Environmental Express AutoBlock III User Manual

Operation Manual

AutoBlock Serial Number: ________________________
Electrical Box Serial Number: ______________________

490 Wando Park Blvd., Mt. Pleasant, South Carolina 29464

800-343-5319 or 843-881-6560 / Fax [phone]

ENVEXP.COM

5528COVER rev3 9/10/09

TABLE OF CONTENTS

page

Introduction
4 What’s Included
4 Uncrating
4 Unpacking

Installation
5 Preparing the AutoBlock lll
5 Space & Weight Requirements

5 Ventilation
6 Front Door Installation

6 Pump Compartment Door Installation
6 Install Reagent Line
7 Reagent Line Assembly
7 Placement of Reagent Rack
7 AutoBlock Reagent Port
8 Install Drain Line & Carboy
8 Electrical Box Installation

System Overview
9 Reagent Flow Path
10 General Cleaning

Touch Screen Controller
11 Main Screen Functions
11 Sensor Indicators
12 Abort
12 Temperature Readouts

13 On Board Keyboard
Start Up Instructions

14 Power Switch & Load Software

14 Test Injection System

15 Sample Injection Tubing / Pump Calibration
15 Maintenance
15 Sensor Validation

Manual Mode

16 Rack Movement
17 Home

17 Fan
17 Graphite
18 Arm
18 Inject

ENVIRONMENTAL EXPRESS

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5528INDEX rev 3 2 9/10/09

TABLE OF CONTENTS

page

Run Mode
19 Rack A / Rack B / Rack C
20 Pause Button
20 Main Screen Abort Button

Program Mode
21 Heat

21 Inject

22 Wait
22 Cool
22 Pause
22 Delete

23 Open

23 Save
23 New
23 Edit
24 Import / Export Method
24 Export Log
25 Syntax Errors

Service Mode
26 Setup Reagents
27 Calibrate Temp
27 Calibrate Pump
30 Maintenance

30 Options
31 Supplies

32 Supplies List
33 Exit
Warranty

34 90-day Warranty
34 9-month Warranty
34 Warranty Disclaimer
34 Charges Not Covered by Warranty
34 How the Warranty Works

Repair
35 Repair Approval
35 In-Lab Troubleshooting & Repairs
35 Repair by Manufacturer
35 Return Packing & Shipping
35 Inspection upon Receipt
35 Additional Information & Help

ENVIRONMENTAL EXPRESS

For technical support call 800-745-8218 or send email to [e-mail]

5528INDEX rev 3 3 9/10/09

INTRODUCTION

The AutoBlock has been designed specifically for your laboratory by providing safe,
clean and efficient digestions. It is capable of digesting water, wastewater, soils, and
other materials typically digested using hotplate chemistry.

What’s included

SINGLE UNIT
1
1 AutoBlock Unit
1 AutoBlock Electrical Unit
1 Power Cord
3 Racks
6’ ½”ID Drain Tube
1 10L Carboy
1 ½” Barb Fitting
5 Flangeless Nut
5+2 extra Flangeless Ferrules
25’ 1/16”ID Reagent Tubing

DUAL UNIT
1
1 AutoBlock Unit
1 AutoBlock Electrical Unit
1 Power Cord
3 Racks
6’ ½”ID Drain Tube
1 10L Carboy
1 ½” Barb Fitting
10 Flangeless Nut
10+2 extra Flangeless Ferrules
50’ 1/16”ID Reagent Tubing

AutoBlock Manual

AutoBlock Manual

Unpacking
Retain all packaging material for a
minimum period of 90-days.

See Warranty for complete details.

Your AutoBlock has been packaged in a custom crate
for shipping purposes. Spend adequate time reading
this instruction manual before unpacking your
AutoBlock. While unpacking keep in mind there are
many fragile components. A quality control sheet from
the factory has been included. Use this list to inventory
components, as they are unpacked.

Note:

Residual water may be found in the internal plumbing of
your AutoBlock. This includes the pump, reagent and
drain lines. This water is non-hazardous, and was used
for system check during quality control inspection.

Uncrating Instructions

• Cut banding from crate, use standard safety precautio ns.

• Lift the entire cover from the crate.

Carefully remove

•

Foam Filler
Inner Box from the side. This box contains the electrical box, power cord & manual
Front Door that is secured to the back of the cabinet

• Remove the 10L carboy, 3-racks, reagent tubing & start up kit. There are several pieces of
packaging material in place for protection. All material must be removed.

• Remove the protective tape from the sample probe cap, reagent entry plate, JC connectors,
pump compartment door & touch screen.

• The unit will need to be cleaned from residue during shipment. Using compressed air, clean the
inside of the AutoBlock.

The AutoBlock unit is now ready to be installed. Please read installation instructions

.

5528INTRO rev 3 4 9/10/09

For technical support call 1-800-745-8218 or send email to [e-mail]

ENVIRONMENTAL EXPRESS

INSTALLATION

on/o

Preparing the AutoBlock

Follow the instructions for uncrating from the quality control sheet supplied with the unit or introduction
section of this manual. Follow the installation procedure step by step to insure proper function of the unit.

Note:

reagent injection lines and drain lines. This water is non-hazardous, and was used for system check
during quality control inspection.

Residual water may be found in the internal plumbing of your AutoBlock. This includes the pump,

Space & Weight Requirements

Lift the AutoBlock from the bottom only. The unit weights approximately 200-lbs. carefully place the unit
on a sturdy counter with the following minimum requirements:

• Counter must be able to support a minimum 300-lb loa d.

• Space requirements: 38”W x 32”L x 26”H these are the minimum requirements. Additional space will

be needed for reagents & a carboy placed under the unit.

JC1
JC2
JC3

Lift Compartment

Exhaust vent

Exhaust
Compartment

electrical connections

Pumping
Compartment

Injection Arm

Power module/ Voltage / Fuse

Graphite Block

reagent ports

Compartment

ABP164

ff switch

Ventilation

The AutoBlock exhaust is located on the top right portion of the unit. Install a 4” diameter acid-resistant
duct and clamp to the exhaust outlet. Vent using state & federal guidelines. When connecting ductwork,
verify zero to negative pressure to prevent backflow. The length of the duct should not exceed 25’. Vent
the duct to the outside of the laboratory building or plumb into the existing ductwork.

ENVIRONMENTAL EXPRESS

For technical support call 1-800-745-8218 or send email to [e-mail]

5528INSTALL rev 3 5 9/15/09

INSTALLATION

Front Door Installation

Unpack the front door assembly using caution not to scratch the acrylic.
Both hinge pins have been inserted into the door assembly

Remove the hinge pin from the left side using a hex wrench.
Place door in cabinet opening,

sliding the right side hinge pin into the cabinet location.
Align the left side hinge pin location & screw in the second hinge pin.

Hand tighten the hinge pin.
Lift the door & close it. It will be a snug fit. Lift the door up & slide back.

After the installation of the front door, Environmental Express does not warranty
breakage due to operator handling.

as shown.

Closing the
Insert edge first along the outside of the cabinet. Tilt the other edge at 10
the cabinet. Push down to close.

lift
door
up

slide door back

Pump Compartment Door

push down

on this edge

angle
pump compartment
door as shown

0

angle along the filter side of

Install Reagent Line

The following steps will connect 2.5 liter or standard 38mm top, reagent bottles to AutoBlock. These are
standard 2.5L acid bottles. For the DI water ports, 1 & 6, use a clean acid bottle filled with H

SINGLE UNIT DUAL UNIT
5 Flangeless Nuts 10 Flangeless Nuts
5 + 2 extra Flangeless Ferrules 10 + 2 extra Flangeless Ferrules
25’ Reagent Lines 1/16”ID 50’ Reagent Lines 1/16”ID

Vented Reagent Caps (optional)
Reagent Bottom of the Bottle Filter (optional)

Uptake Reagent Components

Components are supplied in a start up kit

2

O.

ENVIRONMENTAL EXPRESS

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5528INSTALL rev 3 6 9/15/09

Reagent Line Assembly

1. Cut appropriate lengths of 1/16”ID Teflon tubing, not to exceed 5’ lengths. The ends need to be a
square-cut face.

2. Slide the flangeless nut over the tubing, with the nut threads facing the tubing end.

3. Slide the flangeless ferrule over the tubing, with the tapered portion of

the ferrule facing towards the nut. The large diameter of the ferrule
should be pushed to the end of the tubing.

4. AutoBlock reagent ports are located on the left side of AutoBlock
labeled #’s 1-10.

5. Insert the tubing with the flangeless ferrule into the receiving port

until it bottoms. While holding the tubing, tighten the Flangeless nut
finger tight. The tubing should not be able to move in the port.

Repeat for all ports available.

INSTALLATION

Flangeless nut

Flangeless Ferrule

reference diagram for placement

Placement of Reagent Rack

Position the six-bottle reagent rack (optional) on the left side of AutoBlock.
For dual systems, there may be two six-bottle reagent racks (optional).

AutoBlock Reagent Port

AutoBlock reagent ports are located on the left side of AutoBlock, labeled #’s 1-10.
The reagents have been set up in the following manner:

Single System Dual System**

If these reagents do not suit your application, you may change them. Changing the reagents and ports
numbers are addressed in the SERVICE TAB – SETUP REAGENT section.

*Port #1 H20(1) *Port #6 H20(6)

Port #2 HNO3(2) Port #7 KMnO4(7)
Port #3 HCL(3) Port #8 PERSULF(8)
Port #4 H2O2(4) Port #9 NH2OH(9)
Port #5 H2SO4(5) Port #10 H20(10)

*Ports #1 & #6 must remain H
**In a single system ports #6-10 have been plugged.

0

2

reagent plate

Vented Reagent Caps and Bottom of the Bottle Filter (optional)
Loosen the nut on the top of a vented reagent cap. Insert one end of reagent tubing through the nut until
it reaches the bottom of the 2.5L bottle. Hand tighten the nut.
A bottom of the bottle filter may be used to filer the reagent. Attach this to the end of the tubing before
inserting it into the 2.5L bottle.

ENVIRONMENTAL EXPRESS

For technical support call 1-800-745-8218 or send email to [e-mail]

5528INSTALL rev 3 7 9/15/09

Install Drain Line & Carboy

• Remove the ½” barb fitting from the

bag of parts supplied

• Remove the nut from the fitting

• Remove the cap from the carboy

• Place the fitting into the cap. The treaded portion

of the fitting needs to be on the inside of the cap.

• Place the washer & then nut onto the fitting & tighten.

• Place the cap back onto the carboy.

• The drain line is located on the right side towards the back of the unit. Place the supplied ½” tubing

onto the barb fitting and the other end to the carboy.
direction the entire length.

The system is designed for downward gravity flow throughout the entire length to the carboy.
Place the carboy under the AutoBlock.

Electrical Box Installation

• Position the on/off switch to the off position.

• A 10’ power cord has been supplied.

Power requirements are standard 115VAC 12A US and Canada
Power requirements are standard 220VAC 6A International

Plug the power cord into the power module located in the back of the electrical box and into a
standard AC outlet

• Place the electronic box on the platform of the AutoBlock, left hand side of the unit. The mounting feet
will rest in the recessed holes.

• Connect the three cables from the electrical box to the AutoBlock system on the left side. JC1, JC2
and JC3 have been marked on the cable connector & on the AutoBlock.

INSTALLATION

carboy cap & bulkhead fitting

Insure the tubing goes in a DOWNWARD

ON

OFF

on/off switch

Congratulations

You have finished physically setting up the AutoBlock and are ready to move
onto a systems check and calibration. A systems check and calibration set up
must be done before any methods run.

ENVIRONMENTAL EXPRESS

For technical support call 1-800-745-8218 or send email to [e-mail]

5528INSTALL rev 3 8 9/15/09

System Overview

g

y

on/o

(3)

9

Component Layout

Power module/ Voltage / Fuse

Emer

ABP164

ff switch

ency Stop Assembl

Touch Screen

USB

Stylus

Pumping
Compartment

Lift Compartment

Exhaust
Compartment

Injection Arm

Graphite Block
Compartment

JC1
JC2
JC3

electrical connections

ABP125

lift sensors

ABP125

Inj arm sensor

ABP152

pressure sensor

ABP127

leak detector sensor

ABP128

exhaust fan assembly

reagent ports

ABP151

HEPA filter

RTD -Sample Assembly

ABP130

ENVIRONMENTAL EXPRESS

For technical support call 1-800-745-8218 or send email to [e-mail]

5528OVERVIEW rev3 9 9/10/0

y

g

p

System Overview

Reagent Flow Path

ABP122

5-Valve Assembl

Reagent-Valve

Tubing Kit -single

Reagent Ports/Cabinet

Teflon Tubin

ABP140

Uptake

1/8” Flangeless Nut

1/8” Flangeless Ferrule

for

General Cleaning

Wipe clean with mild cleaner or isopropyl.

ABP154

Pum

Head

Keep debris from inside of graphite block
wells.

ABP143

ABP144

Pump Tubing Kit

1/16” Flangeless Nut

1/16” Flangeless Ferrule

ABP108
Manifold

ottleReagent B

W/Plug

Sample Injection Kit

Injection arm with splitter

ABP159

Injection Guide

ENVIRONMENTAL EXPRESS

For technical support call 1-800-745-8218 or send email to [e-mail]

5528OVERVIEW rev 3 10 9/10/09

TOUCH SCREEN CONTROLLER

The touch screen controller is specifically designed for use with the AutoBlock. Once the system is
turned on, the AutoBlock software will automatically load. Pressing the screen tabs or input boxes with
the attached stylus activates the touch screen. It is not necessary to push very hard, this may damage
the screen.

Main Screen Functions

There are several operations that appear permanently on the touch screen.
There are FIVE tabs of operation located at the top of the touch screen:

The MANUAL screen will appear at start up.

-A pop up message will appear: “READY TO HOME MOTORS?” Press the Continue button.

-Motors will activate to initialize in their home positioning.

-A pop up message will appear: “MOTORS ARE HOMED” Press the Continue button.
To switch between tabs, press the appropriate tab with the stylus. Each tab will be described in this

manual to allow the analysts to fully operate the AutoBlock.
The main screen will go into sleep mode when left unattended. Touch the top of the screen with the

stylus to awaken.

Sensor Indicators

Alarm sensors are located in the upper left portion of the screen and when triggered change color. These
sensors may take a few moments to change its status, it is not instantaneous.

P

Located in the Exhaust Compartm ent. Detection if a pressure drop has occurred.
Green light will indicate a positive operating state
Red light will indicate the sensor has been activated & needs attention.

L

Located in the Pumping Compartment. It will detect if there is a leak present.
Green light will indicate a positive operating state
Red light will indicate the sensor has been activated, immediate attention should be given to this

MANUAL RUN PROGRAM SERVICE EXIT

Pressure Sensor

Leak Detector Sensor

situation. The AutoBlock will not operate until the leak has been resolved. Reference Start Up
Instructions–Sensor Validation section of this manual for addition information.

Manual Tab

ENVIRONMENTAL EXPRESS

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5528TOUCHCREEN Rev 2 11 9/10/09