WIGGENS atexMIX ATEX-Certified Magnetic Drive Stirring Controller

Overview

The WIGGENS atexMIX ATEX-Certified Magnetic Drive Stirring Controller is an intrinsically safe, high-reliability control unit engineered for continuous operation in hazardous laboratory and industrial environments where flammable vapors, gases, or dusts may be present. Unlike conventional electromagnetic stirrers, the atexMIX employs contactless magnetic drive technology—eliminating mechanical wear, brush arcing, and localized heat generation at the drive interface. It operates on the principle of synchronous coupling between a rotating permanent magnet rotor (integrated into the BIOMIX Drive unit) and a precisely phased stator field generated by the controller’s power electronics. This enables precise, low-vibration rotational control across its full 100–2,000 rpm range—even at sub-100 rpm speeds where torque stability is critical for sensitive bioprocesses. Designed for integration with WIGGENS BIOMIX Drive motorized stirrer bases, the atexMIX delivers consistent 20 W output per channel and supports both standard and cleanroom-grade configurations compliant with Zone 1 (II 2G) and Zone 2 (II 3G) explosive atmospheres.

Key Features

• ATEX-certified design meeting EU Directive 2014/34/EU: II 2G EEx de IIC T6 (atexMIX) and II 3G Ex nAC IIC T6 (atexMIX cleanroom), verified by KEMA 03 ATEX 2045 and EPS 10 ATEX 1246 X certificates
• IP65-rated enclosure—dust-tight and protected against low-pressure water jets—ensuring operational integrity in wet or particulate-laden environments
• Four-step programmable power output (25%, 50%, 75%, 100%) enabling optimized energy delivery for low-viscosity cell culture media or high-viscosity fermentation broths
• Digital LED display with real-time rpm and power-level feedback; soft-start algorithm ensures reliable stir bar capture and smooth acceleration without slippage or oscillation
• MIX Watch intelligent monitoring system (optional): continuously verifies stir bar rotation status via back-EMF analysis; triggers automatic stop, repositioning, and restart upon detection of misalignment, stalling, or abnormal drag—critical for unattended overnight or remote bioreactor operation
• Expandable communication architecture: supports optional 0–10 V analog, 4–20 mA current loop, RS232 serial, USB, and Ethernet interfaces for integration into SCADA, LIMS, or PLC-based process control networks
• Auto-memory function retains last-used speed and power settings across power cycles; quick-set dual-parameter interface allows independent definition of start speed and maximum speed ramp profiles

Sample Compatibility & Compliance

The atexMIX controller is compatible exclusively with WIGGENS BIOMIX Drive series magnetic stirrer bases (e.g., BIOMIX Drive 1–6), which utilize sealed, maintenance-free brushless DC motors and rare-earth magnet couplings. It supports glass, stainless steel, and polymer reaction vessels ranging from 50 mL to 5 L, provided appropriate PTFE- or ceramic-coated stir bars are used. The system complies with ISO 8573-1 (compressed air purity), ISO 14644-1 Class 5 (for cleanroom variant), and adheres to GLP/GMP documentation requirements when paired with audit-trail-enabled custom software. Its ATEX certification ensures suitability for use in pharmaceutical synthesis labs handling Class IIA/IIB gases (e.g., ethanol, acetone, hydrogen), as well as fine chemical production facilities governed by IEC 60079 standards.

Software & Data Management

While the atexMIX operates as a standalone unit with local keypad control, it is designed for seamless digital integration. Optional firmware upgrades enable time-stamped event logging (start/stop, speed changes, fault alerts) compliant with FDA 21 CFR Part 11 when deployed with validated third-party software. WIGGENS provides SDK documentation for OEM-level customization, supporting Python, LabVIEW, and MATLAB APIs. Data export formats include CSV and XML; Ethernet-enabled units support Modbus TCP and OPC UA protocols for enterprise-level instrumentation interoperability. All configuration parameters—including MIX Watch sensitivity thresholds and auto-recovery retry limits—are remotely configurable and version-controlled.

Applications

• Continuous stirred-tank reactors (CSTRs) in API synthesis under explosion-proof conditions
• Long-duration mammalian cell culture in CO₂ incubators with integrated stirrer bases
• High-solids fermentation processes requiring stable low-RPM agitation to prevent shear damage
• Cleanroom-based vaccine adjuvant preparation where electrostatic discharge must be eliminated
• Quality control laboratories performing USP or compliant sterile compounding with automated agitation verification
• Academic research in catalytic hydrogenation, where solvent vapors necessitate Zone 1-rated equipment

FAQ

Is the atexMIX controller compatible with non-WIGGENS stirrer bases?
No. The atexMIX is engineered exclusively for use with WIGGENS BIOMIX Drive motorized stirrer units due to proprietary magnetic coupling geometry and closed-loop commutation timing.
Can MIX Watch detect stir bar detachment in opaque or metal-jacketed vessels?
Yes—MIX Watch relies on electrical signature analysis of the drive motor rather than optical or acoustic sensing, making it effective regardless of vessel material or opacity.
Does the ATEX certification cover both electrical and mechanical explosion risks?
Yes. The II 2G EEx de IIC T6 classification certifies protection against both gas ignition (via encapsulation ‘e’ and flameproof enclosure ‘d’) and surface temperature limitations (T6 ≤ 85 °C).
What is the expected service life under continuous 24/7 operation?
Rated for ≥50,000 hours MTBF under nominal load (20 W, 1,200 rpm), based on accelerated life testing per IEC 61508 SIL2 guidelines.
Is calibration required prior to first use?
No routine calibration is specified; however, users should perform functional verification using a calibrated tachometer and verify MIX Watch response with intentional stir bar displacement during commissioning.