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Hach BioTector B3500C User Manual
Summary of BioTector B3500C
Page 1
Catalog number: 10-mat-452 biotector b3500c online toc analyzer user manual november 2012, edition 1 bs5ax 2.02.01a © copyright biotector 2012. All rights reserved. Printed by biotector. Printed in the republic of ireland..
Page 2: Table Of Contents
Page 2 table of contents section 1 safety precautions .......................................................................... 5 1.1 i nformation and s afety s igns used in the m anual ....................................................... 5 1.2 p recautionary l abels a ttached to the i nstrument...
Page 3
Page 3 4.2.4.3 voc (poc) analysis ......................................................................................................................... 48 section 5 installation ....................................................................................... 49 5.1 b asic s ystem r equire...
Page 4
Page 4 8.3.4.5 pressure/flow test program ........................................................................................................... 122 8.3.5 output devices .......................................................................................................................... 12...
Page 5: Section 1
Page 5 section 1 safety precautions please read this manual before unpacking, setting up, or operating the biotector. Biotector should only be used by qualified trained staff and for the purpose it is intended for. Do not use or install this equipment in any way other than the methods specified in t...
Page 6
Page 6 1.2 precautionary labels attached to the instrument the labels and tags attached to the instrument are summarized below. Please read all labels and tags attached to the instrument. If not observed, personal injury or damage to the instrument could occur. This symbol, when displayed on the ins...
Page 7
Page 7 1.3 certification marks attached to the instrument the certification marks attached to the instrument and their meanings are summarized below. This mark, which stands for european conformity "conformité européene", indicates that “the instrument complies with the european product directives, ...
Page 8: Caution
Page 8 1.4 potential system safety hazards the potential safety hazards, which are associated with a running biotector system, are as follows: electrical hazards potentially hazardous chemicals oxygen gas and components generating ozone gas please read the instructions in this manual carefully befor...
Page 9
Page 9 1.4.1 ozone and toxicity ozone is found in gaseous form as a natural ingredient of the earth's atmosphere. It is not a poisonous chemical but a strong oxidizing chemical. Some of the chemical and physical properties of ozone are as follows: terms properties of ozone (o 3 ) molecule weight 47....
Page 10
Page 10 1.5 general safety precautions please pay attention to all caution, warning and danger statements at all times. Non-observance of the safety instructions can result in serious personal injury, death or damage to the equipment. Therefore observe the following: only engineers trained by the ...
Page 11: Danger
Page 11 1.5.1 electrical and burn precautions during system installation, maintenance or servicing: isolate the system power lines before starting any work in the electronic enclosure. All electrical work should be carried out by qualified electrical personnel only. Comply with all local and nationa...
Page 12
Page 12 1.5.2 carrier gas and exhaust gas precautions biotector uses oxygen (o 2 ) gas as the carrier gas during its operation. The oxygen gas must be free of carbon dioxide (co 2 ) and nitrogen (n 2 ) gases. The average rate of oxygen consumption in biotector is 29 l/h (483 ml/min). Carbon dioxide ...
Page 13
Page 13 1.5.3 chemical precautions a number of chemicals and compounds to be used with biotector are listed in section 6 reagents and calibration standards . Some of these compounds are harmful, corrosive, acidic and oxidizing. Appropriate precautions must be taken when handling these chemicals or s...
Page 14
Page 14 1.5.4 sample stream precautions the user is responsible to establish the potential hazard associated with each sample stream. Necessary precautions must be taken, to avoid physical contact with any harmful sample stream, which may contain chemical or biological hazards. System components and...
Page 15
Page 15 1.5.4 précautions relatives aux échantillons l’usager assume la responsabilité d’établir le danger possible que représente chaque échantillon. Il est essentiel de prendre les précautions voulues afin d’éviter le contact physique avec tout échantillon nocif qui pourrait présenter un danger ch...
Page 16: Section 2
Page 16 section 2 operator’s manual 2.1 software screens and software menu diagram the biotector is equipped with a built-in microprocessor, which has been programmed to enable the user to control the instrument using just six buttons of its membrane keypad. By pressing the appropriate button, the u...
Page 17
Page 17 software menu diagram.
Page 18
Page 18 2.1.1 startup state when the biotector is powered up, its lcd screen will automatically display the analysis data screen after a delay of 60 seconds. By pressing the escape key the user moves from the analysis data screen to the analysis graph screen. Pressing the enter keyon the analysis gr...
Page 19
Page 19 2.1.3 analysis data screen b i o t e c t o r r u n n i n g 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 0 9 : 1 3 : 0 2 1 2 - 0 9 - 0 2 r e a c t i o n s t a r t t i c & t o c s t r e a m 2 r e a c t i o n t y p e t o c r e a c t i o n p h a s e 1 r a n g e 2 6 6 s r e a c t i o n t i m e 3 6 0 s r e a c...
Page 20
Page 20 2.1.4 analysis graph screen 1 0 1 . 5 [ k p a ] 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 t i c m g u 1 2 . 4 9 5 6 c o 2 t o c m g u 1 5 6 . 4 4 3 5 6 c o 2 0 s 1 2 0 s 2 4 0 s 3 6 0 s 1 0 . 0 l / h 2 6 c 5 6 c o 2 i 1 2 c o 2 z 2 6 5 s the analysis graph screen gives information on the current analy...
Page 21
Page 21 2.1.6 select level menu s e l e c t l e v e l 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 2 c a l i b r a t i o n 3 m a i n t e n a n c e the select level screen allows the user to access the operation, calibration and maintenance menus. 1. Operation. This menu gives access to the basic operation of t...
Page 22: 2.2 Operation Menu
Page 22 2.2 operation menu operation menu diagram operation menu allows the user to start and stop the analyzer. Menus related to system operation are also accessed using this menu. 2.2.1 start stop the user can start or stop the biotector using the start stop menu. 1. Remote standby. Remote standby...
Page 23
Page 23 2. Start. This function starts the biotector. When biotector is started, the multi-stream operation sequence (if programmed) is reset. Biotector performs ozone purge, pressure/flow test, reactor purge and analyzer purge sequences automatically before starting its analysis. Ozone purge sequen...
Page 24
Page 24 2.2.2 reagents setup this menu allows the user to access the reagent menus. 1. Install new reagents. Menu used to install and prime the reagents in the biotector. Any “85_reagents low” and “20_no reagents” warnings and notifications can also be reset in this menu. 2. Purge reagents & zero. M...
Page 25
Page 25 when all or the necessary reagents have been confirmed to be connected and reset in this menu, and when start new reagent cycle is selected, the install new reagents cycle will be executed. It is the responsibility of the user to make sure that all reagent volumes are programmed correctly in...
Page 26
Page 26 2.2.4 manual program menu m a n u a l p r o g r a m 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 2 r u n a f t e r 0 0 : 0 0 3 r e t u r n t o o n - l i n e s a m p l i n g y e s 4 r e s e t m a n u a l p r o g r a m 5 6 m a n u a l 1 , 4 r a n g e 1 7 m a n u a l 2 , 4 r a n g e 3 8 m a n u a l 3 , 4 ...
Page 27
Page 27 2.2.5 reaction archive screen the reaction archive holds information on tic, toc, tc, voc, cod, bod, stream valve, reaction range, start time and related analysis information for the last 9999 reactions. If the archive is full, then every new reaction overwrites the oldest one in the archive...
Page 28
Page 28 2.2.7 time & date menu this menu allows the system time and date to be set by the user. To change the system time or date (hours, minutes, seconds, day, month and year), press the enter key, enter the new time and date and press the enter key again. In order to change the system date format,...
Page 29: 2.3 Calibration Menu
Page 29 2.3 calibration menu calibration menu allows the user to calibrate the analyzer. Zero and span calibration menus allow the user to run the zero and span calibration cycles for a single range or for all system ranges available. Calibration menu diagram 2.3.1 zero calibration z e r o c a l i b...
Page 30
Page 30 1. The zero adjust settings for each range are updated automatically by the system using the un- calibrated toc measurement (not the results seen on the lcd screen). If a zero check is used to check the zero offset, the sugge sted values are shown in brackets “[ ]” next to the actual zero ad...
Page 31
Page 31 2.3.2 span calibration s p a n c a l i b r a t i o n 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 2 2 1 . 0 0 3 3 1 . 0 0 4 t i c s p a n a d j u s t 1 1 . 0 0 5 2 1 . 0 0 6 3 1 . 0 0 1 0 r u n s p a n c a l i b r a t i o n 1 1 r u n s p a n c h e c k 1 2 1 3 s p a n p r o g r a m 6 1 4 s p a n a v e r...
Page 32
Page 32 4.-6. Tic span adjust. This menu item allows the user to set the tic span adjust factors manually for each range as described for toc span adjust above. 10. Run span calibration. This function starts the span calibration cycle. The span calibration reactions are run at a single range program...
Page 33
Page 33 20. Tc cal std. In voc systems, the sum of the tic and toc calibration standard solution is displayed as tc calibration standard. When toc calibration standard is programmed as 0.0mgc/l, and when a concentration of tic calibration standard is programmed above, biotector displays the tc calib...
Page 34: Section 3
Page 34 section 3 technical specifications typical technical data enclosure: fiberglass reinforced polyester dimensions (hxwxd): 750mm x 500mm x 320mm weight: typically46 kg power consumption: 100 w (va) mains connection: 115v ac, 60hz or 230v ac, 50hz ( 10%) other power options are available on req...
Page 35
Page 35 consumables typical replacement frequency & consumption acid & base: 26 weeks/19 liters (based on standard range and 6 minute analysis cycle) instrument air: 1.5 bar, - 20°c dew point (free of water, oil and dust) average consumption is less than 5.4 m 3 /hour. Filter pack is recommended and...
Page 36
Page 36 sample & environmental conditions sample volume: up to 12.0ml sample inlet pressure: ambient (for applications with high sample pressure, sampling systems are available) drain pressure: ambient (for applications with high drain pressure, optional systems are available) sample inlet temperatu...
Page 37: Section 4
Page 37 section 4 introduction 4.1 biotector major components 4.1.1 analysis enclosure figure 1, figure 2 and table 2 below shows the typical major analysis enclosure components of biotector toc analyzer. Figure 1 biotector analysis enclosure major components (typical tic & toc system) 2 6 4 5 7 8 9...
Page 38
Page 38 figure 2 biotector oxygen concentrator enclosure major components 16 17 19 18 20 21 22 23 25 24 27 26 11 14 30 31 10 28 32 33 29.
Page 39
Page 39 table 2 biotector major components 1 power and input/output board 2 ndir co 2 analyzer 3 ferrite 4 acid pump, p3 5 base pump, p4 6 main power switch 7 cooler 8 ozone generator 9 sample pump, p1 10 manual grab sample/calibration valve, mv5 or multi-stream valve, mv6 11 reactor valve, mv3 12 m...
Page 40
Page 40 4.1.2 motherboard enclosure figure 3 and table 3 below shows the biotector motherboard enclosure components. Figure 3 biotector motherboard enclosure components 1 2 3 4.
Page 41
Page 41 table 3 biotector motherboard components 1 motherboard 2 battery (cr2430, lithium, 3v, 285mah) 3 processor board 4 mmc/sd flash memory card slot and memory card.
Page 42: 4.2 Biotector Operation
Page 42 4.2 biotector operation detailed information on the system operation is available, in presentation and video formats, in the mmc/sd card shipped with the biotector. It is recommended to review these files to understand the system operation. The biotector is designed to provide continuous onl...
Page 43
Page 43 4.2.2 biotector sample injection the biotector analyzes a precise volume of liquid. The sample pump injects a pre-programmed number of pulses (half revolutions of pump) of liquid into the reactor for each measurement and therefore the volume of liquid included in each pulse is consistent. Sa...
Page 44
Page 44 figure 4 biotector analysis layout (typical tic & toc system).
Page 45
Page 45 4.2.3 biotector oxygen concentrator the operation of biotector oxygen concentrator is based on the crystalline zeolite molecular sieves, which permits the separation of oxygen gas from the mixture of gases that comprise air. As air flows through a column or bed of molecular sieve, the compon...
Page 46
Page 46 figure 6 biotector oxygen concentrator layout.
Page 47
Page 47 4.2.4 biotector analysis types biotector toc analyzer has four factory calibrated analysis types: 1. Tic & toc (npoc) analysis: total inorganic carbon & total organic carbon (non-purgeable organic carbon) analysis 2. Tc analysis: total carbon analysis 3. Voc (poc) analysis: volatile (purgeab...
Page 48
Page 48 4.2.4.3 voc (poc) analysis biotector volatile organic carbon (voc) analysis type is a combination of tc analysis followed by a tic & toc (npoc) analysis. The voc result obtained from the voc analysis type represents the purgeable organic carbon (poc) content of the sample. When both tc and t...
Page 49: Section 5
Page 49 section 5 installation 5.1 basic system requirements power and signal requirements mains connection: 115v ac, 60hz or 230v ac, 50hz ( 10%) mains wire specification: number of cores = 3 current rating minimum = 10 amps csa (cross sectional area minimum) = 1.50mm 2 signal wire specification: n...
Page 50: Caution
Page 50 5.2 unpacking and installation the biotector analyzer weighs typically 46kg (101 lb). Therefore, appropriate means should be used for transporting, un-packing, lifting and installing the biotector. The biotector analyzer is shipped ready to be installed, with a kit of parts including sample ...
Page 51
Page 51 5.2.1 analyzer dimensions and mounting the biotector toc analyzer enclosure is a fiberglass reinforced polyester (frp) cabinet. This enclosure facilitates easy access to all components and thus eases the service and maintenance procedures. Figure 7 and table 4 below gives the dimensions of b...
Page 52
Page 52 figure 8 below illustrates the biotector door clearance dimensions. Figure 8 biotector door clearance dimensions it is recommended that a clear space of at least 300mm is allowed around the analyzer from the right and the left sides and from the top and the bottom. The recommended clear spac...
Page 53: Danger
Page 53 5.2.2 wiring power and signal terminals figure 9 below show the typical mains (for both 230 and 115 volts systems) and the 4-20ma signal connections in biotector. The connection to mains power {230v or 115v ac ( 10%), 50/60 hz} should be carried out by a certified electrician, in accordance ...
Page 54
Page 54 figure 9 mains and 4-20ma terminal diagram for 115 / 230 v systems the wiring and earth connections to the analyzer should be carried out in accordance with local regulations, and securely terminated in the phase, neutral and earth terminals in the biotector. Cable glands must be used to sec...
Page 55
Page 55 5.2.3 wiring external power disconnection switches the mains power must be connected through one or more external 2-pole disconnection switches, so that the power to the biotector and/or to the optional air compressor can be isolated without opening the electronics enclosure. The external po...
Page 56
Page 56 when the wiring of the system is completed, the power up of the system should be carried out in the order below: i) while the external disconnection switches are powered off, power on the internal main power switch in the biotector. Ii) close the biotector electronics enclosure. Iii) if inst...
Page 57: Danger
Page 57 5.2.4 system fuse specifications table 5 below summarizes the location and specification of the fuses used in biotector. The locations of the fuses are also displayed in figure 9 above. Table 5 system fuse specifications 230 v systems 115 v systems location board number interru pt rating typ...
Page 58
Page 58 5.3 air supply and reagent connections the orientation of the ferrules inside each fitting of biotector is critical for the correct operation of the system. Incorrect ferrule orientation may create gas/liquid leak and/or introduce air bubbles into the system lines. Therefore, the ferrules on...
Page 59
Page 59 5.3.1 air supply connection the recommended air quality for biotector is -20°c dew point, free of water, oil and dust. A filter pack may be required to meet or exceed the air quality specification. The air can be supplied to biotector from: a) an existing instrument air supply line b) biotec...
Page 60: Danger
Page 60 5.3.2 reagent connections special precautions are needed when working with chemical reagents, both when renewing reagents and when dealing with leaks or spills. Some reagents can cause chemical burns and may cause injury or death if swallowed. Please refer to the symbols and codes on the rea...
Page 61
Page 61 as can be seen in the figure 13 above, base (sodium hydroxide) reagent container does not contain any vent (breathing) hole. The breathing air into the base container is supplied through the co 2 filter, which must be fitted on the base container lid. Figure 14 below shows the detailed conne...
Page 62: Caution
Page 62 5.4 sample, drain and exhaust connections 5.4.1 sample inlet tube position biotector operates on unfiltered samples, the setup of the sampling point is important for the correct operation of the system. Biotector can handle soft particulates up to 100µm in diameter, however hard particulates...
Page 63
Page 63.
Page 64: Warning
Page 64 5.4.2 drain and exhaust connections the biotector should be installed in a well-ventilated area with the exhaust port piped to an external vent. The installation should be carried out in accordance with section 1 safety precautions . All biotector drain tubing must be positioned correctly so...
Page 65: Section 6
Page 65 section 6 reagents and calibration standards 6.1 reagents biotector toc analyzer uses the following reagents: i. Acid: 6.0 n sulfuric acid (h 2 so 4 ) reagent containing 350 mg/l manganese sulfate monohydrate ii. Base: 4.0 n sodium hydroxide (naoh) reagent reagents should not contain high le...
Page 66: Warning
Page 66 6.1.1 sulfuric acid reagent there are a number of factors which affect the purity of the sulfuric acid solution used by the biotector. These can take the form of inorganic or organic contamination. Inorganic contamination does not generally occur in concentrated acids, but there could be som...
Page 67
Page 67 control of normality: in order to check the normality of the acid solution prepared, take a 12 ml sample from the prepared 6.0 n sulfuric acid solution. Add 2-3 drops phenolphthalein and just enough 1.2 n sodium hydroxide until the color of the mix becomes red. If the normality is correct, 6...
Page 68: Warning
Page 68 6.1.2 sodium hydroxide reagent there are a number of factors which affect the purity of the sodium hydroxide solution used by the biotector. These can take the form of inorganic or organic contamination. Inorganic contamination has two main sources: sodium carbonate (na 2 co 3 ), which is pr...
Page 69
Page 69 control of normality take a 10 ml of sample from the 4.0 n sodium hydroxide container. Add 2-3 drops phenolphthalein and just enough 1.0 n hydrochloric acid until it turns clear. If the normality is correct, 40 ml of 1.0 n hydrochloric acid will neutralize 10 ml of 4.0 n sodium hydroxide. Mi...
Page 70: Caution
Page 70 6.2 calibration standards the following compounds can be used to prepare calibration standard solutions in biotector. To prepare a 1000mgc/l total organic carbon (toc) standard solution, use one of the following: potassium hydrogen phthalate, c 8 h 5 ko 4 , 2.13g (99.9% purity) in one liter ...
Page 71
Page 71 the calculation of the quantities required to prepare potassium hydrogen phthalate (khp) standard solutions with various purities are given as an example below: name: potassium hydrogen phthalate formula: c 8 h 5 ko 4 carbon, 12 x8 = 96 oxygen, 16 x4 = 64 potassium, 39 x 1 = 39 hydrogen, 1 x...
Page 72
Page 72 preparation of calibration standard solutions: use eye protection and gloves. Standards solutions greater than 1000mg/l can be prepared directly without any dilution by simply mixing the necessary quantity solvent or salt with deionized water. Standard solutions below 1000mg/l concentration ...
Page 73: Section 7
Page 73 section 7 analyzer commissioning and startup the check list below must be used to ensure that the installation has been properly carried out. Please proceed through the check list in the given order, completing the 5 sections below. Detailed commissioning and startup procedures are available...
Page 74
Page 74 remove the tapes, which are used to seal the ends of the supplied co 2 filter. Fit the co 2 filter to the base container and seal the base container tightly. See figure 13 and figure 14 in section 5.3.2 reagent connections for details. _____ connect the acid (6.0 n sulfuric acid, h 2 so 4 , ...
Page 75
Page 75 oxygen purity test: power up the system for at least 10 minutes before the oxygen purity test is carried out. Using the simulate menu (see section 8.1.2 simulate ) set the mfc (see figure 2 and table 2 in section 4.1.1 analysis enclosure ) flow to 10 l/h and flow oxygen gas through the co 2 ...
Page 76
Page 76 4. Commissioning menu settings: using the commissioning menus (see section 8.2 commissioning menu ), follow below procedures to set up the biotector for specific site requirements: in reaction time menu, program the interval time depending on the required sample analysis frequency. _____ in ...
Page 77
Page 77 5. Zero and span calibration: go to operation, reagents setup, install new reagents menu, confirm the menu items and select the “start new reagent cycle” function for the biotector to prime the reagents and set the zero adjust (zero offset) values automatically. See section 2.2.2.1 install n...
Page 78: Section 8
Page 78 section 8 maintenance menu maintenance menu diagram.
Page 79: 8.1 Diagnostics Menu
Page 79 8.1 diagnostics menu this group of menu allows the user to access the process test, simulate, data output, input/output status and service menus for diagnostic purposes. Diagnostics menu diagram.
Page 80
Page 80 8.1.1 process test this group of menus allows the user to simulate the pressure test, flow test, ozone test, sample pump test and ph test routines. In biotector, when the user enters the process test menus, where the oxygen gas flow will be required, the oxygen generator starts to operate au...
Page 81
Page 81 8.1.1.2 flow test f l o w t e s t 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 2 e x h a u s t f l o w 3 s a m p l e o u t t e s t 4 s a m p l e o u t f l o w t i m e 3 0 s m f c s e t p o i n t 6 0 . 0 l / h m f c f l o w 5 8 . 3 l / h s t a t u s t e s t i n g p r e s s e s c t o a b o r t t h e t e ...
Page 82: Warning
Page 82 8.1.1.3 ozone test the ozone test uses the procedure described in information sheet “t020. Procedure to check the ozone level in biotector system-c (b3500c) ”, which is available in the mmc/sd card shipped with the biotector. The user must read and understand the processes described in this ...
Page 83
Page 83 ozone test, phase 3: o z o n e t e s t 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 * s t a r t t e s t 2 t i m e 5 s s t a t u s t e s t i n g o z o n e g e n e r a t o r i s o n ! ! ! D o n o t o p e n o z o n e t e s t e r the ozone test has now started. Do not open the ozone tester. The user should...
Page 84
Page 84 8.1.1.4 sample pump test s a m p l e p u m p t e s t 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 v a l v e s t r e a m 1 2 3 p u m p r e v e r s e t e s t 4 5 - - > s a m p l e p u m p t i m e 6 s s t a t u s t e s t i n g p r e s s e s c t o a b o r t t h e t e s t this menu enables the user to test ...
Page 85: Warning
Page 85 8.1.1.5 ph test the user must understand the procedure for testing the ph in the biotector. Use eye protection and gloves. Have all the relevant parts for this test ready (primarily beaker and ph paper) before carrying out the test. For the ph test to be accurate, the previous reaction shoul...
Page 86
Page 86 3. Start test. This starts the ph test routine, which goes through the 6 phases described above. 4. Take sample. Not applicable until the test is running. 5. Continue to next phase. Not applicable until the test is running. 6. Stop test. When the test is running, activating this control will...
Page 87
Page 87 ph test, phase 3: p h t e s t 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 2 m o d e t i c + t o c 3 s t a r t t e s t 4 t a k e s a m p l e 5 c o n t i n u e t o n e x t p h a s e 6 s t o p t e s t t i m e 0 s p h a s e p a u s e d m f c = 0 . 0 l / h c o 2 = 1 5 0 . 8 p p m t e s t t i c p h . E x p ...
Page 88
Page 88 ph test, phase 5: p h t e s t 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 2 m o d e t i c + t o c 3 s t a r t t e s t 4 t a k e s a m p l e 5 c o n t i n u e t o n e x t p h a s e 6 s t o p t e s t t i m e 0 s p h a s e p a u s e d m f c = 0 . 0 l / h c o 2 = 1 5 0 . 8 p p m t e s t t o c p h . E x p ...
Page 89
Page 89 8.1.2 simulate s i m u l a t e 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 m f c = 1 0 . 0 l / h c o 2 = 3 5 . 0 p p m 1 2 o z o n e g e n e r a t o r o f f , 1 . 0 0 a 3 o z o n e g e n e r a t o r f a n o f f , 5 . 0 0 v 4 a c i d p u m p o f f , 1 5 b a s e p u m p o f f , 1 6 s a m p l e p u m p o f...
Page 90: Warning
Page 90 1. Mfc. Use this function to set the mfc (mass flow controller) setpoint. Press the enter key, set the required setpoint (e.G. 60 l/h), and press the enter key again. The actual flow is shown at the top of the screen. An “*” is shown when the mfc has been activated. If the flow is 0.0 l/h, t...
Page 91
Page 91 8. Sample valve. Use this function to test the sample valve. To change the state of the device, press the enter key, set the device to on/off, and press the enter key again. If the device is on, it will be marked with an “*”. 9. Reactor valve. Use this function to test the reactor valve. To ...
Page 92
Page 92 21. Temp. Switch the temperature switch output is automatically controlled by the system depending on the system temperature control setting (system fan control), which is programmed as 20°c by default. To test the temperature switch, press the enter key and select device state option: on, o...
Page 93
Page 93 8.1.3 signal simulate s i g n a l s i m u l a t e 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 5 a l a r m 1 - 3 o f f 8 c o 2 a l a r m 1 - 3 o f f 1 1 s y n c r e l a y o f f 1 2 s a m p l e s t a t u s 1 - 3 o f f 1 5 s a m p l e f a u l t 1 - 3 o f f 1 8 c a l s i g n a l o f f 1 9 m a i n t s i g ...
Page 94
Page 94 18. Cal signal (if configured in the system). Use this function to test the calibration signal output. To change the state of the device, press the enter key, set the device to on/off, and press the enter key again. If the device is on, it will be marked with an “*”. See section 8.3.5 output...
Page 95
Page 95 8.1.4 data output d a t a o u t p u t 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 2 s e n d r e a c t i o n a r c h i v e 3 s e n d f a u l t a r c h i v e 4 s e n d c o n f i g u r a t i o n 5 s e n d a l l d a t a 6 7 - - > d a t a p r o g r a m this menu enables the user to select the communication...
Page 96
Page 96 8.1.4.1 send reaction archive s e n d r e a c t i o n a r c h i v e 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 2 n u m b e r o f e v e n t s 1 2 3 3 s t a r t s e n d i n g 4 p a u s e s e n d i n g 5 * s t o p s e n d i n g o u t p u t # 1 2 3 i t e m s this menu is used to download the reaction arc...
Page 97
Page 97 the meaning of the abbreviations used in the downloaded analysis data in both standard and engineering modes (see print mode in section 8.2.10 data program for details) are as follows: standard mode: tic & toc analysis: time the time the reaction started. Date the date the reaction started. ...
Page 98
Page 98 engineering mode (voc analysis): time the time the reaction started. Date the date the reaction started. S1:2 reaction type and range. Co2z co 2 analyzer zero adjust for the current reaction. Tcmgu the un-calibrated tc value in mgc/l (measured value from the tc analysis). Tcmgc the calibrate...
Page 99
Page 99 8.1.4.2 send fault archive this menu is used to download the fault archive. The communication port parameters used are those set up in the data program menu. All items in the fault archive will be downloaded unless the user interrupts the downloading with the pause sending or stop sending fu...
Page 100
Page 100 8.1.5 input/output status input/output status menus are used for monitoring the analog and digital inputs and outputs for advanced diagnostics purposes. Digital input the digital input menu allows the engineer to monitor the system digital inputs. This feature is useful for the system troub...
Page 101
Page 101 8.1.6 oxygen controller status o 2 - c t r l s t a t u s 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 2 v e r s i o n 0 1 . 0 0 3 m o d e m f c / o 2 4 t e m p e r a t u r e s e n s o r 2 5 . 0 c , 1 . 2 4 v 5 a i r p r e s s s e n s o r 1 5 0 0 m b a r , 4 . 4 5 v 6 o 2 p r e s s s e n s o r 4 0 0 m ...
Page 102
Page 102 8.1.7 service s e r v i c e 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 2 s e r v i c e r e q u i r e d i n 1 7 8 d a y s 3 r e s e t s e r v i c e c o u n t e r 4 s e t s e r v i c e z e r o 2 0 , 5 5 r e s e t s e r v i c e z e r o the service menu displays the system service information. It is als...
Page 103: 8.2 Commissioning Menu
Page 103 8.2 commissioning menu the commissioning menus are used during the commissioning and startup of the analyzer. The functions in the menus are used to program system site specific settings. Commissioning menu diagram 8.2.1 reaction time reaction time 4m45s reaction time displays the total rea...
Page 104
Page 104 8.2.2 sample pump sampler forward reverse stream 1 100s 60s 75s stream 2 100s 60s 75s stream 3 45s 60s …………………… manual 1 50s 0s manual 2 manual 3 …………………… calibration 50s biotector sample pump runs forward for the forward time to bring a fresh sample from the stream, manual and/or calibrati...
Page 105
Page 105 stream 1 , 2 range 3 stream 2 , 1 range 3 stream 3 , 4 range 3 ……………… …………… …………… … if the control is programmed as biotector, the multi- stream valve sequence operates according to the stream and range settings defined in this menu. In stream 1 , 2 setting, the first setting “1” represents...
Page 106
Page 106 8.2.5 new reagents program span calibration no span calibration (no by default) defines if the span calibration reactions are part of the install new reagents procedure in reagents setup menu. If span calibration is activated (yes), the standard solution needs to be connected to the calibra...
Page 107
Page 107 acid volume 19.0l ~210 days acid volume allows the user to enter the volume of the acid reagent. When the volume is programmed, system automatically calculates the number of days acid reagent will last. Base volume 19.0l ~210 days base volume allows the user to enter the volume of the b...
Page 108
Page 108 channel 1 stream 1 toc channel 1 25mgc/l inst channel 2 stream 1 tic channel 2 100mgc/l inst ……………………… …………………… …… channel 4 --- tic channel 4 100mgc/l avrg in channel 1 stream 1 toc setting, the first parameter defines the type of 4-20ma output which can be programmed as: stream and manual...
Page 109
Page 109 8.2.9 alarm program alarm 1 toc stream 1 20.0mgc/l alarm 2 tic stream 2 10.0mgc/l alarm 3 cod stream 1 70.0mgo/l if alarm 1-3 is not programmed in output devices menu, this option will not be available in this menu. Alarm 1-3 operates on a specific stream and reaction result type. In “alarm...
Page 110
Page 110 8.2.10 data program mmc/sd card this menu allows the user to program the output device communication port configuration profiles for mmc/sd flash card. Print mode engineering print mode specifies the format in which the data will be sent over the communication port to all output devices. ...
Page 111
Page 111 8.3 system configuration menu system configuration menus are used to configure the system in the factory. The user should avoid any modifications in these menu settings unless it is absolutely necessary. System configuration menu diagram.
Page 112
Page 112 8.3.1 analysis mode analysis type tic+toc analysis type defines biotector’s analysis modes, which are tic+toc (tic&toc), tc and voc. Tic&toc and voc systems can be programmed to run in tic+toc, tc and voc analysis types. If it is necessary to run a tic&toc system in any other analysis modes...
Page 113
Page 113 8.3.2 system program system program 1 system program 1 tic + toc system program 1 tic + toc defines the system parameters for oxidation phase operation in tic & toc analysis mode. In tic & toc analysis mode, the tic and toc contents of a sample are measured consecutively by means of a singl...
Page 114
Page 114 toc sparge time 75s, 20 l/h biotector sparges and measures the toc content of the sample for the toc sparge time (50s by default) with the oxygen flow (20 l/h) settings. If the toc level does not drop below the toc check level (25ppm co 2 by default in reaction check menu) at the end of toc...
Page 115
Page 115 system program 1 tc system program 1 tc defines the system parameters for oxidation phase operation in tc analysis mode. In tc analysis mode, the tc content of a sample is measured by means of a single sample injection into a single reactor. When the analysis type is changed to tc, the syst...
Page 116
Page 116 system program 2 system program 2 tic + toc range change 1-2 50.0mgc/l range change 1-2 defines the concentration levels for the biotector to change its range automatically from range 1 to range 2. The range change 1-2 is typically the top concentration point of toc range 1 in system rang...
Page 117
Page 117 system program 2 tc sample in 5p , p-v sample in defines the amount of sample (in pulses) to be injected into the reactor in tc mode at range 2. System program 2 voc all system parameters for system program 2 voc analysis mode are covered in system program 2 tc and system program 2 tic + to...
Page 118
Page 118 system program 3 tc sample in 5p , p-v sample in defines the amount of sample (in pulses) to be injected into the reactor in tc mode at range 3. Tc acid 58p tc acid states the amount of acid (in pulses) to be injected into the reactor for the tc sparge phase in tc mode at range 3. System pr...
Page 119
Page 119 8.3.4.2 zero program zero program 5 , 3 , 3 in zero program 5, 3, 3 setting, the first, second and third inputs define the minimum number of reactions to be carried out at range 1, range 2 and range 3 respectively during the zero calibration and zero check cycles. Zero cycles are activate...
Page 120
Page 120 service zero 20 , 5 service zero specifies the number of zero calibration cycles to be repeated after a defined number of reactions between each zero calibration cycle. The first setting “20” is the number of reactions between each zero calibration cycle, and the second setting “5” is the t...
Page 121
Page 121 tc cal std 15.0mgc/l in voc systems, the sum of the tic and toc calibration standard solution is displayed as tc calibration standard. When toc calibration standard is programmed as 0.0mgc/l above, and when a concentration of tic calibration standard is programmed above, biotector displays ...
Page 122
Page 122 8.3.4.4 reagents purge acid & base purge 50s , 3 acid & base purge defines the operation time (50 seconds by default) of the acid and base pumps to prime the reagents during the install new reagent cycle. The reagent priming and the subsequent reactor purge operation is repeated three times...
Page 123
Page 123 pressure chck fault 6.0l/h at the end of each reaction during operation, biotector automatically pressurizes the system with oxygen gas and uses its mass flow controller to detect any gas leak in the system. If the measured flow is less than or equal to the programmed pressure check fault f...
Page 124
Page 124 output 1-6 output 1-6 menus typically contain internal output settings related to system operation. These relay outputs, located on the motherboard, are system optional features. Stream 1 is always functional as default within the system software. Output 4-6 menus are not displayed as they ...
Page 125
Page 125 8.3.5.2 programmable outputs pwr brd out 1-6 power board output1-6 menus typically contain output settings related to external devices. These relay outputs, located on the power and input/output board, are system optional features. Power board output1-6 relays can be programmed to a single ...
Page 126
Page 126 8.3.6 reaction check co2 level 100ppm, auto due to the organic and inorganic contamination in the biotector reagents, every toc/tc reaction will generate a small level of co 2 from the reagents alone even if there is no sample present. The first setting (100ppm by default) of co2 level spec...
Page 127
Page 127 8.3.7 result integration toc integration 3 toc integration (3 by default) defines the number of reaction results to be averaged to get the actual toc result. Toc int. Limits 10% , 0.100 toc integration limits controls the averaging function defined in toc integration above. The first parame...
Page 128
Page 128 8.3.8 fault setup low o2 flow time 12s if the o 2 flow drops more than 50% of the mfc set value for longer than the low o2 flow time (12s by default), a “01_low o2 flow - ex” or “02_low o2 flow - so” fault is logged. High o2 flow time 20s if the o 2 flow increases more than 50% of the mfc s...
Page 129
Page 129 ozone test time 18s ozone test time defines the programmed time (18 seconds by default), which passes the ozone test in process test, ozone test menu. The maximum time the ozone generator remains on during the ozone test is 60 seconds. Ozone gen alarm 0.50a , 5s ozone generator alarm define...
Page 130
Page 130 cooler alarm 0.10a , 5s cooler alarm defines the current (0.1a by default) and the time (5 seconds by default) setting for the “107_cooler fault” event. If the current drawn through the cooler has dropped below 0.1 amp for longer than 5 seconds, biotector generates a “107_cooler fault” warn...
Page 131
Page 131 8.3.9 fault status this menu gives a short status history of several system devices before a fault is registered. The default 0.0 values indicate that there are no faults detected for the specific device. O2 flow the o2 flow menu consists of 120 entries for the mfc setpoint value (first col...
Page 132
Page 132 8.3.10 co 2 analyzer analysis graph scale 10000ppm analysis graph scale determines the scale of the y-axis “co2 analyzer’s ppm-co2 readings” on the analysis graph screen (see section 2.1.4 analysis graph screen for details). This function allows the system to display co2 data peaks in optim...
Page 133
Page 133 8.3.11 cooler program mode t control mode defines the operation mode of the cooler. Cooler operates automatically with the default temperature control setting, to achieve the programmed temperature difference below. When mode is programmed as pwm “pulse width modulation”, the cooler operate...
Page 134
Page 134 8.3.12 ozone destructor program pwm duty 50% pulse width modulation defines the standard operation of the ozone destructor heater. The default 50% settings mean that the ozone destructor heater is on for 50% of the time, which is typically 5 seconds on and 5 seconds off during normal operat...
Page 135
Page 135 8.3.13 software update load factory config. Each biotector system contains a configuration which is installed and protected by system flash memory. When any modification is carried out in system configuration, load factory configuration function allows the user to revert back to the origina...
Page 136
Page 136 8.3.14 password operation 0000 calibration 0000 diagnostics 0000 commissioning 0000 system configuration 0000 password menu allows any number from 1 to 9999 to be set as passwords for the operation, calibration, diagnostics, commissioning and system configuration menus (levels). When the se...
Page 137: Section 9
Page 137 section 9 troubleshooting of system fault, warning and notification events 9.1 biotector fault event explanation and remedial action the following fault conditions activate the biotector stop sequence, set all 4-20ma signals to the fault level (1ma by default) programmed in the 4-20ma progr...
Page 138
Page 138 04_reaction error (can also be programmed as a warning condition) no toc (or tc) co 2 peak detected or the co 2 peak is below the “co2 level” for 3 consecutive reactions. See section 8.3.6 reaction check for details. Acid/base containers are empty. Acid/base tube rail installed incorrectly....
Page 139
Page 139 12_high co2 in o2 high level of co 2 has been detected in the input oxygen gas. Go to simulate menu and read the co 2 analyzer ’s co 2 ppm value. If this value is greater than 250-300ppm, check the oxygen purity. Check the quality of oxygen following the oxygen purity test procedures in sec...
Page 140
Page 140 109_hi mpu temp temperature on the micro processor unit (mpu) has been exceptionally high and has exceeded 70°c. Check the filters in the fan and vent. Check the operation of the fan. (note that at temperatures below 25°c, biotector automatically switches the fan off to stabilize system tem...
Page 141
Page 141 9.2 biotector warning event explanation and remedial action the following warning conditions do not activate the biotector stop sequence and leave the 4-20ma signals un-changed and do not activate the fault relay. When the system warning is rectified, acknowledge the warning by pressing the...
Page 142
Page 142 29_pressure test off there are two pressure tests carried out in biotector. One is a daily pressure test and the other, called pressure check, is carried out every analysis cycle. This function relates to the daily pressure test. Pressure/flow test cycle has been switched off. See section 8...
Page 143
Page 143 52_high co2 in base co 2 level in the base reagent, which is checked during the zero calibration or zero check cycles, is higher than the “base co2 alarm” level programmed in fault setup menu. Confirm the base reagent co 2 filter is serviced and in good condition, and the container is seale...
Page 144
Page 144 89_tc span cal fail 90_tc span chck fail tc span calibration/check result is outside the specified tc band defined in span program menu. See section 8.3.4.3 span program for details. Check the concentration of the standard solution used. Check the settings in span calibration menu. Check th...
Page 145
Page 145 95_lo air presure 1 air pressure supply has been less than 0.8 bar for longer than 60 seconds. When the oxygen concentrator is running, the pressure typically cycles from 1.5 bar to 0.9 bar. Extreme fluctuations in air supply pressure or faulty external air regulator. Increase air supply pr...
Page 146
Page 146 100_rotary v stop:on rotary valve stopped with its rotation sensor on (sensor signal 1). The sensor is faulty and it is always showing on (sensor signal 1). See rotary valve and rotary valve sensor in section 8.1.6 oxygen controller status for details. Go to simulate menu, set mfc flow to 2...
Page 147
Page 147 107_cooler fault the current drawn through the cooler has dropped below 0.1 amp for longer than 5 seconds. This indicates cooler peltier element failure. Fuse 3 (for cooler) is blown on the motherboard. See section 5.2.4 system fuse specifications for details. Check fuse 3 (f3) on the mothe...
Page 148
Page 148 112_lo temp standby biotector temperature has dropped below 2°c for longer than 2 minutes. Biotector has been automatically put into standby mode and has stopped analyzing. When biotector temperature increases above 5°c for longer than 2 minutes, biotector continues normal operation. Check ...
Page 149
Page 149 9.3 biotector notification event explanation and remedial action the following notification conditions do not activate the biotector stop sequence, leave the 4-20ma signal un-changed and do not activate the fault relay. Relevant notifications below can be acknowledged in the fault archive m...
Page 150: Section 10
Page 150 section 10 service and maintenance 10.1 weekly maintenance check the air supply pressure: a) an existing instrument air supply line b) biotector compressor check and confirm that the air pressure is 1.5 bar on the filter pack pressure regulator. check the sulfuric acid level in the ac...
Page 151: 10.2 Six Month Service
Page 151 10.2 six month service below procedure is a recommended check list for the 6 th month service on the biotector using the 6 month service kit. Please note that any special models and applications may require additional service items. Detailed service procedures are available in a presentatio...
Page 152
Page 152 check for possible build-up of salts or any material at any of the pfa t fittings located between the ozone generator and the mixer reactor. Clean the fittings and/or the tubing if necessary. _____ remove ozone line filter and wash it with diw (or tap water). Dry the filter well and reinsta...
Page 153
Page 153 warning! A torque screwdriver calibrated to 1.2 nm (120 ncm) is required for the correct service of the mixer reactor. It is strongly recommended not to proceed with the mixer reactor service procedures without a torque screwdriver. Tools required – torque screwdriver with torx 20 bit. An a...
Page 154
Page 154 check the air supply pressure. The set point pressure should be 1.5 bar. When the oxygen concentrator is running, the pressure typically cycles from 1.5 bar to 0.9 bar. Check the o2 pressure sensor reading looking at the o2-controller status menu. The pressure should be 400 mbar (±10 mbar) ...
Page 155: Section 11
Page 155 section 11 system replacement and spare parts.
Page 156
Page 156 biotector parts and spare parts part number and description part number and description 20-b5c-010 b5c oxygen concentrator rebuild module 19-pcb-050 b5c motherboard 20-b5c-013 b5c psu module 20-pcb-036 b5c oxygen controller board 20-pcb-038 b5c termination board 19-max-008 b5c sample pump 2...
Page 157
Page 157 part number and description part number and description 19-b5c-014 b5c type 6606 n/o valve 19-b5c-015 b5c type 6606 n/c valve 19-b5c-016 b5c pinch valve n/o 19-b5c-017 b5c pinch valve c/o 20-b5c-011 b5c oxygen concentrator rotary valve 20-co2-008 b5c co 2 analyzer 20-b5c-025 b5c ozone gener...
Page 158: Section 12
Page 158 section 12 general information 12.1 declaration of conformity and certification declaration of conformity manufacturer: biotector analytical systems ltd. Address: raffeen house, ringaskiddy, co. Cork, ireland. Declares that the following models: biotector system-c biotector b3500c are in co...
Page 159: Declaration Of Compliance
Page 159 12.2 declaration of compliance declaration of compliance manufacturer: biotector analytical systems ltd. Address: raffeen house, ringaskiddy, co. Cork, ireland. Declares that the biotector toc analyzer is in compliance with the following european/irish standard: i.S. En 1484:1998 water anal...
Page 160
Page 160 12.3 warranty and exclusions coverage of biotector warranty the biotector comes with a standard 1 year warranty for agreed applications. The biotector warranty is against manufacturing defects only. The warranty does not cover service/consumable items and consequential damage. Validity of w...
Page 161: Section 13
Page 161 section 13 appendices appendix 1 glossary of terms and abbreviations - - - no function is programmed 4-20ma chng 4-20ma change signal a amperes a1 – a3 24 hours average for stream 1 – 3 alldat all data amp amperes atm atmospheric pressure bod biochemical oxygen demand c-276 hastelloy cal mu...
Page 162
Page 162 ml milliliter ml/min milliliters per minute mmc/sd multi media card/secure digital card n normal n/a not applicable n/d normally de-energized n/e normally energized naoh sodium hydroxide nbr nitrile butadiene rubber ndir nondispersive infrared note notification npoc non-purgeable organic ca...
Page 163
Page 163 zk zero check zm manually input zero adjust zs zero and span.
Page 164: Appendix 2
Page 164 appendix 2 contact information hach company world headquarters p.O. Box 389 loveland, colorado 80539-0389 u.S.A. Tel (800) 227-hach (800) -227-4224 (u.S.A. Only) fax (970) 669-2932 orders@hach.Com www.Hach.Com hach lange gmbh willstätterstraße 11 d-40549 düsseldorf tel. +49 (0)2 11 52 88-32...
Page 165
Page 165 hach lange maroc sarlau villa 14 – rue 2 casa plaisance quartier racine extension ma-casablanca 20000 tél. +212 (0)522 97 95 75 fax +212 (0)522 36 89 34 info-maroc@hach-lange.Com www.Hach-lange.Ma.