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Service Manual
VAP 10
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V1.0 Rev.1
 Table of contents Service Manual Vapodest 10

1. General notes for users of the Service Manual VAP 10

2. Identification of parts

2.1 Front View VAP 10

2.2 Rear View VAP 10

2.2.1 Steam Generator VAP 10

2.2.2 Tubing-connection module VAP 10

2.2.3 Pump-holding module VAP 10

2.2.4.a PCB-module VAP 10, 230V

2.2.4.b PCB-module VAP 10, 115V

2.2.5 Others

2.2.5.a Clamping device

2.2.5.b Solenoid pinch valves

2.2.5.c 2nd condenser

3. Theory of operation

3.1 Description of the function

3.2 Electric control

3.3 Distillation water dosing

3.4 Dosing of sodium hydroxide

3.5 Steam generator and steam path

3.6 Cooling water cycle

3.7 Rinsing of steam generator

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4. Diagrams and schematics

4.1 Block diagram 230 V

4.2 Block diagram 115 V

4.3 Principle of dosing distilling water

4.4 Diagram distilling water

4.5 Schematic steam generator

4.6 Principle steam during standby

4.7 Circuit cooling water

5. General spare part list

6. 12-month maintenance list

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1. General notes for users of the Service Manual VAP 10

This manual was written exclusive for the service staff of C. Gerhardt GmbH & Co. KG and for the service
staffs of our international agencies.

This service manual shall help to get a deeper knowledge of how the instrument is constructed and how it
works. It is an important tool to service and repair the instrument in a safe, competent and specific way. The
transparent structure will enable to order and to store the most useful spare parts. This manual will make
servicing easier, in particular for our international agencies.

To provide yourself against risks during operation or service, the following safety instructions should be
obeyed:

Make sure that no liquid gets into contact with cable conntections or the interior of the
electrical parts of the unit! Danger of electrical shock!

Repairs on electrical, electronic or mechanical parts must only be done by authorized

personnel.

Always switch off the apparatus at the mains and pull the plug before opening! Danger of
electrical shock!

The apparatus must be used according to the instruction manual. It is not allowed to make changes to the
apparatus in order to modify its application.

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2.1 Front View VAP10

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1000353 Screw cap GL45, open 1000357 Silicone seal GL 45
1004322 (white)

1000351 Screw cap GL18, open 1000356 Silicone seal GL18

1004321 (white)

1000350 Screw cap GL14, open 1000358 Silicone seal GL14, with tubing
1004320 (white) connection

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 c

d
b

a) 12-0363 Distribution Head c) 1000058 Condenser

b) 12-0351 Vitone Cone d) 1000496 Silicone tubing, 8/12, 20cm

1000396 Distance piece for distribution head

e) 1000536 Clamp for 12-0363 and 1000058

f) 1001079 Screw
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 b

a) 1000036 Ventilation valve for condenser

b) 1000484 Silicone tubing, 6/10, 12cm

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 c

a) 1002178 PTFE-Inlet tubing, STEAM

b) 1000630 PTFE-sieve
c) 1000250 PP tube joint

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1000399 Drip Tray

1000391 Hinge (pair)

Click here to see Front door

and more details

1003487 Magnetic door switch

This is the mounting hole for the

magnetic door switch.
It is located behind the bottom hinge.

BACK TO FRONT VIEW

 1001263 Front Door

1000392 Handle 1001875 Magnet for Door switch

BACK TO FRONT VIEW

2.2 Rear View VAP10

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View from rear when mounted

1000678 Dummy plug, PP

1000538 PP - distributor

1000070 Tubing connector, 6mm

BACK TO REAR VIEW

1003401 PTFE - tubing, NaOH

1003396 Clamp

1000493 Tubing, Isoversinic

1000081 Non - return valve

1000659 Clamp

1000495 Tubing, Viton

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2.2.1 Steam Generator VAP10

STEAM GENERATOR Top View

Click here for Bottom View

BACK TO REAR VIEW

 1003552 Tubing, PTFE

1000484 Tubing, silicone

1003817 Connector

BACK TO REAR VIEW

 1003480 Steam Generator 230 V

1004178 Steam Generator 115 V

1004703 Insulation , top 1001446 Excess pressure valve

- opens at ~ 1.2 - 1.8 bar

BACK TO REAR VIEW

 1002289 Tubing, Novoprene

1004840 Fitting, complete

1004841 Tubing, PTFE

1004848 Insulation collar

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STEAM GENERATOR Bottom View

READY switch

Exess Temp. switch

BACK TO REAR VIEW

1003482 Excess-temperature switch, 1003481 READY-switch
190C, 230V (105C)
1004857 Excess-temperature switch, - open when cold
190C, 115V - closed when hot

-closed when temperature <~190C

1003483 Thermoelement
(keeps working temperature at approx. 120C)
- resistance when cold ~ 3 Ohms
- resistance when hot ~ 18 Ohms
- green wire + (J17), white wire - (J16)

BACK TO REAR VIEW

2.2.2 Tubing Connection Module VAP10

1000583 Screw

1000401 Tubing connection crosshead

(without parts)

1000363 Cooling water inlet valve

(with pressure switch, > 0,5 bars)

1000397 Connector, Outlet cooling water

1000398 Connector, Inlet distilled water

1000397 Connector, Outlet 2nd condenser

BACK TO REAR VIEW

2.2.3 Pump Holding Module VAP10

1003478
3/2-way valve for dosing
distilled water

1003479
Dosing pump distilled water

1003396 Hose clamp

1004794
Dosing pump NaOH

1000071
Tubing connector, 8mm

1000070 Tubing connector, 6mm

1000495 Tubing, viton, 5cm

1000081 Non-return valve

BACK TO REAR VIEW
 1002066 Spare part set for pump 1000069

1002062 Diaphragm 1002063 Valve plate

1002065 Diaphragm 1002064 O-ring

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2.2.4a PCB Module VAP10, 230V

Internal view

1004847 Selector switch

1001358 Excess current switch

10 Amps.

1000282 Socket with bayonet catch

1004842 Mains socket

BACK TO REAR VIEW
2.2.4b PCB Module VAP10, 115V

1004858 Transformer

1004859 Relay

1001469 Excess current switch, 16 A

1002589 Z-Binder, antikink

1001867 Mains cable

BACK TO REAR VIEW

 1003484 Control PCB

1000233 Semiconductor Relais

(Solid State Relais / SSR)

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Click here

1004845 Signal lamp, green

1004844 Signal lamp, red

1004846 Push button

1004846 Push button

1000229 Mains switch

BACK TO REAR VIEW

 1003273 Adhesive foil, VAP10 1004115 Adhesive foil, VAP10s

1004461 Potentiometer NaOH, 500 k Ohms

1004462 Potentiometer STEAM, 5 k Ohms

1003485 Timer

1003486 Potentiometer Assembly

1003488 Knob for Potentiometer

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2.2.5 a Clamping Device

1000537 Clamping device for sample tube, complete

1001303 Wedge, complete with axis

BACK TO REAR VIEW

1000390 Spring

1000290 Micro switch

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with sample tube inserted:

closed

without sample tube:

open

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2.2.5 b Solenoid Pinch Valves

1000048 Ventilation glass

1000091 Tubing holder (guidance)

1000141 Plug with rectifier and seal

1000090 Pinch valve

1002289 Novoprene tubing

1003127 Y-piece
1003705 angle connector
BACK TO REAR VIEW
2.2.5 c 2nd Condenser

1000036 Ventilation valve

1000496 Tubing, silicone

1000358 Screw cap, GL 14

1000484 Silicone tubing

1000358 Tubing connector,

straight

1000497 Silicone tubing

1000359 Tubing connector, angle

1003274 2nd condenser

BACK TO REAR VIEW

3.0 Theory of operation

3.1 Description of the function

After turning the unit on, the user has to wait a few minutes till the signal Ready flashes up. Only
then a distillation can be started. However, there have to be certain aspects of the safety sensor
technology fulfilled.

- Temperature at the stanby sensor of the steam generator higher than 105C
- Put digestion tube into the instrument ( Micro switch )
- Reservoir level sensor active ( tank not empty ) or dummy plug connected
- Cooling water open ( pressure higher 0.5 bar )
- Door sensor active ( Reed contact active, door closed )

When Ready flashes up, the distillation can be started with the push-button Run if a distillation
time has been set previously at the time relay (e.g. 4 min).
Now, the amount of sodium hydroxide to be added can be set at the potentiometer Reagent
(see explanation further down). At the same time, the steam output can be set at the potentiometer
Steam (see explanation further down).

The following procedure will start:

After pressing the button Run the distillation will be started and the display Busy will be lit. After
expiry of an internal delay time both solenoid pinch valves inside the instrument are put into
operation position so that the path for the steam into the steam distributor is clear. A defined
volume flow of water is introduced into the pre-heated steam generator and evaporates. In the first
seconds the steam condensates in the sample liquid till it is heated up enough; only then the
steam bubbles are visible in the sample. Also, upon expiry of the delay time, the pre-set amount of
sodium hydroxide is added. During the entire distillation process, a constant volume flow of water
is steadly (clocked) added for evaporation. There is an appropriate sensor technology at the steam
generator which makes sure to provide the optimal operating temperature during the distillation
(see explanation further down).
When the distillation is over, both solenoid pinch valves get into idle position. Thus, the steam path
between the steam generator and the steam inlet tubing is interrupted, at the same time, the
steam generator is ventilated and small amount of residue steam can escape through an
additional condenser at the rear of the instrument.
The instrument is then ready for the next distillation, if all criteria for the safety sensor technology
mentioned above are fulfilled again. The heating of the steam generator is kept at the optimal
operational temperature even if there is no distillation in process.

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3.2 Electric control

An analogue electronic circuit in connection with a time relay is used to control all assemblies. You
will find more details in the following documents:

- Block diagram 230 V, drawing no. 1 0127 000 00 00 10 08

- Block diagram 115 V, drawing no. 1 0127 000 00 00 12 08

The cables are concatenated in a wiring loom. All cables in the wiring loom and all access lines of
the electric assembly group are labelled, like the connections on the PCB, so that errors can be
excluded when cable connections are plugged in.

3.3 Distilling water-dosing

The steam generator has an electric power of 1500 W. Thus, the maximum steam power as well
as the respective maximum amount of water to be added is given - as it is the amount that the
steam generator can convert completely into steam and there wont be an excess of water accu-
mulating in the steam generator. The maximum volume flow is at 30 ml/min +/- 2 ml/min taking into
consideration the respective safety aspect. The dosing system has to be set so that this value is
kept. The dosing system consists of the following components:

- Feed pump H2O with integrated swing check valve

- Dosing valve (electrically clocked)
- Hose winding (PTFE-hose, interior diameter 1 mm, 900 mm long)

For further explanations, please see the following documents:

- Principle circuit diagram - distilling water dosing, drawing no. 1 0127 000 00 00 16 08
- Tubing diagram - distilling water, drawing no. 1 0127 000 00 00 09 08

The feed pump is a diaphragm pump, which has an excess of discharge flow. In order to limit or
set the discharge flow (for smaller steam output), there is an electrically clocked magnetic valve at
the feed pump. Depending on the position of the potentiometer Steam, the clock relationship of
the magnetic valve varies. In order to make sure that the pump can also work properly during the
closed phases of the magnetic valve, the feed pump has an adjustable back flow check valve,
where the excess volume flow can be guided back. A certain counter pressure is necessary, so
that the dosing system is working optimally and on a continuous basis when the magnetic valve is
open. This counter pressure is generated by the flow resistance present in the above mentioned
hose winding. If there has been a service done at the dosing system or also, if the PCB has been
replaced, the dosing system has to be checked and if necessary has to be set again. There is a
setting screw with lock nut at the back flow check valve of the feed pump. This way, the maximum
amount of delivery volume is set:

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 - Set the potentiometer Steam to position 10
- Put suction tubing for distilling water into a measuring flask which is filled with 500 ml water
- Set distillation time to 10 min at the time relay and start distillation
- When the distillation time is over, check the water consumption
- If the consumption is higher or lower than 300 ml +/- 20 ml of the total value, the screw at
the back flow check valve has to be set
- As a guide line, on can assume that a quarter turn of the screw corresponds to an
amended time of 3 ml/min. If the screw is turned clockwise, the volume flow is increased.
If the screw is turned counter-clockwise, the volume flow is reduced.
- Make sure to check again after any modifications. The minimum delivery volume in pos.
1 of the potentiometer Steam is an automatic consequence and is about 20 ml/min.

3.4 Dosing of sodium hydroxide

The dosing of the sodium hydroxide is done by a media resistant pump. This pump is automatically
controlled during the program sequence. The duration of the dosing time and thus the dosing volume
can be set using the potentiometer Reagent and thus has an impact on a timing relay of the
analogue regulation. Furthermore, the user can also add sodium hydroxide manually in whatever
quantity, using the switch Reagent, if the instrument is in mode Ready.

3.5 Steam generator and steam path

As already explained under item 4.3, the steam generator gets a volume flow of water which is
continuously evaporated. For further information, please see the following documents:

- Steam generator, drawing no. 1 0127 000 00 00 13 08

- Steam circuit (in principle), drawing no. 1 0127 000 00 00 15 08

The steam generator is heated with an electric heating element (1500 W) which is integrated at
the bottom of the steam generator. The 2-point-control is done with an analogue circuit and a
temperature sensor which is screwed tightly to the bottom of the steam generator. The working
temperature is 120 C. Due to safety precautions, there is an excess-temperature device at the
bottom of the steam generator, which switches off in case of a failure at 190C (reversible). Further-
more, there is an excess-pressure valve at the steam generator, which opens in case of a failure
between 1.2 and 1.8 bar and steam can get out at the back of the instrument. The stand-by sensor
makes sure that the steam generator has working temperature at the start of the distillation. How-
ever, like with all other sensors, you have to make sure the screwing connections are fitting tightly
and that there is a good heat contact.

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During the distillation, the steam generator is kept at a sufficient temperature thanks to the control
circuit and the temperature sensor.
When the distillation starts, both solenoid pinch valves switch into operating position. The steam
from the steam generator can stream through the solenoid pinch valve 1 (now passage is open)
through the steam inlet tubing into the sample. At the same time, the ventilation is closed at this
valve, so that the distillate cannot escape unchecked.
At the solenoid pinch valve 2, the connection to the additional condenser is closed so that no steam
can escape this way. (When the instrument is not working this connection is open). Both valves
switch back into idle simultaneously after termination of the distillation time:

- Valve 1: closes the path from steam generator / sample and at the same time it is
ventilating the sample to prevent sucking back sample into the steam generator.
- Valve 2: Deviation of the residue steam via the additional condenser into garbage.

3.6 Cooling water cycle

In order to run a distillation, the function of the cooling water loop is absolutely necessary. The
cooling water pressure is checked by a pressure switch at the magnetic valve for cooling water inlet
and it is integrated into the safety sensor technology. It is utmost importance that the tubing
connections with screws are tight. Furthermore, all internal tubing connections of the cooling water
loop have to be checked visually.

3.7 Rinsing of steam generator

At the rear of the instrument there is a switch to put the instrument into a mode to allow the cleaning
of the steam generator. This is necessary as in case of a failure, sample/lye/acid, has been sucked
into the steam generator. In this mode now, the steam generator is rinsed extensively with a
water / steam mixture to run again. How to proceed: fill water tank with 5 l water and open the
cooling water.

Turn switch from position D (distillation) to position S (rinsing), switch on the instument and start
a distillation. Make sure that a tubing is connected at the water outlet (steam residue) at the rear of
the instrument which leads to an outlet. Run distillation till the entire water supply is consumed and
no steam respectively water is present. Check pH-value of the last available rinsing water. It is
advisable to repeat process. Then set switch back into position D.

Explanation of the internal process during rinsing mode:

In the rinsing mode, the sensors for door, stand-by, sample tube and cooling water are not checked.
Furthermore, the dosing valve is not clocked, but stays open all the time. After starting the distillation
the solenoid pinch valves are not set into working position either, but remain in idle. Thus, the
following will happen:
The steam generator is supplied with an excess of water, but the steam generator cannot turn all of
it into steam. Thus, it fills with hot or boiling water. Since the solenoid pinch valves are in idle, the
steam inlet tube is not connected to the steam generator. But the path to the additional condenser
via solenoid pinch vale 2 is open. Steam and boiling water are guided through the additional
condenser, cooling down there and then guided out of the instrument at the rear. When the tank is
empty after about 45 min, the remaining amount of water inside the steam generator will boil off.
Now, the instrument is turned off and set back into operation mode D.

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4.1 Block diagram 230V

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4.2 Block diagram 115V

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4.3 Principle Distilling water dosing

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4.4 Diagram Distilling water

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 4.5 Steam generator

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Drawing 1 0127 000 00 00 13 08
 Drawing 1 0127 000 00 00 15 08
4.6 Principle steam during standby

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4.7 Circuit cooling water

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5. General spare parts

General spare part list

VAP10

This kit includes the following recommended parts to be prepared for service calls:

Part-no. Qty. Description

1004321 2 Screw cap, GL18

1000356 2 Silicone seal, GL18

1004322 1 Screw cap, GL 32

1000357 1 Silicone seal, GL 32, with tubing connection

1004320 6 Screw cap, GL 14

1000358 6 Silicone seal, GL 14

12-0351 1 Vitone cone

1000290 1 Micro-switch

1000081 1 Non-return valve

1002289 2m Novoprene tubing

1000497 2m Silicone tubing, 8mm

1000495 0.5m Viton tubing

1000659 2 Clamp

1000250 1 PP tube joint

1000141 1 Plug with rectifier + seal

1000090 1 Solenoid pinch valve

1000071 2 Angle connector, 8mm

1000070 2 Angle connector, 6mm

1000233 1 Semiconductor relais

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6. 12-month maintenace

12-month maintenance list

VAP10

This kit includes the following parts:

Part-no. Qty. Description

1004321 2 Screw cap, GL18

1000356 2 Silicone seal, GL18

1004322 1 Screw cap, GL 32

1000357 1 Silicone seal, GL 32, with tubing connection

1004320 2 Screw cap, GL 14

1000358 2 Silicone seal, GL 14

12-0351 1 Vitone cone

1002289 1m Novoprene tubing

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