning control settings for the Hydro SV or SM.
The Cleaning options allow you to specify both a clean sequence and whether to
use ultrasound as part of the sequence. This ensures that all traces of the sample
just measured are removed so that no contamination of the next sample occurs.
Cleaning following a measurement is essential to ensure that background noise,
consisting of particles agglomerating within the system and forming accumula-
tions, is minimized.
Page 2-8 MAN 0479

Section/option Description
Clean Sequence Each Clean type specifies a set number of cycles (nothing
further is changed in the cleaning method). Select a Clean
type of either Quick, Normal, Extensive or Custom. If Cus-
tom is selected the user must also manually specify the
number of Clean cycles.
If measuring the same sample type in succession a Quick
clean may be sufficient.
If making the last measurement of the session, it is prudent
to perform an Extensive clean to ensure that the system is as
free as possible from contamination in readiness for the next
measurement session.
Tank fill Refer to the Sample dispersion - Accessory section above
behavior for a description of the Tank fill behavior, including filling
(Hydro LV/MV) the tank manually; and the Dispersant source and Degas-
sing options.
Level sensor threshold
The level sensor threshold value is only required for Hydro
units that are fitted with an analogue sensor (MAZ3210/
3310). Refer to the Sample - dispersants (SOP) and the
Accessory Panel: Hydro LV/MV topics.
Ultrasonication Ultrasound can reduce agglomeration, which may help fur-
ther with cleaning. Select whether to Use ultrasound during
the clean sequence or No ultrasound during clean.

Manually controlling the dispersion unit

The docked Accessory control tab in the measurement display is only availa-
ble with the a Mastersizer 3000 / Mastersizer 3000E with Extended software
options.
To control the dispersion unit manually, when running a Manual measurement an

accessory control panel will be present on the right of the active measurement win-
dow. This can be used to initiate and control the currently activated accessory.
Normally, an SOP or Manual measurement controls the accessory's operation

within the context of a measurement. Alternatively, the Accessory controls panel
allows you initiate the current accessory before the measurement is actually made.
This is essential when observing the effects of variation to the accessory's settings
on the live Laser and Light Scattering panels, in order to optimise the sample's
concentration and circulation prior to making a measurement. This option could
also be used as part of a manual cleaning process.
 To access the Accessory control
panel: the instrument must be in Man-
ual Measurement mode, then click the
Accessory controls tab on the right of
the Manual Measurement window.
Tip
The same controls are also available from the Active accessory control
feature (choose Accessories from the Tools command ribbon).
The options available on this panel depend on the active accessory as follows:
Page 2-10 MAN 0479

Hydro LV/MV
The accessory controls panel for the Hydro LV/MV is shown as follows:
Each section can be collapsed to save space on the Measurement window.

Dispersant The Sample - Dispersion SOP window contains a level sen-
- Sensor sor threshold field where a value can be inputted that is suit-
Threshold able for the level sensor to detect the dispersant level when
(Only for Hydro filled. The value will be different depending upon the disper-
MV/LV units that sant used.
are fitted with an Refer to the description in the Sample - Dispersant (Hydro
analogue sensor - MV/LV (MAZ3210/3310 units only) SOP topic earlier in this
MAZ3210/3310) chapter.
The Hydro MV requires additional actions to be carried out

before it can be correctly used with any dispersant other
than water. The threshold value (which will be used in the
SOP settings) will first need to be setup using the threshold
controls in the accessory controls window and then stored in
the dispersant database for use later.
Note: Threshold setting can be done as part of a manual
measurement and for any SOP method development.
To set the threshold:
Select a dispersant from the Database .

If the selected dispersant does not have a valid level sensor
value then the threshold control will turn blue, together with a
Tank full confirmation button , to indicate the
value needs setting
Fill the tank manually to the level of the tank baffle (refer to
introduction and hardware chapter for location of the tank
baffle).
Click the Tank full confirmation button.
This button is greyed-out until the sensor reading value is
greater than zero. Automatic fills are also disabled until the
threshold has been set.
Once the Tank full confirmation has been pressed. The
threshold control will clear and automatic fills are now possi-
ble.
When the dispersant is now selected in the Sample - dis-

persant SOP window, the new threshold value will be used.
Page 2-12 MAN 0479

Dispersant Select Fill to fill the Hydro unit with dispersant.
- Fill The manner of filling depends upon the fill options selected.
Automatic fill
Automatic fill.
Manual fill
This is the default selection and allows back-compatibility
Automatic fill
with previously created SOPs. In this mode, the function
(Internal)
opens the internal dispersant valve (and external valve if con-
Automatic fill
figured) and then pumps dispersant into the unit until the
(External)
correct level is reached (detected by a sensor) and then
closes the dispersant valve.
To prevent overfilling, the Fill button command is disabled
when the Automatic fill option is selected if the chosen dis-
persant has a level sensor threshold of 0 (zero). The thresh-
old value has to be set for the Fill button to become enabled.
The tank indicator next to the Fill button

shows full and empty respectively:
As with the tank light, this indicator can be used when filling
the tank manually.
Manual fill.
Manually fill the tank slowly until the indicator shows full -
this will indicate the correct level for adding sample and run-
ning measurements. If the tank is filled higher than this, sam-
ple and particles may be lost via the over-flow system
(drain), leading to an incorrect particle size distribution being
reported.
Automatic fill (Internal).
This fill mode uses the Lower internally regulated dispersant
inlet port to fill the tank. This is normally used for aqueous
dispersants. As with Automatic fill above, this mode opens
the dispersant valve, pumps dispersant into the unit until the
correct level is reached and then closes the dispersant valve.
Automatic fill (External).
This fill mode uses the Upper externally regulated dispersant
inlet port to fill the tank. This is normally used for non-aque-
ous dispersants.
There is no internal regulator controlling the upper disper-
sant inlet. It is therefore recommended that the supply to this
inlet is enabled and controlled through the use of an external
pump and cable. Refer to the Introduction and hardware
chapter for details on using an external pump.

Dispersant This mode will work like Automatic fill above, except an
- Fill external pump or regulator is used to control the flow of dis-
(continued) persant into the unit. When the correct level is reached, the
external pump (or regulator) will be stopped.
Dispersant Select Degas after fill to remove any bubbles and dissolved
- Degas after fill gases from the fresh dispersant before use. Once the tank is
filled, this runs the stirrer briefly to dislodge any bubbles off
the cell walls and out of cell, then stops the stirrer to allow
the bubbles to be released.
Refer to the Hydro LV/MV/EV Accessory control settings
(SOP) section for more information on degassing.
Dispersant Empties all dispersant (and sample) from the Hydro unit.
- Empty This function opens the drain valve and initiates a pumping
sequence - the process stops when the unit is empty and
then closes the drain valve.
Stirrer Use the slider bar to set the RPM of the stirrer. In Manual
Measurement mode it is necessary to start the stirrer manu-
ally before making the measurement. To initiate the stirrer
once the speed has been set, click the Start button. To stop
the stirrer click the Stop button.
The sliders change to show the difference between the
requested and actual speeds.
The grey bar shows the requested speed:
The actual speed is less the requested speed. This will nor-
mally be seen during a fill operation:
Page 2-14 MAN 0479

Stirrer The actual speed is more the requested speed. This will nor-
(continued) mally be seen during a fill or clean operation:
There will be a small lag as the actual speed adjusts to

match the requested speed.
The optimal stirrer speed is normally a choice between stir-
ring fast enough to ensure that all the sample is suspended,
but not so fast that bubbles occur.
Ultrasound Select the Manual option if you wish to start and stop the
- Manual / Timed ultrasound manually for a period of time.
Select the Timed option to perform a precisely timed period
of ultrasound application. When Timed is selected, the timer
controls become available - click +/- to increase/decrease
the time period for which ultrasound will be applied.
Ultrasound In Continuous mode, sonication is applied continuously.

- Continuous / Choose an appropriate level of ultrasound for the sample by
Pulsed moving the slider bar.
In Pulsed mode, sonication is applied in pulses (with fixed
duration on and off pulses). This option can be used in com-
bination with both continuous or timed sonication mode.
Specify the duration of on and off pulses by entering the
required values (seconds) into the corresponding boxes.
In both modes the Elapsed time is displayed. Press to

reset the clock.
Valves Opens/closes the drain valve.
- Drain valve This will allow any dispersant and sample in the system to
drain naturally. No pump is applied, so this process will not
completely void the system to the same extent as the Empty
function. This could be useful if, for example, the system had
been manually overfilled and needed some adjustment of the
level.

Valves Opens/closes the dispersant inlet valves.
- Dispersant valve Controlling the valve in this way allows a manual fill to be
done using the dispersant inlets.
This might be required to only add a certain amount of dis-
persant, without using the level sensor, or if the system had
been partially drained (using the Drain valve option) and
then needs to be manually topped up.
Three valve options are available:
Auto
This is the default selection and allows back-compatibility. In
this mode, the function opens the internal dispersant valve
(and external valve if configured).
Internal
This fill mode uses the Lower dispersant inlet: (Internally reg-
ulated inlet) to fill the tank.
External
This fill mode uses the Upper dispersant inlet (Externally reg-
ulated inlet) to fill the tank.
Note: It is important that the valve is closed. There is no

automatic closing off the valves using this option. The tank
will continue to fill until manually closed.
Clean Select the cleaning sequence required: Quick (1 cleaning
cycle), Normal (3 cycles), Extensive (5 cycles). The disper-
sion unit will perform a clean sequence, for the selected
duration, that will remove any remaining sample from the
unit.
To start the cleaning sequence select the Clean system but-
ton .
Note: In the Active accessory control window (Tools-
Accessories) pressing Clean will start the cleaning
sequence
Refer to the Dispersant section above - Fill and Degas
options - for a description of the Tank fill behavior and
Degassing function.
Page 2-16 MAN 0479

Hydro EV
The accessory controls panel for the Hydro EV is shown as follows. Each section
can be collapsed to save space on the Measurement window.
the stirrer click the Stop button.
Ultrasound Select the Manual option if you wish to start and stop the
- Manual / Timed ultrasound manually for a period of time.
Select the Timed option to perform a precisely timed period
of ultrasound application. When Timed is selected, the timer
controls become available - click +/- to increase/decrease
the time period for which ultrasound will be applied.
Ultrasound In Continuous mode, sonication is applied continuously.

- Continuous / Choose an appropriate level of ultrasound for the sample by
Pulsed moving the slider bar.
In Pulsed mode, sonication is applied in pulses (with fixed
duration on and off pulses).

Ultrasound This option can be used in combination with both continuous
- Continuous / or timed sonication mode. Specify the duration of on and off
Pulsed pulses by entering the required values (seconds) into the
(continued) corresponding boxes.
In both modes the Elapsed time is displayed. Press to

reset the clock.
Clean Select the cleaning sequence required: Quick (1 cleaning
cycle), Normal (3 cycles), Extensive (5 cycles). The disper-
sion unit will perform a clean sequence, for the selected
duration, that will remove any remaining sample from the
unit.
Clean dispersant in a beaker will need to be provided in
order to complete the clean sequence.
To start the cleaning sequence select the Clean system but-
ton . During the sequence the operator will need

to follow any commands indicted by the software (i.e raise
pump head, etc).
Note: In the Active accessory control window (Tools-
Accessories) pressing Clean will start the cleaning
sequence
Page 2-18 MAN 0479

Hydro SV
The accessory controls panel for the Hydro SV is shown as follows:
the stirrer click the Stop button (or alternatively push on the
speed control dial on the unit).
Stirrer The sliders change to show the difference between the
(continued) requested and actual speeds
The grey bar shows the requested speed:
Note: The software stirrer slider bar, and the SV front panel
manual control dial are synchronized. Altering the slider bar
will alter the front panel display; and vice-versa
The Stirrer speed can be controlled from the software when
the instrument is not installed into the instrument cell bay;
but only when the dispersion unit is 'active', as indicated on
the status bar.

Manual control accessories

Manually controlled accessories may also be connected to the optical unit. These
accessories do not have an automated or manual software control, but will be
controlled directly from the control interface on the accessory itself.
Like the automatic controlled dispersion units, manual accessories are selected
from the SOP Editor:
 On the Home ribbon, select New-SOP from within the Documents group.
ribbon. (To edit an existing SOP, choose Open-SOP instead.)
 Complete the SOP Editor as described in the Mastersizer User Manual.
Hydro SM
The Hydro SM is controlled via the speed control on the front of the controller
unit.
Depending upon the sample being measured and the SOP routine being followed
the speed of the pump can be varied between 350 and 3500rpm. The monitored
speed is shown on the front panel display.
Page 2-20 MAN 0479

3
Maintenance
Introduction
This chapter covers all the user maintenance procedures for the dispersion unit. Do
not attempt any maintenance procedure not specified here. This chapter covers:
Maintenance schedule
This section suggests a maintenance schedule for inspecting and cleaning the dis-
persion unit and its respective components.
Maintenance procedures
This section describes how to perform various maintenance procedures and actions
identified in the schedule to help ensure the dispersion unit is kept working opti-
mally. Maintenance procedures described are:
Cell window inspection and cleaning procedures
This section includes topics on:
 How to inspect the cell windows, in case of poor background results.
 Cell windows removal and inspection.
 How to inspect the quality and cleanliness of the windows.
 Appropriate cleaning techniques.
Dispersion unit cleaning

This section describes how to clean the various components of the dispersion unit
that have been identified in the maintenance schedule. This includes topics on:
 Cleaning of covers.
 Cleaning of the sample flow path and sampling pump head.
 Cleaning after a measurement.
 Checking and replacing of sample and dispersant tubing.

3 Chapter 3 Maintenance
Performing a Quality Audit Standard measurement

Malvern supplies a Quality Audit standard (QAS) specifically designed to test the
performance of the dispersion unit. It is recommended this is performed at least
once a week or as internal quality procedures dictate.
Power connections, lead and fuses

Checking of the power input to the dispersion unit.
Warnings
General
Warning!
The dispersion unit contains no internal serviceable parts. Never attempt
to remove the covers of the optical bench or dispersion unit. Removal of
the covers invalidates the warranty and may expose the user to dangerous
laser radiation.
Warning!
Failure to follow these guidelines could result in the emission of laser radi-
ation or exposure to hazardous voltages. Laser radiation can be harmful to
the body and can cause permanent eye damage.
The Hydro dispersion units do not contain a laser but are connected to the
optical unit that does.
Maintenance and cleaning
Warning!
Before carrying out any maintenance operation, read and observe the safety
warnings listed in the Mastersizer Basic Guide.
Warning!
Before cleaning, always disconnect the unit from the power supply and
computer and disconnect all electrical cables.
Ensure the unit is completely dry before re-applying power.
Page 3-2 MAN 0479

Maintenance Chapter 3
Maintenance schedule
Follow the maintenance schedule below to keep the dispersion unit working well.
This list is only a guide; the exact frequency at which to perform tasks depends on
many factors, including:
 The samples being measured.
 The dispersant being used.
 The environmental conditions.
 The number of measurements made (frequency of use).
The procedures indicated below for each Hydro dispersion unit are described in
the following pages of this chapter.
Hydro MV / Hydro LV
Procedure Period/situation
Inspect cell windows The cell windows should be checked for general
for dirt and scratches cleanliness every day, or if during a background
measurement either of these is seen:
 One of the first few detectors displays a value
above 100 light energy units.
 Background signal over 20 light energy units
recorded by one of the detectors above detector
20 (see below).
Either of these situations would indicate a poor
background; this will effect the quality of any meas-
urements.
Check the window At least once a month. Always watch for signs of
seals for damage leaks and rectify immediately.
Clean the covers Once a month.
Clean the sample flow Contamination by coarse particles or bubbles in the
path dispersant may cause fluctuations in the background.
Clean the path using the cleaning options.
Clean the sample tank If changing dispersant types, or if sample is seen to
adhere to the sample tank and the normal flush rou-
tine fails to remove it.
Replace the dispersant If the tubing leaks or becomes discoloured. This may
tubing allow bubbles to enter, causing rapid fluctuations in
the background (see below).
Perform a Quality Audit At least once a week or as internal quality procedures
Standard measurement specify.

Chapter 3 Maintenance
Hydro EV
20 (see below).
urements.
Clean the path using the cleaning options.
Inspect and clean the If changing dispersant types, or if sample is seen to
sampling pump head adhere to the sampling head and the normal clean
routines fails to remove it.
Page 3-4 MAN 0479

Hydro SM
20 (see below).
urements.
Inspect and clean the If changing dispersant types, or if sample is seen to
tank adhere to the top of the tank and the normal clean
routines fail to remove it.

Hydro SV
20 (see below).
urements.
Check cuvette body for Periodically check for leaks from cuvette body. if any
leaks and damage leaking occurs or damage is visible contact Malvern
instruments
Clean the covers Once a month
Pipette guide tube Clean as required depending upon usage. Also check
for damage ensuring guide tube alignment for adding
sample into cell is correct.
Inspect cell holder Clean the area where the cuvette is positioned.
Check condition of cuvette locks - do they work cor-
rectly.
Inspect stirrer bar Inspect the stirrer bar before use. A worn, damaged
or dirty stirrer bar may not rotate correctly and will
therefore not disperse the sample sufficiently.
Page 3-6 MAN 0479

Maintenance procedures
Inspection of cell windows - Poor background
The cell windows should be inspected for cleanliness every day and after each
measurement session. Problems which indicate the need for cleaning or mainte-
nance are the following. These expand on the situations in the first row of the
maintenance schedule table.
Material stuck to windows

Significant scattering on the detector channels, as shown below , often indicates
that fine material is stuck to the cell windows:
ill 8830
 If your system displays high detector channels, refer to the Cleaning the cell
windows section as described later in this chapter and remove and clean the
cell windows.
Contaminated dispersant or air bubbles in system

Contamination by coarse particles or bubbles in the dispersant may cause fluctua-
tions in the background over time.
This shows as rapidly changing readings  on the first few detectors. For example,
the Light Energy reading for a detector may show 20 units one moment and then
200 units the next as shown in the following illustration:

ill 8829
Bubbles may enter the system because of high pump or stirrer speeds with viscous
dispersants or those containing surfactants, or due to leaking tubing or seals. Check
and replace any damaged tubing or seals as described later in this chapter.
Hydro MV/LV/EV/SM procedures

Cell windows removal and inspection introduction
The cell windows should be inspected for cleanliness every day and after each
measurement session, as described in the previous section.
Cleaning the system by rinsing through with fresh dispersant a couple of times is
usually sufficient to clean the cell windows and prepare for a new measurement;
but over time, users will notice that they cannot achieve such a good background
measurement. If this happens, this is the time to clean the cell windows.
Before starting, ensure that the cell has been drained of dispersant and remove the
cell assembly from the optical unit.
Replace windows if necessary. Always replace both windows at the same time, as
the second window will probably fail an inspection soon after the first.
Note
The cell window faces must not be touched directly during the removal
and replacement procedure. Lens tissues should be placed over the win-
dow faces where necessary.
Standard laboratory gloves should also be used when handling the wet cell
seals. Malvern recommends disposable, powder free, nitrile (NBR)
gloves.
Page 3-8 MAN 0479

Removing a cell window:

Remove all sample from the system, then remove the wet cell from the system.
Lift  and rotate  the cell lock lever to release the cell front cover plate. Once
unlocked, remove the cover plate from the cell holder assembly .
ill 8676
Whilst holding the cover plate slightly above a clean lens tissue, place another lens
tissue over the cell window area and using light pressure push the cell window and
seal out from the cover plate onto the bottom lens tissue.
ill 8677

Holding onto the ends of the seal turn the cell seal and window assembly over, on
the lens tissue, so the seal is uppermost.
ill 8678
While holding the centre of the cell window down with another lens tissue, take
hold of the longest end of the seal, and lift the seal clear of the window.
Repeat the procedure for removing the remaining cell window and seal from the
main body of the cell. This time though place the cell holder on its side again with
a clean lens tissue positioned under the rear cell window, then remove the cell win-
dow and seal as described above.
ill 8679
Caution!
The outer faces of the cell window are optically coated; treat them with the
same care as a camera lens.
Page 3-10 MAN 0479

Inspecting and cleaning a cell window

1. Inspect both sides of the cell window. If there are traces of scratches replace the
windows. Spare windows can be obtained from Malvern Instruments.
2. Remove any dust on the window surfaces using a compressed gas duster can.
Keep the can upright in use to prevent liquid propellant emerging. Do not
shake the can immediately before use or it will emit liquid propellant.
Caution!
Do not wipe the windows with an ordinary dry cloth as this will cause
scratches. Always use the procedure below to clean the surfaces.
3. Inspect the window by reflected light for smears or prints.

4. Clean the windows as described in the Cell window cleaning procedures
section below.
5. Replace the window in the cell using the window tool, taking care not to touch
the glass surface.
Note
The cell windows are part of the optical system and removing them for
cleaning will change their position. Remember to add an Align stage to the
next measurement sequence or click the Align button.
Re-assembling the cell windows

The following procedure details how to fit a new cell window into the cell seal and
reinsert it into the wet cell plate/holder. Take the same precautions when reusing
the existing cell window after cleaning it; protect the cleaned window with lens tis-
sue where necessary.
Take a wet cell seal and place its sealing face onto a flat surface. Use a clean lens tis-
sue under the cell seal.
Without touching the window faces, remove a cell window from its protective
paper wrapping. Hold by ground edges of window.
Insert the cell window in to the circular section of the seal.
Note
Ensure that the face with the larger diameter is facing down when
inserted in to the cell seal.

ill 8727
Place the wet cell cover plate on to a flat surface with the seal cavity facing upward.
Holding by the ends of the seal, pick up the cell seal and window assembly and turn
it over so that the circular section is facing downward. Place over the seal cavity of
the cover plate and line up the lugs on the seal with the corresponding cut-outs in
the circular measurement area of the cover plate, then place it carefully to rest on
top of the plate - do not insert the assembly yet.
Without touching the exposed window face, push the circular section of the seal
into place in the measurement area of the cover plate by rocking the seal and win-
dow down.
 Push the seal/window down at one end  in the places indicated, then repeat
at the other end . Repeat these steps until the window is fully inserted out in
the measurement area.
A
B
Page 3-12 MAN 0479

ill 8681
Once finished the circular section of the seal must be flush with the flat surface of
the measurement area of the cover plate. There must be no bulges in the seal. The
section of the seal with the flat sealing face must be located fully into the seal cavity,
edge to edge.
The seal in its fitted position.
ill 8682
Repeat the above procedure when replacing the cell seal/window assembly into the
main body of the cell.
Cell window cleaning procedures

Follow these guidelines for cleaning the windows.
General guidelines
Laser light scattering systems rely on the cleanliness of the optical components (e.g.
cell windows). Dust on the optics causes light scattering; the system will respond to
particles on the optics in a similar way to particles presented in the flow cell. The
signal from dirty optics will contribute to the background signal, so it is good prac-
tice to keep the optical components as clean as possible.
When optical components have been used for a long period, even in the cleanest
laboratories, assume that they have traces of fine grit on them as well as the obvious
dust. Fingerprints usually contain grease and grit so need careful cleaning.
As optical components are very expensive, take a cautious approach to cleaning,
assuming that the contamination is worse than it appears. As grit is usually as hard,
if not harder, than the glass used to make optical components, it is important to lift
it away from the surface before wipes are used. Use minimal pressure to clean the
surface. Repeat this if it doesn’t work first time, but remember that scratching the
optical surface ruins the component.
When cleaning a window, hold it with the fingertips and try to prevent them pro-
truding above the surface. This prevents any grease from fingers being picked up by
the tissue and deposited on the surface. To further limit problems of grease pick-up

from the fingers, hold the window with the fingers at the top and bottom and wipe
from side to side so that if any grease is picked up, it is not deposited on the surface.
Do not use rubber gloves to hold the window. Gloves invariably have oils and short
chain polymers in the surface; some of these oils, especially silicone components,
are more difficult to remove than finger smears. Never bring silicone products
into close contact with glass optical components. Clean hands are best.
Caution!
If any silicone oils are deposited on the glass surface they adhere so
strongly that it is impossible to clean them off, ruining the component.
Cleaning steps
Depending upon the quality and cleanliness of the windows, use the appropriate
cleaning technique as described. Read through the below steps to determine the
correct techniques required; these are described in order of severity and contami-
nation.
It is recommended to inspect the cell window in reflected light from a fluorescent
tube or other light source.
Gritty surface If the surface has fingerprints on it or has not been cleaned
particles / for a long time, assume there is grit present. First wash the
Smeared surface surface then wipe it as described; refer to the Washing cell
- with grit windows and Wiping cell windows sections.
Dusty surface If the surface is just dusty use a clean air aerosol duster or
soft brush; refer to the “Clean air” aerosol dusters and
Brushing optical surfaces sections below. If marks are pre-
sent afterwards wipe the surface as described in Wiping cell
windows.
Smeared surface If the surface is smeared and you are sure there is no grit on
- no grit it, wipe the surface as described below in Wiping cell win-
dows.
Caution!
The outer faces of the windows have an anti-reflective coating and are
more prone to scratching than the inner surfaces. Be careful not to touch
the faces of the windows or put them down on dirty surfaces.
Page 3-14 MAN 0479

Washing cell windows

Wash the cell windows if there are particles deposited on the surface.
1. Remove the window from the cell.
2. Pour a small amount of dilute detergent solution into a flat container such as a
petri dish. For heavily soiled windows, or when contamination with grit is sus-
pected, use a very dilute detergent solution. A neutral detergent like Decon75 is
best, although most detergents sold for cleaning glassware can be used if suffi-
ciently dilute.
3. Hold the window above the dish with the surface to be cleaned facing down-
wards. Using a very soft brush, such as sable, run the detergent solution across
the surface. The window may need angling slightly to allow the liquid to run
across it. Use the brush to lift the liquid, allowing it to run across the surface,
but not to rub.
4. Once the surface has been flooded a few times, adopt a gently flicking action as
described above. Wet the brush and try to flick away the dirt on the window. As
before, avoid applying any pressure to the surface and work across the whole
area, flicking the grit away.
5. Do not expect to remove all the greasy smears or o-ring marks at this stage;
they will be removed by wiping later. The aim is to weaken the bond between
the grit/grease and the glass surface, allowing it to be lifted away by the water.
6. After carefully cleaning both sides of the surface, wash away the dilute deter-
gent solution by flooding the surface with ethanol from a wash bottle.
Wipe the cell windows as described in Wiping cell windows below to produce the
final clean surface.
“Clean air” aerosol dusters
If used appropriately, aerosol dusters can quickly clean the worst dust off a compo-
nent. These cans use liquefied butane which boils off when the valve is pressed
down, producing a blast of gas to blow dust off the optical surface. Do not use these
in a dusty environment as they can stir up settled dust, which then settles on the
surface being cleaned.
The aerosols only remove the largest and most loosely attached dust particles, but
can often deposit droplets of liquid butane on the optical surface. These droplets
boil away leaving a drying mark on the surface. This effect can be limited by keep-
ing the aerosol perfectly upright, and testing the aerosol first by squirting it in a safe
direction to ensure that the nozzle is clean.
Once the dust is removed, wipe the cell windows as described in Wiping cell win-
dows below to produce the final clean surface.

Brushing optical surfaces

Camera suppliers sell large soft brushes for brushing dust off camera lenses. These
often have a bulb attachment to blow gently on the lens to assist in removing dust.
Use the brush with a light flicking action to knock dust off without applying pres-
sure to the surface.
Avoid a typical “brushing” action; as the brush is moved sideways grit trapped in
the brush is dragged across the surface, scratching it. These scratches accumulate
with subsequent cleaning, causing early failure of the component.
Avoid touching the brush itself as grease from fingers will stick to the brush and be
transferred to the window when the brush is used.
Once the dust is removed, wipe as described in Wiping cell windows below to
produce the final clean surface.
Wiping cell windows
Fold a piece of lint free cloth (a good quality proprietary lens tissue is best) into
quarters. The edge that wipes the surface should be large enough to span the whole
width of the window. If the tissue is too small a corner of the wipe will be drawn
across the surface, leaving a smear.
Do not touch the window with fingers during the cleaning wipe.
Caution!
Never use acetone for cleaning optical components as the adhesives used
to bond them may leach out and be deposited across the component, ren-
dering it useless. Ethanol is much safer.
The procedure is:

1. Gripping the tissue about half way down, dampen the edge of the tissue with a
small quantity of ethanol (too much will flood the tissue). Allow the ethanol to
soak in.
2. To note any marks and smears, inspect the window in reflected light from a
fluorescent tube or other light source. Next, breathe gently on the window,
allowing warm moist air to condense on the optical surface, producing an even
fogging without wet spots. Immediately wipe the whole surface in a single pos-
itive action before the condensed water vapour disappears. Do not put fingers
behind the tissue to press it down; use the stiffness of the tissue to hold itself
against the surface, curving the tissue to increase the pressure if necessary. This
not only limits the pressure that can be applied to the surface but prevents
grease being dissolved off the fingers and passing through the tissue and onto
the surface.
Page 3-16 MAN 0479

3. Use each tissue for one pass only. This is the only way to ensure a clean
undamaged surface. If a wipe has done its job it will be loaded with grease from
the surface. Wiping the surface again will just deposit the grease back on the
surface. Worse, if the wipe has lifted off some remaining grit this could scratch
the clean surface.
4. Marks from the o-rings usually form an oily line around the outer part of the
optical surface. With surfaces contaminated in this way, wiping from the centre
outwards prevents the oily mark from being spread from an unimportant area
across the window centre. If there are smears associated with starting the pass
in the centre of the surface, once the o-ring marks have been completely
removed give the surface a single wipe from side to side.
5. Re-inspect the window; if it’s still marked, repeat the procedure with a new
clean tissue.
Note
If marks remain, use a liquid cleaner such as Ethanol or Propan-2-ol. This
can be soaked on a cotton wool bud and wiped across the window gently.
After one pass over the window discard the bud to avoid scratching. Re-
inspect the window and repeat until clean.
Checking and replacing the sample tubing
Caution!
When changing the tubing do not allow any dispersant or sample to come
into contact with the system covers. Some samples can cause permanent
damage to the surfaces.
Warning!
Do not allow dispersant or sample to come into contact with the skin.
Some dispersants and samples may cause injury.
If organic solvents are regularly used as dispersants, the flexible tubing that con-
nects the dispersion unit to the wet cell may become hard and discoloured. When
tubing loses its elasticity, air will leak into the system at the connections to the sam-
ple unit and cell. The resulting bubbles in the system cause instability in the back-
grounds and sample measurements.
When tubing hardens, moving a dispersion unit relative to the optical unit may
cause the tubing to become detached.

To change the tubing, first ensure that the dispersion unit, wet cell and tubing are
fully drained; and then remove. Push the new tubing onto the pipe boss to a mini-
mum of 7mm. Then secure, where fitted, with the aluminium tubing connectors
The standard sample tubing used with the system will be a grade of Tygon tubing
(available from Cole-Parmer Instrument Company). Tygon is chemically compati-
ble with a wide range of materials and Malvern can supply various grades of Tygon
tubing depending upon the application or solvent being used. Contact the manu-
facturer for full information on compatibility.
To retain chemical compatibility, always replace tubing with tubing of the same or
better grade. Always check the compatibility of new tubing with the samples in
use before connecting and using the system. Refer to the Appendix chapter of this
manual for information on chemical compatibility.
The specification of the tubing supplied with the dispersion unit is:
Internal diameter External diameter Wall thickness

3/16" 5/16" 1/16"
(4.8mm) (8.0mm) (1.6mm)
Hydro MV / Hydro LV specific procedures

Cleaning the flow path
Rinsing fresh dispersant through the cell windows, system tubing and sample flow
path a couple of times is usually sufficient to prepare the system prior to a new
measurement; use the cleaning routine, It is also possible to specify a cleaning
sequence as part of a manual or SOP measurement. See the Mastersizer User
Manual for more information.
Cleaning the tank
Warning!
Never put fingers in the tank when the pump/stirrer shaft is rotating.
Usually the measurement’s cleaning routine is sufficient to keep the tank clean.
However, over time deposits may accumulate in the tank.
Inspect the tank once a week. If it requires cleaning, disconnect the dispersion unit
from the mains power and use a bottle brush to clean it. Use a detergent (e.g.
Decon 90) for cleaning if required.
Make several clean flushes to clear all traces of detergent and deposits in the tank.
Page 3-18 MAN 0479

Hydro EV specific procedures

Inspect and clean the sampling head and flow path
Usually, draining and rinsing the beaker then circulating clean dispersant through
the cell a few times is sufficient. However, over time deposits may accumulate on
the pump/stirrer head.
Inspect the sampling head weekly. If it requires cleaning, disconnect the dispersion
unit from the mains power and use a bottle brush to clean it. Use a detergent (e.g.
Decon 90) if required. Rinse the head thoroughly to remove all detergent traces.
Hydro EV clean sequence
Cleaning is best performed using the 2 beakers supplied with the unit, one for the
clean dispersant and one for the waste. Select Clean system from the
measurement progress bar, or the Clean button from the accessory controls
and follow the displayed instructions.
 Raise the pump head and remove the full beaker that was used for the meas-
urement. Note that the cell and dispersion unit will still contain dispersant.
 Place an empty beaker on to the beaker holder and lower the pump head. The
cell and unit will drain, and after a pause the pump will start. While the cell
drains, rinse the removed beaker and refill with clean dispersant.
 When draining is complete, raise the pump head, remove the current waste
beaker and replace with the clean dispersant beaker; lower the pump head.
 After a pause the pump will start and circulate the clean dispersant through the
system.
 For a standard clean the process will repeat a further 2 times. With the final fill
the stirrer will pulse to remove any bubbles. The clean sequence is now com-
plete.
Hydro SM specific procedures

Inspect and clean the tank and flow path
Usually, draining and rinsing the tank then circulating clean dispersant through the
cell a few times is sufficient. However, over time deposits may accumulate on the
inside of the tank head.
Inspect the tank weekly. If it requires cleaning, disconnect the dispersion unit from
the mains power and use a bottle brush to clean it. Use a detergent (e.g. Decon 90)
if required. Rinse the thoroughly to remove all detergent traces.
Make several clean flushes to clear all traces of detergent and deposits in the tank.

Hydro SV specific procedures

Cuvette and stirrer bar cleaning - general internal wash
Note
The cuvette must not be taken apart for cleaning. users should only follow
the maintenance procedures specified.
Note
The cuvette and stirrer bar should be cleaned thoroughly before first use
and before performing any subsequent measurements.
Stirrer bar initial cleaning (before first use)

The stirrer bar may still have some PTFE particles attached to it so will need clean-
ing and any particles removed before being use.
 Clean the stirrer bar with IPA or Acetone using a lint free cloth.
 Leave the stirrer bar to dry on a clean sheet of lint free cloth.
Cuvette initial cleaning (before first use)
Cleaning the SV cuvette is done using the washstation.
ill 8865
 Place the cuvette upside down in the washstation. Ensure correct orientation
and the cuvette is firmly in place. The spout should face away from the waste
exit/dispersant input.
Page 3-20 MAN 0479

 First with some IPA, fill a syringe.
Caution!
Ensure the cuvette is fitted correctly before continuing and using
the syringe, otherwise you may be sprayed with dispersant or other
cleaning chemicals. It is advised that eye protection is used.
 Place the syringe into the cleaning inlet.

 Push the syringe plunger firmly in; this will force the clean dispersant around
the inside of the cuvette.
 Repeat 3 to 4 times as required.
 Leave the cuvette to dry upside down on a clean sheet of lint free cloth.
Cleaning after a measurement
After a measurement, clean the cuvette as described below. Once clean the cuvette
can be used for the next measurement sequence.
If cleaning after performing an aqueous measurement.
When cleaning between each individual analysis:
 Empty the sample and dispersant from the cuvette into a beaker, retrieve
the stirrer bar, and then discard the sample and dispersant.
 Clean the cuvette in washstation as described above using clean de-ionised
water.
Clean the stirrer bar using clean de-ionised water using a lint free cloth.
 The cuvette and stirrer bar can now be used for the next analysis.
Cleaning and storing after all analysis have been completed:
 Clean the cuvette as above then do a final flush with IPA. This will remove
any smears or marks that may occur after cleaning with de-ionised water.
Clean the stirrer bar with IPA using a lint free cloth.
 Leave the stirrer bar, and the cuvette to dry upside down on a clean sheet of
lint free cloth.
If cleaning after performing a non-aqueous measurement.
When cleaning between each individual analysis:
 Empty the sample and dispersant from the cuvette into a beaker, retrieve
the stirrer bar, and then discard the sample and dispersant.

 Using the washstation, clean the cuvette with IPA or Acetone depending
upon the dispersant used in the analysis. Note it may be required to use a
glass syringe.
Discard the IPA or Acetone from the cuvette.
Repeat 2 to 3 times as required.
 With clean dispersant that is to be used in the analysis, fill the cuvette as
described in the filling the cuvette section.
Discard the dispersant from the cuvette.
 Clean the stirrer bar first with IPA or acetone depending upon the disper-
sant used in the analysis, then clean again using the analysis dispersant.
 The cuvette and stirrer bar can now be used for the next analysis.
Cleaning and storing after all analysis have been completed:
 Discard the sample and dispersant from the cuvette.
 Using the washstation, clean with IPA or Acetone depending upon the dis-
persant used in the analysis. Note it may be required to use a glass syringe.
Discard the IPA or Acetone from the cuvette.
Clean the stirrer bar with IPA or acetone depending upon the dispersant
used in the analysis.
 Leave the stirrer bar, and the cuvette to dry upside down on a clean sheet of
lint free cloth.
Cuvette cleaning - Intensive internal window clean
For more intensive cleaning of the internal faces and edges of the cuvette, use
optics quality cleaning cloth and the cuvette cleaning spatula. These are
included in the consumable kit supplied with the SV
 First clean the cuvette with the washstation as described above, to ensure any
grit, if present, is removed. Cleaning by first using the spatula may scratch the
windows if any grit, etc. is present.
 Wrap a small sheet of “low shedding” optics quality cleaning cloth around the
spatula. wet with IPA or Acetone and push into the cuvette opening until it
meets the base
 Slide the spatula along the cuvette left and right, ensuring the spatula reaches
along each side and the bottom of the cuvette. Do this 3 to 4 times as required
using a fresh sheet of optics cloth, and then remove spatula.
 Finally, using IPA, use the washstation again to remove any loose and dis-
lodged contaminants.
Page 3-22 MAN 0479

Cuvette cleaning - External windows clean

Before using the cuvette the windows must be clear of grit, fingerprints and smears.
If these are present the measurement may be affected. Refer to the Cell windows
cleaning section and wiping cell windows procedures
Caution!
The outer faces of the cuvette windows are optically coated; treat them
with the same care as a camera lens.
Caution!
The outer faces of the windows have an anti-reflective coating and are
more prone to scratching than the inner surfaces. Be careful not to touch
the faces of the windows or put them down on dirty surfaces.
Cleaning the cuvette body and cuvette holder
Note
The cuvette must not be taken apart for cleaning. users should only follow
the maintenance procedures specified.
It is important that the datum/positioning points in the corners of the cuvette

holder and cuvette are kept clean. Any dirt may cause cuvette misalignment and
therefore affect the measurement.
Clean the cuvette body and cuvette holder using IPA and optics cloth. This is to
minimize the risk of contaminating the cuvette.
Cleaning and handling the stirrer bar

Follow the below guidelines for cleaning and handling the stirrer bar
 Clean the stirrer bar in a small amount of IPA
 It is recommended to use the Malvern supplied stirrer bar. Other stirrer bars
may have a different diameter and different magnetic qualities that may affect
the sample dispersion within the cuvette, as well as its coupling to the stirrer
motor.
 Inspect the stirrer bar before use. A worn, damaged or dirty stirrer bar may not
rotate correctly and will therefore not disperse the sample sufficiently.
 Ensure that the stirrer bar is not placed near any external magnets, or a mag-
netic probe is used to remove the bar from the cuvette after use. This may

demagnetize the stirrer bars coupling to the stirrer motor thus affecting its
rotation and dispersion performance.
 Never run the stirrer motor if a dry cuvette is fitted with the stirrer bar
inserted. The stirrer bar will spin directly on the windows possibly scratching
the cuvette windows.
 It is recommended to only run the Hydro SV only as long as the dispersion or
measurement is required.
External dispersant pump specific procedures

If the external pump is not to be used for long periods of time, it is recommended
that the tube is removed from the accessory and the pumphead. This will maximise
the life of the tube.
Cleaning the covers
Caution!
The surfaces of the system may be permanently damaged if samples or dis-
persants are spilt on them. If a spillage occurs, disconnect the system from
the power supply before carefully cleaning it up.
Periodically clean the covers thoroughly using a mild soap solution.

Never use excessive liquid for cleaning and always avoid electrical components
(connectors, etc.) and the cell windows.
Never use a solvent based solution for cleaning; it may damage the surface.
Power connections, lead and fuses

Power is supplied to the Hydro series wet dispersion units via the CAN cable from
the Mastersizer optical unit. This cable will supply both power and communica-
tions for the dispersion unit. Consult the Mastersizer User Manual and Basic
Guide for maintenance information on the optical unit and power connections.
Page 3-24 MAN 0479

Consumable kits
Consumable kits and additional spares for maintaining the Hydro series wet sam-
pling dispersion units are available from your Malvern representative. Please con-
tact them for full details and requirements.
The consumable kits include the following components:
Hydro LV consumable kit
Standard wet cell Solvent resist (SR) wet cell

Quality Audit Standard (QAS) - pack of Quality Audit Standard (QAS) - pack of
10 2.5g vials 10 2.5g vials
Tygon tubing (350mm) Solvent resist tygon tubing (350mm)
Lens tissues Lens tissues
Standard wet cell windows and seals Solvent resist wet cell windows and
pack (FKM) seals pack (FFKM)
Hydro MV and SM consumable kit

Hydro EV consumable kit

Tubing retaining clips Tubing retaining clips

Hydro SV consumable kit
SV cell
10ml disposable syringe and needle
attachment
Stirrer bar
Lint free wipes
Pipette
Cuvette cleaning spatula and cloth
Washstation drain tube
Page 3-26 MAN 0479

4
Appendix
Specification
The following tables detail the specification of the Hydro series wet dispersion
units and Hydro series wet cell. Full specifications of the optical unit and the Mas-
tersizer as a complete system can be found in the Mastersizer User Manual and
Basic Guide.
All specifications correct at time of publication, but may be subject to alteration.
Hydro MV / Hydro LV
Dispersion type Wet
Capacity
-- Hydro MV 120ml
-- Hydro LV 600ml
Typical applications
-- Hydro MV Solvent-based suspensions, Pharmaceuticals.
-- Hydro LV Minerals, fillers, chemicals, foodstuffs, emulsions
Sonication power / fre- 40W max, 40kHz (nominal)*
quency * Dispersant dependent.
Dispersion mechanisms Continuously variable pump / stirrer and ultrason-

ics.
Modes of operation Automatic via SOPs.
Manual via software dialogues.
Weight 5kg
Dimensions Width: 180mm
Height: 300mm
Depth: 280mm

4 Chapter 4 Appendix
Power Supplied via CAN cable from the Optical unit

Power consumption 5W - Standby / 80W - Nominal*
96W - Maximum operating power**
* The power recorded on a typical unit using maximum pump
speed and maximum ultrasonics, with water as the dispersant.
** The maximum power available through the CAN ports.
Maximum size of particles

-- Hydro MV 1400μm (density 2200kg/m³)*†
-- Hydro LV 2100μm (density 2200kg/m³)*†
* Sample dependent.
† Upper limit is 1000 microns when used with a Mastersizer
3000E with the Extended software upgrade
Hydro EV
Dispersion type Wet
Capacity 600ml / 1000ml (using a standard laboratory
beaker)
Sonication power / fre- 40W max, 40kHz (nominal)*
quency * Dispersant dependent.
Typical applications Minerals, fillers, chemicals, foodstuffs, emulsions

Dispersion mechanisms Continuously variable pump / stirrer and ultrason-
ics.
Manual via software control panel.
Weight 4kg
Height: 300mm
Depth: 220mm
speed and maximum ultrasonics, with water as the dispersant.
Maximum size of particles 2100μm (density 2200kg/m³)*†

* Sample dependent.
† Upper limit is 1000 microns when used with a Mastersizer
3000E with the Extended software upgrade
Page 4-2 MAN 0479

Appendix Chapter 4
Hydro SM
Dispersion type Wet
Capacity 120ml maximum
Typical applications Solvent-based suspensions, Pharmaceuticals.
Minerals, fillers, chemicals, foodstuffs, emulsions
Dispersion mechanisms Continuously variable pump / stirrer
Modes of operation Manual via controller unit
Weight 9.75kg
-- Controller unit 1kg
-- Dispersion unit 8.75kg
Dimensions
-- Controller unit Width: 70mm / Height: 225mm / Depth: 170mm
-- Dispersion unit Width: 390mm / Height: 140mm / Depth: 175mm
speed, with water as the dispersant.
Maximum size of particles Up to 600μm*

* Sample dependent.
Hydro SV
Dispersion type Wet
Capacity 7ml maximum
Typical applications Solvent-based suspensions, Pharmaceuticals.
Minerals, fillers, chemicals, foodstuffs, emulsions
Dispersion mechanisms Continuously variable stirrer
Manual via Front panel control dial
Weight
-- SV cell and cuvette 3.05kg
-- Washstation 1.5kg
Dimensions Width: 110mm / Height: 280mm / Depth: 210mm
speed, with water as the dispersant.
Maximum size of particles Up to 200μm*

* Sample dependent.

Chapter 4 Appendix
Hydro series wet cell

Weight 2.46kg
Height: 273mm
Depth: 227mm
Liquid temperature range - 0 to 50°C
water jacket connections
Maximum pressure - 0.5 bar g
water jacket connections
Page 4-4 MAN 0479

Appendix Chapter 4
Chemical compatibility
Components of the dispersion unit that may come into contact with the sample are
manufactured from materials that are considered to give the widest protection from
chemical attack. However, it is important to check that any sample, dispersant or
titrant used is chemically compatible with the materials mentioned. The tables
below indicate the components of the Hydro series of wet dispersion units that
may come into contact with either sample or dispersant.
Warning!
It is advisable that the chemical compatibility is checked against the materi-
als identified below before inserting a sample. It is also recommended that
a test is performed on the material with the sample before more permanent
usage is undertaken.
Any cleaning and maintenance procedures necessary are described in the Mainte-
nance chapter of this manual.
Hydro EV
Component Materials
Pump assembly Stainless steel 316
Stirrer PEEK (Glass fibre reinforced)
Impeller Stainless steel 316 / PEEK
Ultrasonic transducer Stainless steel 316 / Titanium nitride /
PTFE
Sample flow pipework (internal) Stainless steel 316 / PEEK (Natural) /
FFKM / PTFE/
Sample flow tubing (external to wet Tygon
cell)
Wet cell assembly Borosilicate Glass / Stainless steel 316
/ FKM / FFKM
Sample beaker Glass
Drip tray PEEK (Glass fibre reinforced)
Beaker holder Stainless steel 316
/ FKM or FFKM

Chapter 4 Appendix
Hydro MV / Hydro LV
Component Materials
Splash guard Acrylic
Tank surround PEEK (Glass fibre reinforced)
Tank and pump chamber PEEK (Glass fibre reinforced)
Pump shaft Stainless steel 316
Impeller PEEK (Glass fibre reinforced)
Ultrasonic transducer Stainless steel 316 / Titanium nitride
Dispersant input tubing (External) PTFE / (TUB0007)
Dispersant input tubing, pipework and Stainless steel 316 / FEP/ PTFE/ Kalrez
fittings (Internal)
Dispersant input valve (regulator) Stainless steel 316 / PTFE
Solvent (non-aqueous) input pipework Stainless steel 316
(internal)
Drain Valve Stainless steel 316 / PTFE / FFKM
Drain tubing (internal) Stainless steel 316 / PTFE
Drain tubing (external) PTFE / Acetal
Sample flow tubing (internal) Stainless steel 316 / FEP/ PTFE/ FFKM
Sample flow tubing (external to wet Tygon
cell)
Tubing connectors Aluminium
/ FKM or FFKM
i
Note
For the Hydro MV / LV Fluoroelastomer (FKM) seals in the wet cell can
be upgraded to Perfluoroelastomer FFKM to improve the chemical com-
patibility. Contact the Malvern representative for details.
External dispersant pump
Component Materials
Dispersant input tubing (External) Tygon (MH2075 / HC F-4040-A) - Sol-
vent compatible*
Page 4-6 MAN 0479

Appendix Chapter 4
Hydro SM
Component Materials
Tank, pump chamber and body PEEK (Glass fibre reinforced)
Pump shaft Stainless steel 316
Impeller PEEK (Glass fibre reinforced)
Drain Valve assembly Stainless steel 316 / PTFE / FFKM
Sample flow tubing (external to wet Tygon (St R-3603) - standard*
cell) Tygon (MH2075 / HC F-4040-A) - Sol-
(*sample dependent) vent compatible*
Tubing connectors (at cell) Aluminium
/ FKM or FFKM
Hydro SV
Components of the SV unit that may come into contact with the sample are manu-
factured from Perlast® perfluorolastomer solvent-resistant seals, glass, 316 stainless
steel, PTFE, chemically resistant epoxy resin. These include:
Component Materials
Cuvette Borosilicate Glass / Stainless steel 316
Stirrer bar PTFE
Washstation Stainless steel 316
Note
For chemical compatibility of the Mastersizer 3000 optical unit, refer to
the Mastersizer 3000 basic guide.
Regulatory Information
Regulatory information for all Mastersizer 3000 instruments and dispersion units,
can be found in the Mastersizer 3000 basic guide.

Chapter 4 Appendix
Page 4-8 MAN 0479

Malvern Instruments Limited
Grovewood Road, Malvern
Worcestershire, WR14 1XZ, UK
Tel +44 1684 892456

Fax +44 1684 892789
www.malvern.com
PARTICLE SIZE
MASTERSIZER 3000
HYDRO SERIES
WET DISPERSION UNITS
MAN0479
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Tel +44 1684 892456

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Malvern Instruments pursues a policy of continual improvement due to technical development. We

Malvern Instruments Ltd.

Tel + [44] (0)1684-892456

Tygon is a registered trademark of Saint-Gobain Corporation.

PEEK is a registered trademark of Victrex.

Software and Control

Hydro series wet dispersion units Page i

Page ii Hydro series wet dispersion units

Dispersion unit Description Model number

This manual is a supplement to the following manuals:

Hydro series wet dispersion units Page 1-1

Introduction and Hardware

Software and Control

Page 1-2 MAN 0479

Hydro dispersion units - overview

Hydro series wet dispersion units Page 1-3

adequate dispersion and representative sampling prior to a measurement being per-

Hydro MV and LV dispersion units

Hydro EV dispersion units

Hydro SM dispersion units

Page 1-4 MAN 0479

Additional accessories: Heater/chiller unit (not shown)

Control of the Hydro dispersion units

Hydro series wet dispersion units Page 1-5

Hydro MV and LV dispersion units

How is the dispersion performed

Page 1-6 MAN 0479

Hydro series wet dispersion units Page 1-7

Features of the Hydro MV / LV dispersion units.

 Sampling tank  Lower Internally regulated disper-

Page 1-8 MAN 0479

 Tank light  Breather holes

 Over-flow system and drain

Hydro series wet dispersion units Page 1-9

Notes on manually filling the tank:

Page 1-10 MAN 0479

Sampling pump and stirrer

Ultrasonic transducers have a recommended lifetime; this is with respect to the

Hydro series wet dispersion units Page 1-11

Page 1-12 MAN 0479

Lower internally regulated dispersant inlet port

Upper externally regulated dispersant inlet port

Hydro series wet dispersion units Page 1-13

In the software this is referred to as Auto-

Connecting the upper/non-aqueous dispersant tubing

To cell / From cell connections

Page 1-14 MAN 0479

From cell connection

Drain Button (MAZ3210/3310 only)

Hydro series wet dispersion units Page 1-15

Hydro EV dispersion unit

How is the dispersion performed

Page 1-16 MAN 0479

Features of the Hydro EV dispersion unit

Sampling area / beaker

Hydro series wet dispersion units Page 1-17