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DuMaster D-480
Operation Manual
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Buchi DuMaster D-480 Operation Manual

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DuMaster D-480
Operation Manual
11593626C en
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ProductIdentification:
Operation Manual (original) DuMaster D-480 11593626Cen
06.2016
BÜCHILabortechnikAG Meierseggstrasse40 Postfach CH9230Flawil1
EMail:quality@buchi.com
BUCHIreservestherighttomakechangestothemanualasdeemednecessaryinthelightofexperi ence;especiallyinrespecttostructure,illustrationsandtechnicaldetail.
Thismanualiscopyright.Informationfromitmaynotbereproduced,distributed,orusedforcompetitive purposes,normadeavailabletothirdparties.Themanufactureofanycomponentwiththeaidofthis manualwithoutpriorwrittenagreementisalsoprohibited.
Copyright Note 3
Copyright ©BÜCHI Labortechnik AG All rights reserved
®
Windows
, Windows XP® und Windows 7® are trademarks of Microsoft Corporation.
MS-Excel® und MS-Access® are trademarks of Microsoft Corporation.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
Contents 5
Contents
CHAPTER 1 General 13
About this document .................................................................................................................................... 14
Display conventions .................................................................................................................................... 15
General information on the operating instructions ....................................................................................... 15
CHAPTER 2 Basic security settings 17
Working with the operating instructions ....................................................................................................... 18
Representation of safety instructions .......................................................................................................... 18
Instructions for disposal of consumables ..................................................................................................... 18
Intended use of the instrument .................................................................................................................... 19
Warning: residual risks ................................................................................................................................ 19
Safety devices in the analyzer ..................................................................................................................... 20
Warning signs on the analyzer .................................................................................................................... 22
Warning: changes to the instrument ............................................................................................................ 23
Warning: unsuitable spare parts and consumables ..................................................................................... 23
Required user knowledge and skills ............................................................................................................ 23
Required personal safety equipment ........................................................................................................... 24
Warning notes during operation .................................................................................................................. 24
CHAPTER 3 Product description 31
Analytical characteristics and technical specifications ................................................................................. 32
Analytical characteristics .................................................................................................................. 33
Technical specifications ................................................................................................................... 33
Instrument design ........................................................................................................................................ 35
Front view ........................................................................................................................................ 36
Rear view ......................................................................................................................................... 37
Right side view ................................................................................................................................. 37
Left side view ................................................................................................................................... 38
Top view ........................................................................................................................................... 39
Peripherals and their function .......................................................................................................... 40
CHAPTER 4 Understanding the instrument and planning its use 41
Layout and mode of functioning .................................................................................................................. 42
Functional units ................................................................................................................................ 43
The thermal conductivity detector (TCD) .......................................................................................... 45
Processes in the instrument during a measurement ................................................................................... 46
Sample insertion and initiation of measurement .............................................................................. 47
Substance digestion and preparation of the reaction gas mixture .................................................... 47
Detection of measuring components and evaluation of the measuring signal .................................. 48
Formulas for determining element concentration of analysis samples (Solids) ................................ 48
Basic facts about working with the instrument ............................................................................................. 49
Instrument equipment ...................................................................................................................... 50
Background knowledge required for calibration ............................................................................... 51
Calibration curve calculation method criteria .................................................................................... 52
Calibration formulae ......................................................................................................................... 54
Routine measuring work .................................................................................................................. 55
Formulae for blank value determination and compensation ............................................................. 56
Formula for determining the daily factor ........................................................................................... 57
Understanding the operating software ......................................................................................................... 58
Basic functions of the operating software ......................................................................................... 59
Software user interface .................................................................................................................... 60
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
Contents 6
Sample view ..................................................................................................................................... 61
Combi view ...................................................................................................................................... 63
Status view ....................................................................................................................................... 66
Right mouse button function ............................................................................................................ 67
Data administration and data security ......................................................................................................... 69
Laboratory information and management system (LIMS) ................................................................ 70
Conditions for operating the LIMS .................................................................................................... 70
21 CFR Part 11 functionality ............................................................................................................ 71
Versioning ........................................................................................................................................ 72
Linking the analyzer and software .................................................................................................... 72
CHAPTER 5 Work performed by the system administrator 73
Installing and updating the software ............................................................................................................ 74
Configure analyzer ...................................................................................................................................... 75
What can you modify in the configuration? ...................................................................................... 76
Defining logon timeout ..................................................................................................................... 76
Creating new sections ...................................................................................................................... 77
Defining LIMS export settings ..................................................................................................................... 78
LIMS export settings ........................................................................................................................ 79
Setting up user administration ..................................................................................................................... 80
User administration .......................................................................................................................... 81
Recommendations for user administration ....................................................................................... 81
Granting authorizations .................................................................................................................... 81
Defining interfaces ....................................................................................................................................... 83
Defining the analyzer / PC interface ................................................................................................. 84
Defining the LIMS / PC interface ...................................................................................................... 84
Defining the balance / PC interface .................................................................................................. 85
Editing analysis data ................................................................................................................................... 86
When does it make sense to edit analysis data? ............................................................................. 87
Limits for modifying analysis data .................................................................................................... 87
Consequences of modifying analysis data ....................................................................................... 87
Performing checks ....................................................................................................................................... 88
Checking documents for authenticity ............................................................................................... 89
Signing documents........................................................................................................................... 89
Viewing the logbook ......................................................................................................................... 90
Working with the database .......................................................................................................................... 91
Database .......................................................................................................................................... 92
Administrative work on the database ............................................................................................... 92
Defining the autoexport directory ..................................................................................................... 93
Database backup ............................................................................................................................. 93
Starting the database backup .......................................................................................................... 94
Reorganize database ....................................................................................................................... 94
Reloading an old database file ......................................................................................................... 95
Ways of optimizing the use of the analyzer ................................................................................................. 96
Optimizing basic instrument settings ................................................................................................ 97
Optimizing sample data editing ........................................................................................................ 97
"Balance" weighing data input program ........................................................................................... 98
Optimizing data evaluation ............................................................................................................... 99
Performing other administrator tasks ......................................................................................................... 100
Modifying the registration ............................................................................................................... 101
Printer setup ................................................................................................................................... 101
CHAPTER 6 Starting up and shutting down the instrument 103
Setting up and starting up the instrument .................................................................................................. 104
Rules for first-time start-up ............................................................................................................. 105
Instructions for operating the furnace ............................................................................................. 105
Installation site requirements ......................................................................................................... 105
Gases and chemicals to be provided ............................................................................................. 106
Start-up .......................................................................................................................................... 107
Connecting peripherals .................................................................................................................. 108
Connecting supply lines and waste gas lines ................................................................................. 109
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
Contents 7
Removing the transport protection ................................................................................................. 110
Switching on ................................................................................................................................... 112
Default instrument settings ............................................................................................................. 112
Heating up the furnace ................................................................................................................... 113
Shutting down the instrument .................................................................................................................... 114
Shutting the instrument down for short measuring breaks (standby) ............................................. 115
Shutting the instrument down for long measuring breaks (switching off) ....................................... 115
CHAPTER 7 Using the instrument 117
Measurement settings ............................................................................................................................... 118
Defining keywords for blank and conditioning samples .................................................................. 119
Viewing list of defined factor, monitor and standard samples ........................................................ 119
Defining custom standard substances ........................................................................................... 119
Defining standard substances as factor and monitor samples ....................................................... 120
Defining standard substances as calibration samples.................................................................... 120
Specifying the computation method for blank value and daily factor .............................................. 121
Enabling/disabling acoustic signals ................................................................................................ 121
Configuring error handling .............................................................................................................. 122
Preparing samples .................................................................................................................................... 123
Sample preparation instructions ..................................................................................................... 124
Determining sample weight ............................................................................................................ 124
Showing or hiding the weight window ............................................................................................ 125
Packing samples ............................................................................................................................ 125
Preparing measurement work ................................................................................................................... 127
Software usage rules ..................................................................................................................... 128
Starting the operating software ...................................................................................................... 128
Showing or hiding the toolbar ......................................................................................................... 128
Waking up the instrument .............................................................................................................. 128
Viewing method settings ................................................................................................................ 129
Defining custom methods ............................................................................................................... 129
Defining the Kjeldahl factor ............................................................................................................ 130
Copy methods ................................................................................................................................ 130
Settings for sample input ................................................................................................................ 131
Importing weighing data ................................................................................................................. 131
Prioritizing urgent samples ............................................................................................................. 132
Optimizing sleep and wake-up behavior ........................................................................................ 132
Performing measurement work ................................................................................................................. 134
Values for oxygen dosing ............................................................................................................... 135
Performing measurements ............................................................................................................. 136
Performing routine measuring work ............................................................................................... 138
Checklist for blank value / conditioning and daily factor measurements ........................................ 139
Checklist for real sample measurement ......................................................................................... 140
Types of blank value determination and their settings ................................................................... 141
Determining blank values ............................................................................................................... 141
Determining the daily factor ........................................................................................................... 142
Stopping continuous analysis ......................................................................................................... 144
Preparing measuring data for evaluation ................................................................................................... 146
Configuring the sample view .......................................................................................................... 147
Determine measuring units and number of decimal places. ........................................................... 147
Saving the sample view ................................................................................................................. 148
Loading a sample view ................................................................................................................... 148
Configure statistics view ................................................................................................................. 148
Generating statistical data .............................................................................................................. 148
Formulae for generating statistical data ......................................................................................... 149
Manual peak integration ................................................................................................................. 150
Configuring the graph view ............................................................................................................ 154
Setting the size of the graph .......................................................................................................... 154
Configure report ............................................................................................................................. 155
Display print preview ...................................................................................................................... 155
Data backup and printing ............................................................................................................... 156
Overview of export and import file formats ..................................................................................... 157
Exporting analysis data to MS Excel and viewing .......................................................................... 157
Exporting LIMS data....................................................................................................................... 158
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
Contents 8
Working with documents ........................................................................................................................... 159
Creating new documents ............................................................................................................... 160
Editing documents.......................................................................................................................... 160
Deleting documents ....................................................................................................................... 161
Finding documents ......................................................................................................................... 161
Copying documents via the clipboard ............................................................................................ 162
Importing documents ...................................................................................................................... 163
Signing documents......................................................................................................................... 163
Checking documents for authenticity ............................................................................................. 164
CHAPTER 8 Maintaining the instrument 165
Important information about maintenance ................................................................................................. 166
Maintenance work to be performed by the customer ..................................................................... 167
Viewing the status of maintenance intervals .................................................................................. 168
Defining maintenance intervals in the software .............................................................................. 168
Installing used tubes ...................................................................................................................... 169
Preparing and following up maintenance work ............................................................................... 169
Conditioning newly installed tubes ................................................................................................. 170
Performing the calibration ......................................................................................................................... 173
Viewing list of defined factor, monitor and standard samples ........................................................ 174
Defining standard substances ........................................................................................................ 174
Viewing calibration coefficients ...................................................................................................... 175
Optimizing instrument condition for calibration ............................................................................... 175
Performing the calibration .............................................................................................................. 175
Assessing the calibration curves .................................................................................................... 179
Calibration tables....................................................................................................................................... 182
Calibration table for nitrogen calibration ......................................................................................... 183
Replacing the ash crucible ........................................................................................................................ 184
Purpose and frequency of crucible replacement ............................................................................ 185
Removing the ash crucible ............................................................................................................. 185
Installing the ash crucible ............................................................................................................... 188
Refill the Regainer ..................................................................................................................................... 190
Purpose and frequency of refilling of the Regainer ........................................................................ 191
Refill the Regainer.......................................................................................................................... 191
Replacing sealing elements ...................................................................................................................... 194
When to replace sealing elements ................................................................................................. 195
Removing sealing elements from grooves ..................................................................................... 196
Ball valve maintenance ............................................................................................................................. 197
Removing and dismantling the ball valve ....................................................................................... 198
Cleaning, assembling and installing the ball valve. ........................................................................ 202
Maintaining the Ni flap and the O2 lance ................................................................................................... 206
Purpose and frequency of maintaining the Ni flap and O2 lance ................................................... 207
Removing and cleaning the Ni flap ................................................................................................ 207
Installing the Ni flap ........................................................................................................................ 209
Removing, cleaning and re-installing the O2 lance ........................................................................ 211
Removing, cleaning and installing the quartz glass bridge ........................................................................ 213
Removing the quartz glass bridge .................................................................................................. 214
Cleaning and installing the quartz glass bridge .............................................................................. 214
Removing, cleaning and installing the carousel ........................................................................................ 217
Removing, cleaning and installing the carousel ............................................................................. 218
Emptying and filling reaction tubes ............................................................................................................ 220
Emptying reaction tubes ................................................................................................................. 221
Filling the combustion tube ............................................................................................................ 221
Filling the post combustion tube ..................................................................................................... 223
Reductor replacing ......................................................................................................................... 224
Removing/installing and conditioning the reaction tubes ........................................................................... 225
Removing the reaction tubes from the furnace .............................................................................. 226
Installing reaction tubes in the furnace and conditioning ................................................................ 228
Filling, removing and installing the absorption and drying tubes ............................................................... 232
Filling the drying tubes ................................................................................................................... 233
Removing and installing the drying tubes ....................................................................................... 235
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
Contents 9
CHAPTER 9 Repairing the instrument 237
Interpreting PC error messages ................................................................................................................ 238
Performing a system test ........................................................................................................................... 239
Performing a leak test ............................................................................................................................... 240
Leak test procedure ................................................................................................................................... 241
Replacing fuses ......................................................................................................................................... 241
What to do after a computer crash ............................................................................................................ 245
Reacting to a power failure ........................................................................................................................ 245
Stopping continuous analysis .................................................................................................................... 248
Re-weighing after sample loss .................................................................................................................. 248
Changing the position of the carousel ....................................................................................................... 249
Export analysis data for support ................................................................................................................ 249
CHAPTER 10 Menu and dialog descriptions 251
Dialog descriptions key ............................................................................................................................. 252
File menu .................................................................................................................................................. 253
File > New (Command) .................................................................................................................. 254
Select document name (Dialog) ..................................................................................................... 254
Select version (Dialog) ................................................................................................................... 256
Save file as (Dialog) ....................................................................................................................... 257
File > Delete (Command) ............................................................................................................... 258
Comment modification (Dialog) ...................................................................................................... 258
Sign (Dialog) .................................................................................................................................. 259
Verify digital signature (Dialog) ...................................................................................................... 259
Export to LIMS (Dialog) .................................................................................................................. 260
Export peak graphics (Dialog) ........................................................................................................ 261
Configure report (Dialog) ................................................................................................................ 261
Print (Dialog) .................................................................................................................................. 263
Print preview (Dialog) ..................................................................................................................... 264
Printer setup (Dialog) ..................................................................................................................... 265
Open (Dialog) ................................................................................................................................. 266
Load balance file (Dialog) .............................................................................................................. 267
Configure backup (Dialog) ............................................................................................................. 267
Clean database (Dialog) ................................................................................................................ 269
Restore database (Dialog) ............................................................................................................. 269
Log in as (Dialog) ........................................................................................................................... 270
File > Logoff (Command) ............................................................................................................... 271
File > Exit (Command) ................................................................................................................... 271
File > Export/Import > Create Excel sheet (Command).................................................................. 271
Edit menu .................................................................................................................................................. 272
Edit > Undo (Command) ................................................................................................................ 273
Edit > Redo (Command) ................................................................................................................ 273
Edit > Cut (Command) ................................................................................................................... 273
Edit > Copy (Command) ................................................................................................................ 273
Edit > Paste (Command) ................................................................................................................ 274
Edit > Insert line (Command) ......................................................................................................... 274
Edit > Delete line (Command) ........................................................................................................ 274
Swap samples (Dialog) .................................................................................................................. 275
Edit > Modify (Command) .............................................................................................................. 275
Set stop tag (Dialog) ...................................................................................................................... 276
Select current sample (Dialog) ....................................................................................................... 276
Set current weighed sample (Dialog) ............................................................................................. 277
View menu ................................................................................................................................................ 278
View > Toggle (Command) ............................................................................................................ 279
Zoom in/out (Dialog) ....................................................................................................................... 279
Configure sample view (Dialog) ..................................................................................................... 279
Save sample pane (Dialog) ............................................................................................................ 280
Load sample pane (Dialog) ............................................................................................................ 281
Delete sample pane (Dialog) .......................................................................................................... 281
View > Gridview > Auto align (Command) ..................................................................................... 282
Configure graph view (Dialog) ........................................................................................................ 282
View > Graphic > Auto align (Command) ....................................................................................... 283
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
Contents 10
Configure statistics view (Dialog) ................................................................................................... 283
View > Statistic > Auto align (Command) ....................................................................................... 284
Select columns (Dialog) ................................................................................................................. 284
Column properties (Dialog) ............................................................................................................ 284
Weighing window (Dialog) .............................................................................................................. 285
System menu ............................................................................................................................................ 287
System > Auto run (Command) ...................................................................................................... 288
System > Single run (Command) ................................................................................................... 288
System > Stop (Command) ............................................................................................................ 288
System > Auto zero (Command) .................................................................................................... 289
Furnace switch off/on (Dialog) ....................................................................................................... 289
Initialize the instrument (Dialog) ..................................................................................................... 289
System > Wake up (Command) ..................................................................................................... 290
Feeding (Dialog)............................................................................................................................. 290
Adjust carousel position (Dialog) .................................................................................................... 290
Math menu ................................................................................................................................................ 292
Math > Blank values > Calculate (Command) ................................................................................ 293
Blank values (Dialog) ..................................................................................................................... 293
Math. > Factor (Command) ............................................................................................................ 294
Define type of peak (Dialog) ........................................................................................................... 294
Define peak start / end (Dialog) ..................................................................................................... 294
Area assignment (Dialog) ............................................................................................................... 295
Standard samples display (Dialog)................................................................................................. 296
Math. > Recalculate (Command) ................................................................................................... 297
Statistics menu .......................................................................................................................................... 298
Statistics > Via names (Command) ................................................................................................ 299
Statistics > Group (Command) ....................................................................................................... 299
Statistics > Sort group (Command) ................................................................................................ 299
Statistics > Delete group (Command) ............................................................................................ 299
Statistics > Clear statistic (Command) ........................................................................................... 299
Statistics > Include/Exclude sample (Command) ........................................................................... 300
Statistics > Include/Exclude value (Command) .............................................................................. 300
Statistics > Create Excel sheet (Command)................................................................................... 300
Calibration menu ....................................................................................................................................... 301
Calibration coefficients (Dialog) ..................................................................................................... 302
Configure calibration (Dialog) ......................................................................................................... 303
Specify lower and upper calibration range (Dialog) ........................................................................ 304
Calibration > Next sample (Command) .......................................................................................... 305
Calibration > Previous sample (Command).................................................................................... 305
Calibration > Next (Command) ....................................................................................................... 305
Calibration > Previous (Command) ................................................................................................ 305
Options menu ............................................................................................................................................ 306
Maintenance intervals (Dialog) ....................................................................................................... 307
Replace part (Dialog) ..................................................................................................................... 308
Adjust carousel (Dialog) ................................................................................................................. 309
Leak test (Dialog) ........................................................................................................................... 310
Leak test: Test phases (Dialog) ..................................................................................................... 311
System test (Dialog) ....................................................................................................................... 312
Error buffer (Dialog) ....................................................................................................................... 314
Error display (Dialog) ..................................................................................................................... 314
Options > Diagnostics > Baseline recording (Command) ............................................................... 315
Input options (Dialog) ..................................................................................................................... 315
Standard samples (Dialog) ............................................................................................................. 316
Keywords (Dialog) .......................................................................................................................... 317
Acoustic signals (Dialog) ................................................................................................................ 318
Configure Calculations (Dialog) ..................................................................................................... 318
LIMS settings (Dialog) .................................................................................................................... 319
Method (Dialog) ............................................................................................................................. 322
Monthly logbook (Dialog) ............................................................................................................... 323
Select period (Dialog) ..................................................................................................................... 324
Device configuration (Dialog) ......................................................................................................... 325
Error handling (Dialog) ................................................................................................................... 328
Sleep / wake-up function (Dialog) .................................................................................................. 329
Configure key value (Dialog) .......................................................................................................... 330
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
Contents 11
Windows menu .......................................................................................................................................... 332
Windows > Toolbar / Run-Bar (Command) .................................................................................... 333
Toolbar ........................................................................................................................................... 333
Windows > Recent sample (Command) ......................................................................................... 334
Windows > Status view (Command) .............................................................................................. 334
Windows > Default layout (Command) ........................................................................................... 334
Help menu ................................................................................................................................................. 335
Help > Content (Command) ........................................................................................................... 336
Help > Find (Command) ................................................................................................................. 336
Help > BÜCHI Labortechnik AG on the WEB (Command) ............................................................. 336
Product registration (Dialog) .......................................................................................................... 336
Help > About... (Command) ........................................................................................................... 337
CHAPTER 11 Appendix 339
Revision history ......................................................................................................................................... 340
Warranty .................................................................................................................................................... 341
Warranty of the overall instrument ................................................................................................. 342
Warranty on the furnace ................................................................................................................. 342
Accessories, spare parts and consumables .............................................................................................. 343
Smallest workable unit ................................................................................................................... 344
Required accessories ..................................................................................................................... 345
Optional accessories ...................................................................................................................... 346
Declaration of conformity ........................................................................................................................... 347
Declaration of conformity ............................................................................................................... 348
Index 349
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
General information on the operating instructions .........................................................................15
CHAPTER 1
General
Purpose
This chapter contains general topics of the document.
In this chapter
About this document ......................................................................................................................14
Display conventions .......................................................................................................................15
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
1 - General 14
About this document
Status of the operating instructions
The status of the operating instructions is: 16.10.2014.
Identification number
The operating instructions identification number is: 11593627.
Validity
The operating instructions are valid for all instruments as from serial number: 16144001.
Analyzer
The operating instructions describe the basis type of the instrument D-480.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
1 - General 15
Display conventions
Formatting convention
Type of information
Denote amongst others the names of dialogs in the software, e. g.
Before you start using this guide, it is important to understand the terms and typographical conventions used in the documentation. The following kinds of formatting in the text identify special information.
Triangular bullet () Step by step procedure. You can follow these instructions to
Special bold Items you must select, such as menu options (e. g. File > New),
Italics
CAPITALS Names of keys on the keyboard, for example, SHIFT, CTRL, or
KEY+KEY Key combinations for which the user must press and hold down
"Quotation marks"
{Symbolic name} Denotes a symbolic name, e. g. {Element} stands for the
complete a specific task.
command buttons (e. g. Cancel), or common accentuation.
Used to emphasize the importance of an item or for variable expressions such as parameters.
ALT.
one key and then press another, for example, CTRL+P, or ALT+F4.
the "Replace part" dialog.
corresponding name of an element.
General inform ati on on the op er ati ng ins tr uc t ions
Pictures
The instruments of BÜCHI Labortechnik AG underlie a permanent development and adjustment regarding the optimum parameter settings. This may lead to deviations in terms of picture display of the manual and the current instrument status which are not relevant for the understanding of the instrument operation.
The valid numbers of the parameter settings and/or variables can be found in the current text part. Therefore, numbers in the pictures of software dialogs are mainly replaced by spaces or only reflect examples. They do not reflect the proper, recommended set values.
Reading aids
Subheadings are displayed in the left margin as reading aids. They sum up the content of the particular section and are useful for quick navigation.
Index
An index is given at the end of the operating instructions that helps you locate certain topics more easily. Index entries always refer to the first page of the section in which the index term is found. Therefore, don't be confused if the index term does not appear on the first page but rather on one of the following pages.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
Warning notes during operation ....................................................................................................24
CHAPTER 2
Basic security settings
Target group
Personnel working with the instrument.
Purpose
This section describes basic safety rules required to avoid risks for the user of the analyzer.
In this chapter
Working with the operating instructions .........................................................................................18
Representation of safety instructions .............................................................................................18
Instructions for disposal of consumables .......................................................................................18
Intended use of the instrument ......................................................................................................19
Warning: residual risks ..................................................................................................................19
Safety devices in the analyzer .......................................................................................................20
Warning signs on the analyzer ......................................................................................................22
Warning: changes to the instrument ..............................................................................................23
Warning: unsuitable spare parts and consumables .......................................................................23
Required user knowledge and skills ..............................................................................................23
Required personal safety equipment .............................................................................................24
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
2 - Basic security settings 18
Working with the operating instructions
Risk level
Consequences
Probability
Operating the analyzer
Read the operating instructions thoroughly before performing work with the analyzer.
Storing the operating instructions
Store the operating instructions carefully and make sure the instructions are accessible for all relevant personnel.
Passing on the operating instructions
If you pass on the analyzer, always pass on the operating instructions, too.
Representation of safety instructions
Safety signs
This is a safety sign. Instructions with this sign contain warnings about risks of injury and even death. These instructions must always be observed in order to avoid risks.
Risk levels
The safety instructions are categorized according to the following risk levels:
Risk
Warning
Caution
Death / serious injury (irreversible) high
Death / serious injury (irreversible) medium
Minor injury (reversible) medium
Caution
Damage to property possibly
Instructions for disposal of consumables
Rules
Observe the following rules for disposal of consumables: Dispose of the consumables according to the relevant disposal categories.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
2 - Basic security settings 19
Read the instructions on the individual chemicals in the safety data sheets. The risk notes for
individual chemicals can be found in the R-Phrases. Safety advice can be found in the S­Phrases.
Intended use of the instrument
Intended use
This section describes what the instrument is suitable for and what substances may be analyzed with it.
Description of the instrument
The elementary analyzer is an instrument for fully automatic and quantitative analysis of the element N.
Suitable analysis samples
Only samples that can be decomposed in a controlled manner under the method-dependent combustion conditions are suitable for analysis.
Advice on difficult applications
You have the following ways of getting advice on difficult applications: You will find useful tips in the "Application notes" on the provided CD.
You will find also the "Application notes" section on the www.buchi.com website.
Warning: residual risks
Hot components inside the instrument
During operation, the furnaces inside the instrument heat certain components to very high temperatures. Even after switching off the instrument, these components stay hot for long periods of time that you can suffer serious burns if working inappropriately inside the instrument.
Observe the relevant instructions exactly in order to avoid burns.
Live components inside the instrument
There are live parts (up to 230V) inside the instrument. When you are working on the electrical components, you may suffer electrocution if you do not work properly. Never bring liquids or leak-test spray in the vicinity of live components.
Observe the relevant instructions exactly in order to avoid injuries caused by electrocution.
Unsuitable consumables and spare parts
If you use consumables and spare parts of an unsuitable type and quality, you risk:
Injuries to the operating personnel  Damages to the instrument  Distortion of analysis results  loss of warranty.
Only use original spare parts and original consumables that you have purchased from BÜCHI Labortechnik AG or authorized dealers.
Samples with potential risks
Samples to be analyzed may pose the following risks:
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
2 - Basic security settings 20
Contact with the substances may lead to chemical burns or poisoning.  Combustion analysis of larger quantities of the substance may lead to explosions.
These sample substances include:
Aggressive chemicals such as acids or alkaline solutions  Organic solvents  Explosives  Substances that develop toxic or explosive gas mixtures
You are obliged to protect yourself prior to contact with hazardous substances and to reduce the quantity of the substance to a safe amount.
You are also obliged to observe the safety instructions of the chemical manufacturer on the label of the bottle or in the safety data sheets. The safety data sheets contain risk information about a chemical in the R-Phrases and safety information in the S-Phrases.
Safety devices in the analyzer
Note
The analyzer may only be operated if all of the safety devices indicated in this section are in place and in working order.
Gas supply
Gas supply is only possible if the mains switch is switched on and the software is running.
Temperature monitoring
A temperature limiter automatically switches off the instrument in the event of excess temperature inside the instrument. All heating is monitored by an integrated microprocessor controller. All furnaces are automatically shut down in the event of the following malfunctions:
The heating fails to reach setpoint temperature within the set time.  A thermocouple is defective or displays an illegal value.  The set threshold temperature is exceeded.
Instrument casing
The instrument casing comprises the following, as seen from the top left in the picture:
Right side door
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
2 - Basic security settings 21
Front door  Left side door  Rear wall  Instrument cover.
The casing separates hot, live parts from the surroundings.
Protective earth conductor
The electrical components of the analyzer are grounded by a protective earth conductor:
The first protective earth conductor is located on the rear wall of the analyzer.  The second protective earth conductor is located outside the cover of the electrical area (arrow).  The third protective earth conductor is located intside the cover of the electrical area (arrow).
If the protective earth conductor connections need to be detached, they must be re-connected correctly when re-assembling.
Waste gas lines
The operator is obliged to connect waste gas lines if the national limits for toxic gases in workplace air are exceeded. The waste gas lines must discharge into the open or into an exhaust hood. The end of the waste gas lines must discharge into the open at a location protected from the wind as pressure fluctuations, e.g. caused by wind, cause detector instabilities.
In addition, the installation room should be well ventilated.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
2 - Basic security settings 22
Warning signs on the analyzer
Warning sign
Meaning
Warning sign furnace
The following picture shows the warning sign on the furnace heat protection cladding:
Warning sign electrical area
The following picture shows the warning sign on the electrical section cover:
Meaning of the warning signs
The following table explains the meaning of the warning signs:
Warning: hot surfaces
Electric current hazard
Note
You are obliged to keep the warning signs on the instrument complete and in a legible condition.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
2 - Basic security settings 23
Warning: changes to the instrument
Section
Required knowledge and skills
Safe instrument
The analyzer is designed and delivered in such a way to ensure safe working if you observe the instructions in the operating instructions.
Warning: Changes to the instrument
If you make any changes to the instrument, you risk rendering the instrument unsafe.
The consequences would be:
Injuries to the operating personnel  Damages to the instrument  loss of warranty.
Therefore, never make any unauthorized additions/conversions to the instrument.
Warning: unsuitable spare parts and consumables
Warning
If you use spare parts and consumables of an unsuitable type and quality, you risk:
Injuries to the operating personnel  damage to the instrument  Distortion of analysis results  Loss of warranty.
Only use original spare parts and original consumables that you have purchased from BÜCHI Labortechnik AG or authorized dealers.
Required user knowledge and skills
Knowledge and skills
Depending on the specific task, the user must have different knowledge and skills. The following table indicates which sections of the operating instructions require what knowledge and skills:
Work performed by the system administrator
Starting up or shutting down the instrument
Using the instrument Personnel with basic knowledge of chemistry and
Maintaining the instrument Personnel authorized by BÜCHI.
Repairing the instrument Personnel authorized by BÜCHI and having undergone
Personnel with good knowledge of the operating system and administrative settings.
Personnel authorized by BÜCHI and having undergone training.
experience with laboratory work (e.g. laboratory worker).
training.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
2 - Basic security settings 24
Required personal safety equipment
Protective glasses
You require protective glasses for many activities. Make sure that protective glasses are always available nearby the analyzer.
Protective gloves
BÜCHI two kinds of protective gloves with the instrument: The protective leather gloves for protection against cuts on broken glass from cold quartz
components.
The heat protection gloves for protection against burns on hot components.
Always keep the protective gloves nearby the analyzer. Replace the protective gloves immediately if required.
Laboratory clothing
For work on and with the instrument you need:
Sturdy shoes  Cotton apron  Hair tie to tie back long hair  Obedience of general rules for safe work in the laboratory
Warning notes during operation
Note
Always pay attention to careful handling when working with the instrument, especially for modifications, maintenance and repairing works. The following notes have to be strictly observed when performing the corresponding works.
Replacing the ash crucible/finger
Please observe the following instructions: Warning
Hot instrument parts and hot ash particles!
Risk of burning due to hot instrument parts.
When replacing:
Wear protective glasses.  Wear the enclosed heat protection gloves.  Place the hot instrument tubes in a tube rack on a level, non-combustible
surface.
Protect the hot instrument parts from unauthorized access.  Never leave the instrument unattended when the furnace has been pulled
out.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
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Warning
Damaged base panel
Please observe the following instruction: Caution
Gas pressure
Please observe the following instruction: Warning
Gas pressure and caustic substances in the instrument
Consumables may escape under pressure and cause chemical burns. Before performing the work:
Shut off the gas supply. To do so, execute the Options > Maintenance > Replace parts command.
Damaged base panel!
Damage to the base panel will impair proper functioning of the carousel.
Before starting maintenance work, always remove all samples from the carousel.
When dismantling and cleaning the carousel:
Never use pointed objects to dismantle the carousel.  Never use sharp or aggressive cleaners.
Gas pressure and caustic substances in the instrument
Consumables may escape under pressure and cause chemical burns. Before performing the work:
Shut off the gas supply. To do so, execute the Options > Maintenance > Replace parts command.
Hot instrument parts
Please observe the following instruction: Warning
Hot instrument parts!
Risk of burning due to hot instrument parts. Before performing the work:
Allow the furnace to cool down  Disconnect the power supply plug
Cleaning and installing/removing the quartz glass bridge
Please observe the following instruction: Warning
Sharp pieces of broken glass!
When cold quartz or glass components break there is a risk of cut injuries.
Wear the enclosed protective leather gloves and protective glasses when handling cold quartz and glass parts.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
2 - Basic security settings 26
Removing reaction tubes
side the instrument there is a risk of burning as many parts of the
Please observe the following instructions:
Warning
Warning
Filling reaction tubes
Please observe the following instructions:
Warning
Caution
Hot reaction tubes!
Risk of burning due to hot instrument parts.
When replacing the reaction tubes:
Wear protective glasses.  Wear the enclosed heat protection gloves.  Place the hot tubes in a tube rack on a level, non-combustible surface.  Protect the hot tubes from unauthorized access.  Never leave the instrument unattended when the furnace has been pulled
out.
Gas pressure and caustic substances in the instrument
Consumables may escape under pressure and cause chemical burns. Before performing the work:
Shut off the gas supply. To do so, execute the Options > Maintenance > Replace parts command.
Sharp pieces of broken glass!
When cold quartz or glass components break there is a risk of cut injuries.
Wear the enclosed protective leather gloves and protective glasses when handling cold quartz and glass parts.
Cutting sealing elements apart/out (o-rings, quad rings, half shells, ferrules).
When cutting sealing elements apart/out with a knife you may damage sealing surfaces.
Never remove sealing elements with a knife but rather with tweezers.
Installing and conditioning the reaction tubes
Please observe the following instructions:
Warning
Caution
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
Hot components in the instrument
When working in instrument are hot.
When working inside the instrument always wear protective glasses and the enclosed heat protection gloves.
Overheating if tube fillings are not appropriate for the operating mode!
Overheated tube fillings melt, run into the furnace area and destroy the furnace.
Make sure that the tube fillings correspond to the selected operating mode.
2 - Basic security settings 27
Emptying reaction tubes
A lack of ventilation leads to overheating of the analyzer. Before you switch off the
til the temperature displayed is less than 55
Please observe the following instruction:
Warning
Warning
Replacing fuses
Please observe the following instructions:
Risk
Risk
Caution
Sharp pieces of broken glass!
When cold quartz or glass components break there is a risk of cut injuries.
Wear the enclosed protective leather gloves and protective glasses when handling cold quartz and glass parts.
Harmful substances when glass is broken!
When filled quartz or glass components break there is a risk that harmful substances may be released.
Wear a dust mask when handling cold quartz and glass parts.
Live parts!
When replacing fuses there is a risk of electrocution.
Before replacing fuses:
Allow the furnace to cool down.  Disconnect the power supply plug.
High voltage!
Using the wrong fuses can pose a risk of electrocution or fire.
Only use fuses matching the indicated type and the indicated voltage on the fuse holder.
Lack of ventilation of the analyzer!
instrument:
Switch off the furnace. To do so, execute the following command: System >
Furnace
Allow the furnace to cool down un
°C.
Filling the drying tube
Please observe the following instructions:
Warning
Warning
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
Caustic substance Sicapent® (phosphorus pentoxide)!
Danger of chemical burns when handling Sicapent®. Wear protective glasses and the enclosed protective leather gloves.
Sharp pieces of broken glass!
When cold quartz or glass components break there is a risk of cut injuries.
Wear the enclosed protective leather gloves and protective glasses when handling cold quartz and glass parts.
2 - Basic security settings 28
Installing/removing the drying tube
Improper changes impair proper operation of the system and may destroy system
Please observe the following instructions:
Caution
Warning
Lack of ventilation of the analyzer!
A lack of ventilation leads to component overheating
Do not open the front door too long when the furnaces are hot and the furnace is not pulled out. Otherwise the ventilation will not work properly.
Caustic substance Sicapent® (phosphorus pentoxide)!
Danger of chemical burns when handling Sicapent®.
Wear protective glasses and the enclosed protective leather gloves.
Overheating of tube fillings
Please observe the following instruction: Caution
Overheating if tube fillings are not appropriate for the operating mode!
Overheated tube fillings melt, run into the furnace area and destroy the furnace.
Make sure that the tube fillings correspond to the selected operating mode.
Working with the database
Please observe the following instructions:
Caution
Caution
Improper changes
Please observe the following instruction: Caution
Data loss After reorganizing the database via Clean all sample data and the contents of the
logbook are irrevocably deleted. Always backup your data before reorganizing the database via Clean.
Data loss Restoring the database via Restore irrevocably overwrites all sample data, the
contents of the logbook and the database configfuration parameters. Always backup your data before restoring the database via Restore.
components.
Only configure the instrument if you are authorized to do so and observe the operating instructions.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
2 - Basic security settings 29
Baking out combustion tube and reductor
When working inside the instrument there is a risk of burning as many parts of the
Please observe the following instructions: Warning
Gas pressure and caustic substances in the instrument!
Consumables may escape under pressure and cause chemical burns. Before performing the work:
Shut off the gas supply. To do so, execute the Options > Maintenance >
Replace parts command.
Warning
Mixing up gas inlets
Please observe the following instruction: Caution
Hot components in the instrument
instrument are hot.
When working inside the instrument always wear protective glasses and the enclosed heat protection gloves.
A mix-up of the gas inlets may lead to destruction of the instrument.
Connect the supply lines carefully and observe the diagram.
Operating instructions DuMaster D-480 ©BÜCHI Labortechnik AG
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