Page 1
Scrubber K-415
Operation Manual
11593505 en
Page 2
Document History
Index Date Author Changes
A 23/MAR/2012 NAGG Initial version
B 20/FEB/2014 OTTD Declaration of conformity, noise level, degree of protection
deleted, note concerning access to mains plug added, text
in improper use added, pictures updated
Imprint
Product Identification:
Operation Manual (Original), Scrubber K-415
11593505 en
Publication date:
06.2015, Version B
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 experience; 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.
Page 3
Table of contents
2
K-415 Operation Manual, Version B
Table of contents
1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.1 Reference documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.2 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.1 User qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Safety warnings and safety signs used in this manual . . . . . . . . . . . . . . . . . 10
2.5 Product safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.1 General hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.2 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.3 Built-in safety elements and measures . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 General safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1 DuoScrub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.2 TripleScrub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.3 TripleScrub
ECO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.4 QuadScrub
ECO
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.1.5 Standard accessories for all scrubber models . . . . . . . . . . . . . . . . . . . . . 17
3.1.6 Optional upgrade sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Technical data overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Materials and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Recommended consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Information on type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Description of function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Functional principle of the Scrubber . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Scrubber capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Installation site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.1 Anti-seismic-tie-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 General installation procedure for all Scrubber models . . . . . . . . . . . . . . . . 26
5.3 Equipping the Scrubber with the condenser unit . . . . . . . . . . . . . . . . . . . 28
Read this manual carefully before installing and running your system and note the safety precautions
in chapter 2 in particular. Store the manual in the immediate vicinity of the instrument, so that it can be
consulted at any time.
No technical modifications may be made to the instrument without the prior written agreement of
BUCHI. Unauthorized modifications may affect the system safety or result in accidents.
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.
The English manual is the original language version and serves as basis for all translations
into other languages. Other language versions can be downloaded at www.buchi.com.
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K-415 Operation Manual, Version B
5.4 Installing the Reaction vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.5 Receiving vessel with outlet - Total Kjeldahl Nitrogen set (optional) . . . . . . . . . . 30
5.6 Connecting the cooling water control (ECO-versions only). . . . . . . . . . . . . . . 31
5.7 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.7.1 Hose connections of the DuoScrub . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.7.2 Hose connections for the TripleScrub . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.7.3 Hose connections for the TripleScrub
ECO
. . . . . . . . . . . . . . . . . . . . . . . 34
5.7.4 Hose connections for the QuadScrub
ECO
. . . . . . . . . . . . . . . . . . . . . . . 35
5.8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.9 Preparing washing solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.9.1 Washing solutions for acidic vapors and gases . . . . . . . . . . . . . . . . . . . . 37
5.9.2 Washing solutions for alkaline vapors and gases . . . . . . . . . . . . . . . . . . . 37
5.10 Filling up the prepared washing solution . . . . . . . . . . . . . . . . . . . . . . . . 38
5.11 Preparation of the adsorption vessel. . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.12 Filling the reaction stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.1 Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.1 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.2 Glass parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.3 Hoses / hose connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4 Sealing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.1 Cleaning the gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.2 Replacing the seals / GL 14 connector . . . . . . . . . . . . . . . . . . . . . . . . 44
7.5 Washing insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.6 Washing solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.7 Active charcoal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.8 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.9 Hose cooling control / condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.10 Hose water control feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.11 Power supply fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.12 Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.13 Functional test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.14 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.1 Malfunctions and their remedy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
9 Shutdown, storage, transport and disposal . . . . . . . . . . . . . . . . . . . . . . . . 51
9.1 Storage and transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9.2 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
10.1 Spare parts on the exploded instrument view . . . . . . . . . . . . . . . . . . . . . 53
10.2 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
11 Declarations and requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
11.1 FCC requirements (for USA and Canada) . . . . . . . . . . . . . . . . . . . . . . . 57
11.2 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Page 5
1 About this manual
4
K-415 Operation Manual, Version B
Page 6
1 About this manual
5
K-415 Operation Manual, Version B
1 About this manual
This manual describes the Scrubber and provides all information required for its safe operation and to
maintain it in good working order.
It is addressed to laboratory personnel in particular.
NOTE
The symbols pertaining to safety (WARNINGS and ATTENTIONS) are explained in chapter 2.
1.1 Reference documents
For information on the digestion instrument, please refer to the corresponding manuals available in
English, German, French, Italian and Spanish
• Digest System K-437, Operation Manual numbers 96760 - 96764
• Digest Automat K-438/432, Operation Manual numbers 96765 - 96769
• SpeedDigester K-425/K-436, Operation Manual numbers 11593346 - 15593350
• SpeedDigester K-439, Operation Manual numbers 15593351 - 15593355
• WetDigester B-440, Operation Manual numbers 096790 - 096794
• KjelDigester K-446/K-449, Operation Manual numbers 11593546 - 11593552, 11593643
1.2 Abbreviations
CR: Chloroprene Rubber
EPDM: Ethylene Propylene Dimonomer
FEP: Fluorinated Ethylene Propylene
FPM: Fluoroelastomer
pa: per analysis
PA: Polyamides
PMMA: Polymethylmethacrylate
POM: Polyoxymethylene
PP: Polypropylene
PPS: Polyphenylenesulfide
PTFE: Polytetrafluoroethylene
PUR: Polyurethanes
P+G: Plastic & Glass
PA12: Poly amide 12
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2 Safety
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K-415 Operation Manual, Version B
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K-415 Operation Manual, Version B
2 Safety
This chapter points out the safety concept of the instrument and contains general rules of behavior
and warnings from hazards concerning the use of the product.
The safety of users and personnel can only be ensured if these safety instructions and the safetyrelated warnings in the individual chapters are strictly observed and followed. Therefore, the manual
must always be available to all persons performing the tasks described herein.
2.1 User qualification
The instrument may only be used by laboratory personnel and other persons who on account of
training or professional experience have an overview of the dangers which can develop when
operating the instrument.
Personnel without this training or persons who are currently being trained require careful instruction.
The present Operation Manual serves as the basis for this.
2.2 Proper use
The instrument has been designed and built for laboratories. It serves for the neutralization and
adsorption of gases that arise during chemical reactions and syntheses.
Only gases with known chemical composition may be drawn off.
2.3 Improper use
Applications not mentioned above are improper. Also, applications, which do not comply with the
technical data, are considered improper. In particular no gases with unknown chemical composition
may be drawn off.
If the equipment is used in a manner not specified by the manufacturer, the protection provided by the
equipment may be impaired.
The operator bears the sole risk for any damages caused by such improper use.
The following uses are expressly forbidden:
• Use of the instrument in rooms which require ex-protected instruments.
• Use on samples, which can explode or inflame (example: explosives, etc.) due to shock, friction,
heat or spark formation.
• Use in overpressure situations.
• Drawing off liquids.
• Drawing off solvents.
• Drawing off vapors of organic solvents.
• Use for cleaning of room air.
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K-415 Operation Manual, Version B
2.4 Safety warnings and safety signs used in this manual
DANGER, WARNING, CAUTION and NOTICE are standardized signal words for identifying levels of
hazard seriousness of risks related to personal injury and property damage. All signal words, which are
related to personal injury are accompanied by the general safety sign.
For your safety it is important to read and fully understand the table below with the different signal
words and their definitions!
Sign Signal word Definition Risk level
DANGER
Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
★★★★
WARNING
Indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
★★★☆
CAUTION
Indicates a hazardous situation which, if not avoided, may result
in minor or moderate injury.
★★☆☆
no
NOTICE
Indicates possible property damage, but no
practices related to personal injury.
★☆☆☆
(property damage only)
Supplementary safety information symbols may be placed in a rectangular panel on the left to the
signal word and the supplementary text (see example below).
Space for
supplementary
safety
information
symbols.
!
SIGNAL WORD
Supplementary text, describing the kind and level of hazard / risk seriousness.
• List of measures to avoid the herein described, hazard or hazardous situation.
• ...
• ...
Table of supplementary safety information symbols
The reference list below incorporates all safety information symbols used in this manual and their
meaning.
Symbol Meaning
General warning
Electrical hazard
Harmful to life-forms
Inhalation of substances
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K-415 Operation Manual, Version B
Symbol Meaning
Heavy weight, avoid overexertion
Chemical burns by corrosives
Fragile components
Explosive gases, explosive environment
Device damage
Wear laboratory coat
Wear protective goggles
Wear protective gloves
Additional user information
Paragraphs starting with NOTE transport helpful information for working with the device / software or
its supplementaries. NOTEs are not related to any kind of hazard or damage (see following example).
NOTE
Useful tips for the easy operation of the instrument / software.
2.5 Product safety
The Scrubber K-415 has been designed and built in accordance with current state-of-the-art technology, at the time of development. Safety warnings in this manual (as described in section 2.4) serve
to make the user alert to and avoid hazardous situations emanating from residual dangers by giving
appropriate counter measures.
However, risks to users, property and the environment can arise when the instrument is damaged,
used carelessly or improperly.
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K-415 Operation Manual, Version B
2.5.1 General hazards
The following safety messages show hazards of general kind which may occur when handling the
instrument. The user shall observe all listed counter measures in order to achieve and maintain the
lowest possible level of hazard.
Additional warning messages can be found whenever actions and situations described in this manual
are related to situational hazards.
!
DANGER
Death or serious injuries by use in explosive environments.
• Do not store or operate the instrument in explosive environments
• Remove all sources of flammable vapors
• Do not store chemicals in the vicinity of the device
!
CAUTION
Risk of minor or moderate cuts by sharp edges.
• Do not touch defective or broken glassware with bare hands
• Do not touch thin metal edges
NOTICE
Risk of instrument damage by liquids or mechanical shocks.
• Do not spill liquids over the instrument or its components
• Do not drop the instrument or its components
• Keep external vibrations away from the instrument
2.5.2 Personal protective equipment
Always wear personal protective equipment such as protective eye goggles, protective clothing and
gloves. The personal protective equipment must meet all requirements of all data sheets for the
chemicals used. These instructions are an important part of the Scrubber K-415 and must be made
available at all times to the operating personnel at the place where the equipment is deployed. This
also applies to additional language versions of these instructions, which can be reordered separately.
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K-415 Operation Manual, Version B
!
WARNING
Serious chemical burns by corrosives.
• Observe all data sheets of the used chemicals
• Handle corrosives in well ventilated environments only
• Always wear protective goggles
• Always wear protective gloves
• Always wear protective clothes
• Do not use damaged glassware
2.5.3 Built-in safety elements and measures
Neutralization vessel P+G coated
The protective P+G coating of the neutralization vessel protects operators from risks, caused by parts
of broken glass.
2.6 General safety rules
Responsibility of the operator
The head of the laboratory is responsible for training his/her personnel.
The operator shall inform the manufacturer without delay of any safety-related incidents which might
occur during operation of the instrument or its accessories. Legal regulations, such as local, state and
federal laws applying to the instrument or its accessories must be strictly followed.
Duty of maintenance and care
The operator is responsible for the proper condition of instrument. This includes maintenance, service
and repair jobs that are performed and on schedule by authorized personnel only.
Spare parts to be used
Use only genuine consumables and spare parts for maintenance to assure good system performance,
reliability and safety. Any modifications of spare parts or assemblies are only allowed with the prior
written permission of the manufacturer.
Modifications
Modifications to the instrument are only permitted after prior consultation and with the written approval
of the manufacturer. Modifications and upgrades shall only be carried out by an authorized BUCHI
technical engineer. The manufacturer will decline any claim resulting from unauthorized modifications.
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3 Technical data
This chapter introduces the reader to the instrument specifications. It contains the scope of delivery,
technical data, requirements and performance data.
3.1 Scope of delivery
Check the scope of delivery according to the order number.
NOTE
For detailed information on the listed products, see www.buchi.com or contact your local dealer.
3.1.1 DuoScrub
Table 3-1: DuoScrub K-415
Product Order number
230 V / 50/60 Hz 114152320
120 V / 50/60 Hz 114151220
100 V / 50/60 Hz 114151020
3.1.2 TripleScrub
Table 3-2: TripleScrub K-415
Product Order number
230 V / 50/60 Hz 114152330
120 V / 50/60 Hz 114151230
100 V / 50/60 Hz 114151030
Standard accessories
Silicone hose 6/9 3 m 048355
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K-415 Operation Manual, Version B
3.1.3 TripleScrub
ECO
Table 3-3: TripleScrub
ECO
K-415
Product Order number
230 V / 50/60 Hz 114152331
120 V / 50/60 Hz 114151231
100 V / 50/60 Hz 114151031
Standard accessories
Hose for water control 11057146
Adapter with sieve for tap 11058398
Multi-tool 11058474
Silicone hose 6/9 3 m 048355
Connection cable to digester 030973
3.1.4 QuadScrub
ECO
Table 3-4: QuadScrub
ECO
K-415
Product Order number
230 V / 50/60 Hz 114152341
120 V / 50/60 Hz 114151241
100 V / 50/60 Hz 114151041
Standard accessories
Hose for water control 11057146
Adapter with sieve for tap 11058398
Multi-tool 11058474
Silicone hose 6/9 3 m 048355
Connection cable to digester 030973
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K-415 Operation Manual, Version B
3.1.5 Standard accessories for all scrubber models
Table 3-5: Standard accessories
Product Order number
1 power cable
Type CH 010010
Type Schuko / Japan 010016
Type GB 017835
Type USA 033763
Type AUS 017836
Operation Manual:
English 11593505
German 11593506
French 11593507
Italian 11593508
Spanish 11593509
Chinese 11593510
Japanese 11593511
3.1.6 Optional upgrade sets
Table 3-6: Optional upgrade sets
Product Order number
Condensation step 11058460
Reaction step 11058461
TKN set 11057333
Cooling water valve 11058462
Tray for adsorption storage 11057332
Connection cable to digester 030973
IQ/OQ Scrubber K-415 11058568
Repeating OQ Scrubber K-415 11058569
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K-415 Operation Manual, Version B
3.2 Technical data overview
Table 3-7: Technical data
Scrubber Unit K-415
Dimensions (W x H x D)
(completely equipped instrument)
DuoScrub
TripleScrub
TripleScrub
ECO
QuadScrub
ECO
248 x 412 x 526 mm
347 x 417 x 526 mm
347 x 417 x 543 mm
347 x 450 x 543 mm
Weight DuoScrub
TripleScrub
TripleScrub
ECO
QuadScrub
ECO
10.1 kg
11.2 kg
12.3 kg
12.9 kg
Power system voltage / frequency /consumption / fuse 230 V ± 10 % / 50/60 Hz
120 V ± 10 % / 50/60 Hz
100 V ± 10 % / 50/60 Hz
140 W T1A L 250 V
140 W T2A L 250 V
140 W T2A L 250 V
Installation site For indoor use only
Temperature + 5 °C to + 40 °C
Altitude up to 2000 m above sea level
Humidity
maximum relative humidity 80 % for temperatures up to 31 °C,
decreasing linearly to 50 % relative humidity at 40 °C
Pump suction capacity (max.) 32 L/min (air)
System suction capacity adjustable approximately between 50 and 400 mbar
below atomspheric pressure
Overvoltage category II
Pollution degree 2
Noise level < 70 dB
3.3 Materials and Approvals
Table 3-8: Materials and Approvals
Component Material designation
Housing PUR
Minor hardware PP, PA, POM
Lip gasket acid- / base-resistant FPM, EPDM
Gasket PTFE, CR
Cover of neutralization vessel PMMA
Glass parts Borosilicate 3.3, P+G plastic coated glass
Pump PPS, CR, FPM
Hoses CR, FEP
Cooling water control brass, FKM (sealing)
Water hose (black) Polychloroprene Rubber
Water hode (white) brass, PA12
Approvals CE, CSA
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K-415 Operation Manual, Version B
3.4 Recommended consumables
Table 3-9: Active charcoal for adsorption vessel
Product Order number
Fluka, granules impregnated with potassium hydroxide for the chemisorption of acid
vapors
Fluka 29238
Fluka, purum p.a. 4 - 8 mm Fluka 05110
Merck, granulated Merck 102518
Table 3-10: Glasswool for adsorption vessel
Product Order number
Glass wool 033701
Table 3-11: Color indicator for washing solution
Product Order number
Bromothymol blue, Merck Merck 3026
3.5 Information on type plate
a Instrument type code
b Serial number
c Supply voltage range / type
d Frequency of supply voltage
e Nominal power rating
f Year of manufacture
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4 Description of function
This chapter explains the basic principle of the instrument, shows how it is structured and gives a
functional description of the assemblies.
The pump draws off the gases and vapors produced in chemical reactions via a condenser providing
a receiving vessel underneath. The suction performance of the pump can be regulated via a bypass
valve on the rearside of the instrument.
The condensation stage is used as a preliminary extractor for vapors, water steam (to prevent
warming or an increase in volume of the washing solution) and for the liquids carried along with them,
thus extending the service life of the neutraliza tion stage.
The acid or alkaline gases are washed and neutralized in the neutralization stage.
The next stage, the adsorption stage, holds back most of the undesired particles by means of
granules of activated charcoal or a universal adsorption granulate. It also enables the aerosols to
recondensate.
In the reaction stage that follows specific redox reactions are accomplished.
The used air is directly lead into an exhaust or into the open air through a silencer. The
ECO
-versions of
the K-415 are equipped with a cooling water control unit that allows an automatic start and stop of the
cooling water flow, triggered by the digester (or by the on/off switch of the K-415).
4.1 Functional principle of the Scrubber
2
4
3
1
5
6
a Receiving vessel
b Condenser
c Reaction tubelet (Reaction stage)
d Adsorption vessel
e Neutralization vessel
f Tray for adsorption vessel and tube connector
Fig. 4.1: Overview over the Scrubber
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K-415 Operation Manual, Version B
a Fume inlet into condenser
b Condenser
c Receiving vessel
d Cooling water inlet of condenser
e Cooling water outlet of condenser
f Fume outlet of condenser
g Neutralization vessel with washing solution
h Adsorption vessel (filled with activated charcoal)
i Reaction stage
j Fume exhaust pump
Fig. 4.2: Functional principle of the Scrubber
Condensation stage
• Condensation of vapors
• Condensation of water steam (prevention of warming or an increase in volume of the washing
solution)
• Condensation of the liquids carried along
Neutralization stage
• Neutralization of acid or alkaline gases
Adsorption stage
• Specific adsorptions and retention of particles (using granules of activated charcoal or a universal
adsorption granulate)
• Recondensation of aerosols
Reaction stage
• Specific reactions (e.g., redox reactions)
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K-415 Operation Manual, Version B
4.2 Scrubber capacity
The suction capacity of the Scrubber K-415 is designed for digestion units with a maximum of 20
sample tubes.
Connection examples:
• Connection of up to two SpeedDigesters K-425 (6 places each)
• Connection of one SpeedDigester K-436 / K-439 (12 places)
• Connection of one WetDigester B-440
• Connection of one KjelDigester K-446 / K-449 (20 places)
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K-415 Operation Manual, Version B
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5 Putting into operation
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K-415 Operation Manual, Version B
5 Putting into operation
This chapter describes how the instrument is installed and gives instructions on initial startup.
NOTE
Inspect the instrument for damages during unpacking. If necessary, prepare a status report immediately to inform the postal company, railway company or transportation company.
5.1 Installation site
!
DANGER
Death or serious injuries by use in explosive environments.
• Do not store or operate the instrument in explosive environments.
• Remove all sources of flammable vapors.
• Do not store chemicals in the vicinity of the device.
!
CAUTION
Risk of minor or moderate injury by heavy weight of the instrument.
• Lift the instrument carefully and avoid over exertion.
• Do not drop the instrument or its transport box.
• Place the instrument on a stable, even and vibration-free surface.
• Keep limbs out of crushing zone.
!
WARNING
Serious chemical burns by corrosives.
• The instrument may only be operated within a fume hood.
• Handle corrosives in well ventilated environments only.
• Always wear protective goggles.
• Always wear protective gloves.
• Always wear protective clothes.
• Do not use damaged glassware.
NOTE
Place the Scrubber K-415 on the left side of a digestion unit (e.g. SpeedDigester, Digest System
K-437 or Digest Automat K-438/K-432). The Scrubber ventilation is located on the left side. In case
the Scrubber is placed on the right side of another unit, cool air will hit the digestion sample and cool
it down, so that no digestion can take place.
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5 Putting into operation
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K-415 Operation Manual, Version B
5.1.1 Anti-seismic-tie-down
For the use in earthquake-susceptible regions, the instrument can be equipped and secured with the
anti-seismic-tie-down, contained in the standard delivery of the instrument.
The fixing device can be attached to the instrument from the bottom side of the instrument, close to
the housing foot on the right rear side of the instrument.
• Slide the fixing bracket a into the provided groove b and fix it with the provided screw c.
• The instument can now be tied to the setup.
Fig. 5.1: Fixing the anti-seismic-tie-down
5.2 General installation procedure for all Scrubber models
To commission the Scrubber K-415, proceed as follows:
• Make sure that the silencer (a in figure 5.2) is filled with polyester fibres and install it:
1
Fig. 5.2: The silencer on the rear side of the instrument
• Check the glass for flaws and cracks.
• Check the seals and gaskets (embrittlement, scratches). If they are not OK, take them out and
replace them (see also chapter 7).
• Carefully insert the glass parts. Otherwise there is a risk of damaging the glassware.
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K-415 Operation Manual, Version B
• Attach the tray for adsorption storage (optional available for DuoScrub) to the housing: Slide the
tray a from the side into the groove in the housing b and fix it by tightening the screw c. After
the tray has been attached to the housing of the scrubber, the adsorption vessel and the inlet
tubing of the neutralization vessel can be stored in the tray, while the neutralization vessel is taken
away from the instrument.
Fig. 5.3: Fixing the tray for adsorption storage
Fig. 5.4: Swiveling adsorption vessel and tubing to the tray
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K-415 Operation Manual, Version B
5.3 Equipping the Scrubber with the condenser unit
To prepare a Scrubber model for operation with a condenser, proceed as follows:
• Unless the carrier-plate a for the condenser is not yet installed, slide it into the housing from the
side and fix it with the two screws from below. The groove b must point away from the opening in
the housing (see figure 5.5).
Fig. 5.5: Fixing the carrier plate
• Carefully slide the condenser from top into the opening in the housing and fix it on the carrier plate
a with the rubber strap c. The rubber strap has to be passed through the groove on the backside of the carrier plate to prevent it from sliding up or down and to guarantee a tight positioning of
the condenser (see arrow in figure 5.6). Make sure the connections of the condenser are pointing
backward.
• The receiving vessel d can be attached from below and secured with the catchpot clip e.
Fig. 5.6: Fixing the condenser with the rubber strap
For the determination of the total Kjeldahl nitrogen (TKN) the optional TKN set can be used as an alter-
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5 Putting into operation
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K-415 Operation Manual, Version B
native to the receiving vessel. For details please refer to chapter 5.5.
The connections of the condenser can be seen from the following schema:
4
1
2
3
a Cooling water outlet
b Connection to neutralization stage
c Fume inlet (connection to emission source / digester)
d Cooling water inlet
Fig. 5.7: Connections of the condenser
5.4 Installing the Reaction vessel
• Screw the screw cap c together with the gasket ring b loosely onto the reaction vessel a.
• Insert the introduction tube assembly d . Tighten the screw cap c.
• Insert the mounted reaction vessel a from the side to the housing and place it in the groove i
on the bottom of the housing (the introduction tube assembly d has to protrude from the round
opening on top of the housing j).
• Attach the provided tubing g and h using the provided screw caps f and gaskets e (GL 14).
(See also chapter 5.7.4)
• (Dismount in the reversed order.)
1
4
9
10
Fig. 5.8 Installing the Reaction vessel
1
2
3
4
5
6
7
5
6
8
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K-415 Operation Manual, Version B
5.5 Receiving vessel with outlet - Total Kjeldahl Nitrogen set (optional)
A receiving vessel with outlet a is optionally available. It serves for the digestion of samples with a
large water content. Using the drain cock b it is possible to drain the collected volume of liquid during
operation.
To install the optional TKN-set, proceed as follows:
• Attach the receiving vessel a with outlet to the condenser from below and secure it with
the
catchpot clip
c.
• Attach the provided hose to the outlet of the cock and secure it with a hose clamp. Connect the
other end of the hose to an appropriate collection tank or sink.
Fig. 5.9 Connecting the TKN set
NOTE
During manual operation of the K-415 the cock of the TKN receiving vessel has to be kept closed otherwise the suction performance of the K-415 may not be sufficient to draw off all fumes produced
by the digester. The cock shall only be opened for a very short time while the receiving vessel is
discharged.
Manual operation:
1. Reduce the suction performance to a minimum.
2. Open the cock b of the receiving vessel.
3. Wait until the receiving vessel is completely emptied, then close the cock again.
4. Set the suction performance back to the previously used level .
Automatic operation:
1. Place an additional bigger vessel with sufficient capacity to the floor.
2. Connect the tube from the TKN set to this vessel.
3. Tighten the connection between the tube and the vessel (otherwise the suction capacity
of the scrubber will go down and will no longer be sufficient to draw off all fumes produced by the digester).
4. The cock b of the receiving vessel a can now be left open permanently.
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5.6 Connecting the cooling water control (ECO-versions only)
The
ECO
-versions of the Scrubber are equipped with a cooling water control ensuring the flow of the
cooling water is switched on every time the K-415 is switched on by the digestion instrument and is
turned off the same time, the digester is turned off. (Assumed the external cooling water source is
always turned on).
The cooling water control a can be found on the rear side of the instrument with cooling water inlet b
at the bottom and the cooling water outlet on top. The cooling water inlet can be horizontally swivelled
around in a range of 180 degrees. This makes it possible to orient the inlet towards the available
cooling water supply.
To swivel the cooling water inlet, proceed as follows:
• Loosen the nut on the bottom of the inlet c, using the matching end of the provided Multi-tool d.
• Swivel the inlet b to the appropriate position.
• Tighten the nut c with the Multi-tool d.
NOTE
After swiveling the cooling water inlet to the preferred position make sure the fixing nut c is tight and
check all connections and tubing of the cooling water control for tightness.
1
2
3
4
5
6
7
8
Fig. 5.10 Swivelling the cooling water inlet
• Connect the provided hose for the water control e on one side to the inlet b of the cooling water
control and tighten it with the matching end of the Multi-tool d.
• Connect the provided adapter f with sieve g and sealing h to the water source and tighten it
using the Multi-tool.
• Connect the other end of the hose to the adapter at the water source and tighten it.
• Check all connections for tightness before putting the instrument into operation.
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5.7 Hose connections
NOTE
Use clips and cable ties where necessary to secure the hoses in place.
5.7.1 Hose connections of the DuoScrub
The DuoScrub consists of the neutralization and the adsorption vessel.
To establish the hose connections, proceed as follows:
• Connect the adsorption vessel c to the bypass valve d using the PTFE hose and secure it with
the GL 14 hose connectors at both ends.
• Connect the emission source via a Woulff bottle to the neutralization vessel b and secure all
connections with hose clamps.
3
2
1
4
5
a Neutralization stage
b Inlet for fumes from the emission source
c Adsorption vessel
d Bypass valve
e Silencer
Fig. 5.11: Hose connections of the DuoScrub
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5.7.2 Hose connections for the TripleScrub
The TripleScrub consists of the neutralization vessel, the adsorption vessel, and the condenser unit.
To establish the hose connections, proceed as follows:
• Put hose connectors GL 14 with seals on all PTFE hoses.
• Connect the emission source to the condenser inlet e.
• Connect the condenser outlet f to the neutralization vessel a.
• Connect the adsorption vessel b to the bypass valve c.
• Cut off a piece of the provided silicone hose and connect the cooling water source to the cooling
water inlet of the condenser g
. Secure it with a hose clamp
.
• Cut off a piece of the provided silicone hose and connect the cooling water outlet of the condenser
h to the waste water system.
1
2
3
4
5
6
7 8
9
a Neutralization stage
b Adsorption vessel
c Bypass valve
d Silencer
e Inlet for fumes from emission source
f Outlet to neutralization vessel (top)
g Cooling water inlet (bottom)
h Cooling water outlet (top)
i Condenser
Fig. 5.12: Hose connections for the TripleScrub
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K-415 Operation Manual, Version B
5.7.3 Hose connections for the TripleScrub
ECO
The TripleScrub
ECO
consists of the neutralization, the adsorption vessel, the condenser unit and the
cooling water control.
To establish the hose connections, proceed as follows:
• Put hose connectors GL 14 with seals on all PTFE hoses.
• Connect the emission source to the condenser inlet g.
• Connect the condenser outlet h to the neutralization vessel a.
• Connect the adsorption vessel b to the bypass valve e.
• Connect your cooling water source to the cooling water tube of the water control c using the
provided adapter with sieve and tighten it (see chapter 5.6).
• Cut off a piece of the provided silicone hose and c
onnect the cooling water outlet d of the water
control c to the cooling water inlet i of the condenser. Secure both connections with hose clamps.
• Cut off a piece of the provided silicone hose and connect the cooling water outlet j of the
condenser k to the waste water system.
3
6
4
5
9
8
11
1
2
10
7
a Neutralization stage
b Adsorption vessel
c Water control
d Water control (outlet)
e Bypass valve
f Silencer
g Inlet from emission source (digester)
h Outlet to neutralization vessel (top)
i Cooling water inlet (bottom)
j Cooling water outlet (top)
k Condenser
Fig. 5.13: Hose connections for the TripleScrub
ECO
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K-415 Operation Manual, Version B
5.7.4 Hose connections for the QuadScrub
ECO
The QuadScrub
ECO
consists of the neutralization, the adsorption vessel, the condenser, the cooling
water control and the reaction stage.
To establish the hose connections, proceed as follows:
• Put hose connectors GL 14 with seals on all PTFE hoses.
• Connect the emission source to the condenser inlet i.
• Connect the condenser outlet j to the neutralization vessel a.
• Connect the adsorption vessel b to the top of the reaction tubelet c.
• Connect the reaction tubelet (connection on the side d) to the bypass valve g.
• Connect your cooling water source to the cooling water tube of the water control e using the
provided adapter with sieve and tighten it (see chapter 5.6).
• Cut off a piece of the provided silicone hose and c
onnect the cooling water outlet f of the water
control e to the cooling water inlet k of the condenser m . Secure both connections with a hose clamp.
• Cut off a piece of the provided silicone hose and connect the cooling water outlet l of the
condenser m to the waste water system.
3
6
7
4
5
9
8
11
1
2
10
13
12
a Neutralization stage
b Adsorption vessel
c Reaction stage (upper port)
d Reaction stage (side port)
e Water control
f Water control (outlet)
g Bypass valve
h Silencer
i Inlet from emission source (digester)
j Outlet to neutralization vessel (top)
k Cooling water inlet of condenser (bottom)
l Cooling water outlet of condenser (top)
m Condenser
Fig. 5.14: Hose connections for QuadScrub
ECO
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K-415 Operation Manual, Version B
5.8 Electrical connections
Notice
Risk of instrument damage by wrong mains supply.
• External mains supply must meet the voltage given on the type plate.
• Check for proper grounding.
• Exchange defective cabling instantly.
• Make sure the used digester and the K-415 are suitable for the same power system (voltage
and frequency) when both instruments share the same power source.
Connect the Scrubber K-415 to the mains with the power cord contained in the scope of delivery.
To start the Scrubber automatically at the same time the digestion process starts, connect it to the
SpeedDigester K-439, to a Digest System K-437 or to a Digest Automat K-438/K-432 with the
optional connection cable.
NOTE
To cut the power in case of an emergency by unplugging, the instrument or any other item must not
block the mains plug! In this case, the plug must be able to be pulled out instantly.
5.9 Preparing washing solutions
!
WARNING
Serious chemical burns by corrosives.
• Observe all data sheets of the used chemicals.
• Handle corrosives in well ventilated environments only.
• Always wear protective goggles.
• Always wear protective gloves.
• Always wear protective clothes.
• Do not use damaged glassware.
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5.9.1 Washing solutions for acidic vapors and gases
• Sodium hydroxide 8-10 %, max. 20 %
• Sodium carbonate
– dissolve 600 g Na2CO3 in 3 L distilled warm water, or
– dissolve 1.7 kg Na2CO3 · 10 H2O in 3 L distilled warm water
Color indicator
A color indicator is added to the washing solution to assess its washing power visually as well.
We recommend to use a spatula tip of color indicator for 3 L of washing solution.
Bromothymol blue serves as a stan dard indicator. The transition area here is between pH 6.0 to 7.6.
Thus the fresh solution has a blue color while the neutralized or acidic solution has an orange yellowish
color.
Depending on the application purpose, other suitable color indicators should be used.
5.9.2 Washing solutions for alkaline vapors and gases
• Hydrochloric acid, max. 15 %
• Sulphuric acid, max. 20 %
Depending on the area of application, it is recommended to use different washing solutions or concentrations. The Scrubber K-415 is supplied ex works with a base-resistant lip gasket.
NOTE
For operating with acid washing solutions, an acid-resistant lip gasket should be used.
Color indicators
Table 5-1: Indicators for washing solutions for alkaline vapors and gases
Name Transition pH range Color change
Bromocresol green 3.8 - 5.4 yellow to blue
Bromothymol blue 5.8 - 7.6 yellow to blue
Methylen red 4.4 - 6.2 yellow to red
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5.10 Filling up the prepared washing solution
!
WARNING
Risk of serious chemical burns by corrosives.
• Allways use the glass handles of the neutralization vessel to lift or carry it.
• Never try to lift or carry the neutralization vessel while holding it on the cover of the neutralization vessel.
To fill up the washing solution, proceed as follows:
• Remove the adsorption vessel a by gently pulling it upwards. (If available store it on the tray f.)
• Loosen the hose connector GL 14 b at the neutralization vessel and pull off the hose. (If available
store it on the tray f.)
• Take the neutralization vessel with the attached cover away from the instrument. Lift or carry the
neutralization vessel solely by using the glass handles h of the vessel.
• Remove the cover of the neutralization vessel c togehter with the attached swirl discs d.
• Carefully pour the prepared washing solution into the neutralization vessel and fill up to the blue
wavy optimal filling mark g.
• Reassemble the instrument in the reverse order.
NOTE
Make sure the cover is pressed firmly against the neutralization vessel to ensure tightness of the
system!
5
1
2
3
4
6
7
8
a Adsorption vessel
b Nut GL 14
c Cover with swirl discs
d Washing insert
e ON/OFF switch
f tray
g filling mark
h glass handles
Fig. 5.15: Filling up the washing solution
NOTE
For information on how and when to exchange the washing solution, see chapter 7.6.
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K-415 Operation Manual, Version B
5.11 Preparation of the adsorption vessel
NOTE
When you carry out Kjeldahl digestions, the suction capacity might become too high. Therefore we
recommend to fill activated charcoal into the adsorption vessel and to add glass wool at both ends.
The glass wool prevents charcoal from being drawn into the vacuum pump. The activated charcoal
should be grainy with a particle size of 2 to 6 mm.
!
CAUTION
Risk of instrument damage and risk of serious chemical burns by corrosives.
• Never use charcoal in the form of powder or with a particle size below 2 mm - otherwise the
adsorption vessel will get clogged and as a result the pump will get damaged.
Fig. 5.16: Adsorption vessel with activated charcoal and glass wool
5.12 Filling the reaction stage
For digestions with aqua regia it becomes necessary to fill the reaction stage with around 350 mL of a
saturated FeSO4 solution (~27 g/100 mL) to dispose of the nitrous gases.
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K-415 Operation Manual, Version B
6 Operation
This chapter gives examples of typical instrument applications and instructions on how to operate the
instrument properly and safely.
!
CAUTION
Risk of minor or moderate cuts when handling damaged glass parts.
• Handle glass parts with care.
• Visually inspect every glass part before mounting.
• Exchange damaged glass parts immediately.
• Do not touch cracks or bits of broken glass with bare hands.
ATTENTION
Switch on the K-415 before a connected instrument produces gases. Check the level of the liquid in
the neutralization vessel before putting the scrubber into operation - the optimal liquid level can be
checked against the blue filling mark (wave) on the neutralization vessel.
If the K-415 is controlled via a digester do not switch the K-415 off. If the K-415 is equipped with
cooling water control (
ECO
-versions) leave the external cooling water supply switched on as well.
6.1 Typical applications
Table 6-1: Typical applications
Gases and vapors Chemical formula Neutralization (stage 2) Specific reactions (stage 4)
Kjeldahl digestions SO2, H2SO
4
saturated soda / NaOH
8 - 10 % (max. 20 %)
Sulfur dioxide SO
2
saturated soda / NaOH
8 - 10 % (max. 20 %)
Sulfuryl chloride SO2Cl
2
NaOH 8 - 10 % (max. 20 %)
Hydrochloric or hydrobromic
acids
HCI, HBr NaOH 8 - 10 % (max. 20 %)
Thionyl chloride SOCl
2
NaOH 8 - 10 % (max. 20 %)
Cyanuric chloride C3N3Cl
3
NaOH 8 - 10 % (max. 20 %)
Carbonic acid chloride R-COCI NaOH 8 - 10 % (max. 20 %)
Ammonia NH
3
HCI max. 15 % / H2SO4 max. 20 %
Nitrous oxides (nitrous gases)
Nitric acid / aqua regia
NO
X
NaOH 20 % FeSO4 saturated
Chlorine, bromine, iodine Cl2, Br2, J
2
NaOH 8 - 10 % (max. 20 %) FeSO4 saturated
Thiophenols Ar-SH NaOH 8 - 10 % (max. 20 %) KMnO4 saturated
Thioalcohols, mercaptan R-SH NaOH / javelle water KMnO4 saturated
Hydrogen sulphide H2S NaOH 8 - 10 % (max. 20 %) KMnO4 saturated
Carbon disulphide CS
2
NaOH 8 - 10 % (max. 20 %) KMnO4 saturated
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6.2 Operation
1
2
• Switch on the power switch a.
• Make sure that the cooling water flow rate
>1.2 L/min (≤ 25 °C) is pulse-free and does not
exceed 2.7 bar.
• The
ECO
-models of the Scrubber K-415 come
equipped with an automatic water-control. The
automatic water control will start the flow of
cooling water automatically once the instrument
is switched on and stop it, when the instrument
is switched off (this is also valid, if the K-415 is
controlled via a digester).
• The suction performance can be regulated,
using the bypass valve b. To reduce the suction
perfomance, turn the knob counter-clockwise.
Turning the knob clockwise will close the valve
and maximise the suction performance.
2
2
Fig. 6.1: Operation
NOTE
For most applications it is recommended to keep the bypass valve completely closed and to work
with the maximum available suction performance.
In case you find out the suction performance is to high for your requirements (e.g. for small sample
volumes or small numbers of samples) turn the knob counter-clockwise until the suction performance
is reduced to an adaquate proportion.
The bypass valve can be adjusted in the range of 100 to 400 mbar below atmospheric pressure.
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K-415 Operation Manual, Version B
7 Maintenance
This chapter gives instructions on all maintenance work to be performed in order to keep the instrument in good working condition.
NOTE
Use only genuine consumables and spare parts for any maintenance and repair work in order to
assure warranty and continued system performance. Any modifications of the Scrubber or parts of it
need prior written permission of the manufacturer.
!
WARNING
Death or serious burns by electric current.
• Switch off the instrument and disconnect the power cord before performing any maintenance
work.
• Do not spill liquids over the instrument or parts of it.
!
CAUTION
Risk of minor or moderate cuts when handling damaged glass parts.
• Handle glass parts with care.
• Visually inspect every glass part for good condition before mounting.
• Exchange damaged glass parts immediately.
• Do not touch cracks or bits of broken glass with bare hands.
NOTICE
Risk of housing and instrument damage by liquids and detergents.
• Do not spill liquids over the instrument or parts of it.
• Wipe off any liquids instantly.
• Use ethanol or soapy water as detergent only.
Table 7-1: Service intervals
Part Service intervals See chapter
Housing Check and clean once a week 7.1
Glass parts Check and clean once a month (or if required) 7.2
Hoses /hose connectors Check and clean once a week 7.3
Sealing system Check and clean once a month (or if required), replace sealing
once a year
7.4
Washing insert Check from time to time 7.5
Washing solution Check and replace in appropriate time 7.6
Charcoal in adsorption vessel Replace if necessary 7.7
Pump Flush once a week or after hard work 7.8
Hose water control / condenser Check on a monthly base 7.9
Hose water control feed Check sieve on a monthly base, check hose once a year 7.10
Rubber strap check and replace if required
Power supply fuses Replace if necessary 7.11
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K-415 Operation Manual, Version B
Table 7-1: Service intervals
Part Service intervals See chapter
Silencer Replace once a year 7.12
Functional test 7.13
Customer Service 7.14
7.1 Housing
Check the housing for defects (switches, plugs) and clean it once a week with a damp cloth.
7.2 Glass parts
Take out and clean the glass parts once a month or if required with commercially available cleaning
agents or in an ultrasonic bath. After the glass parts have been cleaned and fully dried, check each
part visually for cracks, scratches and for any parts or sections that might have splintered off. Take out
and replace any damaged glass parts.
7.3 Hoses / hose connectors
Visually examine the hose connections regularly. When hoses become cracked and brittle, replace
them with new hoses.
Grease all joints on the condenser side regularly to achieve optimum tightness of the system.
Flush out the hoses at least once a week with water or ethanol.
For the
ECO
-versions check the cooling water hose for tightness and clean the sieve of the adapter on a
regular base.
7.4 Sealing system
ATTENTION
When removing and reinstalling the seals and gaskets, make sure not to damage them. Always move
them perpendicularly to the axis of the glass parts and ensure no damage occurs to the sealing lip.
Never apply grease to the seals and never touch them with sharp objects, otherwise they will get
damaged.
7.4.1 Cleaning the gaskets
To prolong the lifetime of the gaskets (lip-gasket, gasket ring), rinse them at least once a month or if
required (e.g. when exchanging the washing solution) with water, especially if working with crystalline
products. Afterwards, dry them with a soft cloth.
7.4.2 Replacing the seals / GL 14 connector
Seals are subject to wear and tear, thus you should check them regularly and replace them, if necessary, e.g. if the system becomes untight.
We recommend to replace the seals periodically as follows:
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K-415 Operation Manual, Version B
Table 7-2: Replacing seals and silencer unit
Position in Fig. 10.1 Order no. Description Replacing interval
8 + 7 040296 Set of seals / connectors (straight) once a year
30 + 7 040295 Set of seals / connectors (bent) once a year
28 037928 O-ring to adapter (37777) once a year
13 003575 Gasket SVL 42 x 30 PTFE once a year
17 + 7 041999 Lip gasket GL 14 (FEP) once a year
23 037873 Seal for receiving vessel once a year
32 037925 Gasket ring once a year
3 037871 Silencer unit once a year
41 003576 Gasket SVL 22 x 16 PTFE (with silicone bearing) once a year
39 003575 Gasket SVL 42 x 30 PTFE once a year
7.5 Washing insert
The washing insert must be cleaned from time to time and the lip gasket must be replaced when brittle.
1
3
2
2
4
5
6
7
8
a Nut M20
b Swirl disc
c Spacer tube
d Swirl disc holder
e Lip gasket
f Cover
g O-ring 24 x 2.5
h Hose connector adapter M20 GL 14
Fig. 7.1: Exploded view of the washing insert
To (re)assemble the washing insert, proceed as follows:
• Insert the lip gasket e into the cover of the neutralization vessel f.
• Place the cover of the neutralization vessel f on the swirl disc holder d.
• Screw on the adapter h with the O-ring g and tighten it.
• Insert the first swirl disc b.
• Insert the spacer tube c.
• Insert the second swirl disc b.
• Screw the washing insert into the nut a.
• Insert the complete washing insert into the neutralisation vessel.
• Press the cover f on the neutralization vessel and center the neutralization vessel.
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7.6 Washing solution
Used washing solutions may impair the functionality of the Scrubber K-415 especially in the range of
the neutra lization point as a result of strong foaming. Changing the washing solution in appropriate
time (when the color indicator undergoes a color change) keeps the adsorption stage and/or reaction
stage from getting soiled and pre vents the possibility of the pump getting damaged. For a discription
of how to prepare and fill up the washing solution, see chapters 5.9 and 5.10.
NOTE
Make sure to dispose of the used washing solution according to your laboratory guidelines.
7.7 Active charcoal
Exchange the active charcoal as soon as it clumps together or white crystals or other residues
become visible.
7.8 Pump
Flush the pump once a week or after hard use.
To flush the pump, proceed as follows:
• Close the bypass valve a completely (for maximum suction power).
• Disconnect the suction hose d from the absorption vessel and put it into a suitable vessel c with
at least 500 mL of distilled water.
• Disconnect the silencer and remove it.
NOTICE
Risk of a water leakage and power failure.
• Do not pull on the pump output hose.
• Place a
suitable vessel b on the pump output.
•
Switch on the device and collect the waste water from the pump.
• Flush the pump until the collected waste water is clear
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Fig. 7.2: Flushing the pump
7.9 Hose cooling control / condenser
Check the hose monthly and replace it as soon as it becomes porous.
7.10 Hose water control feed
• Check the sieve once a month for residues and clean it if necessary.
• Check the adapter, its sealings and the sieve on a yearly base and replace defective parts.
7.11 Power supply fuses
1
2
To replace the power supply fuses, proceed as
follows:
• Pull out the power supply cable.
• Remove the fuse holder a.
• Replace the defective fuse with a new fuse b of
the same type:
– 100 V: T2A L 250 V
– 120 V: T2A L 250 V
– 230 V: T1A L 250 V
• Put the fuse holder back.
Fig. 7.3: Replacing the power supply fuses
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7.12 Silencer
Replace the silencer once a year.
7.13 Functional test
A functional test to check whether the bypass valve functions properly and if the complete system of
the K-415 is tight can be performed by your service technician. Please contact your BUCHI service
center concerning this matter.
7.14 Customer service
Only authorised service personnel are allowed to perform repair work on the instrument. These
persons have a comprehensive technical training and knowledge of possible dangers which might
arise from the instrument.
Addresses of official BUCHI customer service offices are given on the BUCHI website under:
www.buchi.com. If malfunctions occur on your instrument or you have technical questions or application problems, contact one of these offices.
The customer service offers the following:
• Spare part delivery
• Repairs
• Technical advice
• Troubleshooting
• Instrument qualification (IQ) and operative qualification (OQ)
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K-415 Operation Manual, Version B
8 Troubleshooting
This chapter helps to resume operation after a minor problem has occurred with the instrument. It lists
possible occurrences, their probable cause and suggests how to remedy the problem.
The troubleshooting table below lists possible malfunctions and errors of the instrument. The operator
is enabled to correct some of those problems or errors by him/herself. For this, appropriate corrective
measures are listed in the column “Corrective measure”.
The elimination of more complicated malfunctions or errors is usually performed by a BUCHI technical
engineer who has access to the official service manuals. In this case, please refer to your local BUCHI
customer service agent.
8.1 Malfunctions and their remedy
Table 8-1: General malfunction and their remedy
Malfunction Possible cause Corrective measure
K-415 does not work No mains connection?
Fuses defective?
Mains switch defective?
Check whether the instrument is connected
to the mains.
Replace the defective fuses.
Contact the BUCHI customer service.
No digestion running while instrument is
controlled by digester?
Wait for digestion to start.
Pump does not work Wiring defective?
Pump defective?
Contact the BUCHI customer service.
Contact the BUCHI customer service.
Cooling water not running External cooling water source switched
off?
Switch external cooling water source on.
Loss of cooling water Untight hose connections? Check hose connections and water control.
Fumes are not exhausted
during digestion (Scrubber
suction capacity too weak)
Suction system leaking?
Hose bent or porous?
Adsorption vessel clogged?
Washing solution dirty?
Adsorbents clogged?
Pump dirty?
Silencer unit clogged?
Overpressure valve dirty?
Cock of TKN receiving vessel open?
Wrong adjustment of bypass valve?
Tighten the hose and glass connections .
Check the hoses.
Check the adsorption vessel and the
contained activated charcoal.
Exchange the washing solution.
Renew the adsorbents.
Clean the pump.
Replace the silencer unit.
Contact the BUCHI customer service.
Close the cock.
Readjust the bypass valve.
Fumes are exhausted
too fast during digestion
(Scrubber suction capacity
too strong)
Suction system clogged?
Adsorbents clogged?
Silencer unit defective?
Wrong adjustment of bypass valve?
Bypass valve defective?
Check all stages and the connected digestion unit as well.
Exchange the adsorbents.
Replace the silencer unit.
Readjust the bypass valve.
Contact the BUCHI customer service.
Unsufficient neutralization Washing solution used up?
Swirl discs blocked?
Exchange the washing solution.
Clean swirl discs and washing solution.
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K-415 Operation Manual, Version B
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9 Shutdown, storage, transport and disposal
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K-415 Operation Manual, Version B
9 Shutdown, storage, transport and disposal
This chapter instructs how to shut down the instrument, how to pack it for storage or transport, and
specifies the storage and shipping conditions.
!
WARNING
Death or serious poisoning by contact or incorporation of harmful substances.
• Wear safety goggles
• Wear safety gloves
• Wear a laboratory coat
• Clean the instrument and all accessories thoroughly to remove possibly dangerous substances
• Do not clean dusty parts with compressed air
• Store the instrument and its accessories at a dry place in its original packaging
9.1 Storage and transport
Switch off the instrument and remove the power cord. To disassemble the Scrubber K-415 follow
the installation instructions in section 5 in reverse order. Clean the instrument thoroughly! Remove all
liquids and dusty residues before packaging the instrument.
9.2 Disposal
To dispose of the instrument in an environmentally friendly manner, a list of materials is given in
chapter 3. This helps to ensure that the components are separated and recycled correctly.
Please follow valid regional and local laws concerning disposal.
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K-415 Operation Manual, Version B
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K-415 Operation Manual, Version B
10 Spare parts
This chapter lists spare parts, accessories, and options including their ordering information. Order the spare
parts from BUCHI. Always state the product designation and the part number when ordering spare parts.
Use only genuine BUCHI consumables and genuine spare parts for maintenance and repair to assure
good system performance and reliability. Any modifications to the spare parts used are only allowed
with the prior written permission of the manufacturer.
10.1 Spare parts on the exploded instrument view
6
7
30
9
10
11
12
13
14
19
18
20
37
38
39
40
41
42
17
7
43
31
32
33
34
17
7
36
17
7
35
21
22
24
23
25
26
27
28
17
7
29
30
23
1
2
3
4
15
16
17
8
7
5
Fig. 10.1: Spare parts on the exploded instrument view
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K-415 Operation Manual, Version B
Table 10-1: Spare parts on the exploded instrument view
Position Product Order number Position Product Order number
1 Tray for adsorption storage (with
screw)
11057332 23 Swirl disc 037821
2 Anti-seismic-tie-down - 24 Spacer tube 037852
3 Silencer unit
(filled with polyester fibres)
11056985 25 Swirl disc holder 037851
4 Neoprene hose (8/2 x 250) 11056456 26 Lip gasket
EPDM (resistant against bases)
FPM (resistant against acids)
037874
038064
5 Hose clamp (10 - 16 mm) 043297 27 Cover of neutralization vessel 11057139
6 Receiving vessel 11057153 28 O-Ring 24 x 2.5
(with hose connector adapter)
037928
7 Screw cap GL 14 (Set of 10
pcs.)
041956 29 Hose connector adapter M20 GL
14
037777
8 + 7 Connector straight for GL 14
with FPM sealing (set of four,
including screw caps)
040296 30 + 7 Connector bent for GL 14
(set of four, including screw caps)
040295
9 Rubber strap 11059813 31 Reaction vessel, 1.0 L 037797
10 Condenser S35 11057152 32 Gasket ring 037925
11 Hose condenser /
washing solution (FEP)
11057155 33 Screw cap SVL 42 003551
12 Carrier plate for condeser - 34 Introduction tube assembly 037778
13 Screws for carrier plate (M4x16) - 35 Hose reaction / pump (FEP) 11057157
14 Catchpot clip S35 003275 36 Hose adsorption / reaction (FEP) 11057156
15 Hose connection S19 (ball joint) 11057159 37 Axial Gasket ring 049485
16 Ball joint clamp 11057149 38 Adapter piece for adsorption 11057147
17 + 7 Gasket FEP (GL 14) (set of 10,
incl. screw caps)
041999 39 Gasket SVL 42 x 30 PTFE 003575
18 Receiving vessel with cock
(TKN-set)
11056979 40 Adsorption vessel 037774
19 Hose clamp (10 - 16 mm) 043297 41 Gasket SVL 22 x 16 PTFE
(with silicone bearing)
002070
20 Tube for TKN-set (1.5 m, 8/12) 020136 42 Adapter SVL 22 / GL 14 037972
21 Neutralization vessel (P+G) 11057138 43 Hose adsorption / pump 11057154
22 Nut M20 037855
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K-415 Operation Manual, Version B
10.2 Miscellaneous
Table 10-2: Miscellaneous
Product Order number
Set of sealings FPM (10 pieces) 040040
Set of screw caps GL 14 (10 pieces) 041956
Set of screw caps GL 14 and sealings FEP (10 pieces) 041999
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11 Declarations and requirements
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K-415 Operation Manual, Version B
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K-415 Operation Manual, Version B
11 Declarations and requirements
11.1 FCC requirements (for USA and Canada)
English:
This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to both Part 15 of the FCC Rules and the radio interference regulations of the Canadian
Department of Communications. These limits are designed to provide reasonable protection against
harmful interference when the equipment is operated in a commercial environment.
This equipment generates, uses and can radiate radio frequency energy and, if not installed and used
in accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference in which case
the user will be required to correct the interference at his own expense.
Français:
Cet appareil a été testé et s’est avéré conforme aux limites prévues pour les appareils numériques
de classe A et à la partie 15 des réglementations FCC ainsi qu’à la réglementation des interférences
radio du Canadian Department of Communications. Ces limites sont destinées à fournir une protection adéquate contre les interférences néfastes lorsque l’appareil est utilisé dans un environnement
commercial.
Cet appareil génère, utilise et peut irradier une énergie à fréquence radioélectrique, il est en outre
susceptible d’engendrer des interférences avec les communications radio, s’il n’est pas installé et
utilisé conformément aux instructions du mode d’emploi. L’utilisation de cet appareil dans les zones
résidentielles peut causer des interférences néfastes, auquel cas l’exploitant sera amené à prendre les
dispositions utiles pour palier aux interférences à ses propres frais.
Page 57
11.2 Declaration of conformity
Page 58
Quality in your hands
BUCHI Affiliates:
We are represented by more than 100 distribution partners worldwide.
Find your local representative at: www.buchi.com
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