Environmental Express SPE-Express with Cover User Manual
SPE-Express™ Automated System
for Oil and Grease
Operation & Instruction Manual
Call 800.343.5319 or 843.881.6560 • www.environmentalexpress.com
Copyright, Environmental Express, Inc, January 2013
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Contents
Product Features and Benefits 4
Specifications 5
1.0 General Information 6
1.1. Markings 6
1.2. Safety – Potential Hazards 6
1.3. Installation Requirements 6
1.3.1. Hardware 6
1.3.2. Software 6
1.4. Electrical Requirements 7
1.5. What’s Included 7
1.6. Other Items Needed 7
2.0 Getting Started 8
2.1 Unpacking Your Unit 8
2.2 Setting Up the Hardware 8
2.2.1 Electrical Connections 8
2.2.2 Reagent Tubing Kit 9
2.2.3 Nitrogen Ports 9
2.2.4 Filter O-Ring 10
2.2.5 Exhaust Duct 10
2.2.6 Flow Control Valve 10
2.2.7 Connecting Two Units 11
2.3 Setting Up the Software 12
2.3.1 Log-In Screen 14
2.3.2 Change Password Screen 14
2.3.3 Edit Users Screen 15
2.3.4 Add New User Screen 16
2.3.5 System Configuration Screen 17
2.3.6 Method Creation Screen 19
2.3.6.1 Pre-Rinse 19
2.3.6.2 Disk Activation 19
2.3.6.3 Sample Filtration 19
2.3.6.4 Elution 20
2.3.6.5 Solvent Evaporation 20
2.3.6.6 Method Parameters 21
2.4 Flushing the System 22
3.0 System Operation 24
3.1 Sample Set Up - Operator Test Screen 25
3.1.1 Pre-Test Interface 25
3.1.2 Station Status 25
3.1.3 Testing Status Summary 26
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3.1.4 Test Control and Status 26
3.1.5 Bottle Rack Status 26
3.2 Operating A Test 27
3.2.1 Starting a Test 27
3.2.2 Flushing a Station 29
3.2.3 Draining a Station Manually 30
3.2.4 Cleaning a Station Manually 30
3.2.5 Aborting a Test 31
3.3 Operating Multiple Samples on One Station 31
3.4 Operating Multiple Stations 33
3.5 Operating Two Units 33
3.6 Manual Operation 34
3.6.1 Solenoid Control Interface 34
3.6.2 Ball Valve 35
3.6.3 Status Indicators 35
3.6.4 Main Fans 35
3.6.5 Sensor Chart 35
3.6.6 Temperature Control 36
3.6.7 Bottle Rack Status 36
3.6.8 Abort 36
3.6.9 Exit 36
4.0 Data Recovery 37
5.0 Care and Maintenance 38
5.1 Removing and Cleaning Lower Glass Chamber 38
5.2 Removing and Cleaning Barb Fittings 38
5.3 Cleaning the Sample Release Port 38
5.4 Replacing the Lower Glass Chamber 39
5.5 Recalibrating the Fluid Sensor 39
5.6 Changing the Bottle Adapters and Injection Heads 40
5.7 Detaching the Bottle Harness 41
6.0 Parts List 43
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The SPE-Express system is specifically designed for the extraction and evaporation required by EPA Method 1664 for Oil and
Grease Analysis.
SPE-Express is the ONLY system that:
• Both extracts your sample and evaporates the n-Hexane eliminating the transfer step
• Uses a fluid sensor to verify that the sample vessel is empty improving accuracy
• Runs multiple samples simultaneously on up to 6-stations improving analyst efficiency
Simply load the 3-station SPE-Express with standard one-liter sampling jars and walk away. The system flushes itself clean,
preps the extraction disk, then filters and extracts the sample through sodium sulfate with n-Hexane. In the final stage the
SPE-Express automatically transfers the extract to a pre-weighed aluminum pan where it is evaporated to dryness. Remove
the pan for final weighing and the process is complete. User-friendly PC software controls the functionality while recording
data for downloading to LIMS.
SPE-Express is the only system that both extracts your sample and evaporates the n-Hexane. And the only one that utilizes a
fluid sensor to verify that the sample vessel is empty. It will reduce time and labor in your lab, improve accuracy plus
minimize analyst contact with hazardous chemicals.
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Product Features and Benefits
•
Each system has three stations
•
Two systems can be joined and connected to one PC for a total of 6 stations
•
System is controlled with a PC using a single USB cable
•
System comes with software containing one default method and offers the ability for the customer to create
customized methods
•
System utilizes wide mouth amber jars designated by the EPA method
•
Each station can begin processing a new sample while a previous sample is being evaporated
•
SPE-Express software allows different users to have varying levels of access
•
System is available in 120 or 220 volts
SPE-Express performs the entire process through evaporation to dryness in approximately 40-45 minutes depending on
how dirty the sample is.
Prep – 5 Minutes
Filter Sample – 15 minutes
Elution – 15 minutes
Evaporation – 7 minutes
The SPE-Express automates Oil and Grease Extraction and Evaporation as outlined in EPA Method 1664:
Preps the System
• Rinses all system components with n-Hexane.
• Preps the extraction disk with Methanol then replaces the Methanol with DI water to avoid co-solvent elution.
Filters the Sample
• Vacuums the aqueous sample through the filter until the sample bottle is empty and all free liquid is removed from
the filter.
• Elutes the sample with n-Hexane and removes any sample residue from the sample bottle.
• Vacuum filters the eluted sample through the extraction disk then transfers the eluted n-Hexane through the drying
cartridge into a glass chamber.
Evaporates the Eluted Sample
• Transfers the sample to a heated, pre-weighed aluminum pan for evaporation to dryness.
• Allows the analyst to begin processing a new sample on the same station while the first is being evaporated.
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Unit Specifications
•
Unit Footprint: 22.5" w x 26.255" d x 22.343"h
•
Clearance: 2" all sides
•
Weight: 118 lbs.
•
Crated Weight: 200 lbs.
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1.0 General Information
1.1 Markings
•
V = voltage
•
AC = alternating current
•
Hz = frequency
•
A = amperes
1.2 Safety – Potential Hazards:
•
The SPE-Express should only be operated by properly trained personnel using standard laboratory safety
practices.
•
Use extreme caution when operating the SPE-Express. During operation certain surfaces of the SPE-Express
may be too hot to safely touch with bare hands.
•
The SPE-Express contains electrical circuits, devices and components operating at dangerous voltages.
Contact with these circuits, devices and components can cause serious injury or painful electric shock.
•
Proper grounding is essential to avoid a potentially serious electric shock hazard. Ensure that there is an
internal ground connection between the system and the 3-pin, earth-grounded pin.
•
See individual SPE-Express specifications for power requirements.
•
Application of the wrong supply voltage can create a fire hazard and a potentially serious shock hazard,
and could seriously damage the SPE-Express system. See specifications for the SPE-Express system.
•
Users should be aware of the potential dangers from heating certain types of compounds and handling
certain types of chemicals. Such dangers may include explosion or the release of toxic or flammable gases.
•
Always lift the SPE-Express from the bottom, with one person on each side of the unit. Avoid lifting from
the front of the unit.
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1.3 Installation Requirements
1.3.1 Hardware
•
Locate the SPE-Express on a stable, level surface, and allow a minimum of 2" clearance on all sides.
•
The following environmental conditions should be observed:
- Ambient temperature range: 5°C - 30°C
- Ambient relative humidity: 0-90% RH
- Altitude: sea level to 2,500 meters
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1.3.2 Software
•
Computer must be Windows based, XP or newer with a minimum 2 GB RAM. Dual core processor
recommended.
1.4 Electrical Requirements
•
Required Voltage is 120VAC, ~60 Hz, 15A for the G8000 and 220-240VAC, ~50 Hz, 7.5A for the G8000-240.
•
Power should not vary greater than 10%. Use the supplied power cord or equivalent to connect to the
power supply. For safety reasons, a separate power receptacle should be provided for each SPE-Express.
Do not use extension cords or outlet adaptors. Make certain that power outlets are earth-grounded at the
grounding pin.
1.5 What’s Included
•
Box # 1:
SPE-Express System
Base 3-Station Unit
Software Flash Drive
Operation and Instruction Manual
•
Box # 2:
Reagent Rack Kit
Carboy
Tubing with Bottle Harnesses
•
Box # 3:
(2) 5.5 Gram Na2SO4 Drying Cartridges, 50 pack
Aluminum Weigh Dishes, 105mm, 100 pack
UltraFlow Filter Assemblies, Disposable 47mm, 100 pack
•
Other items included:
USB Cable, Power Cable, 15 Pack of Filter O-Rings, Fastener Tool, Adapter Wrench, Drying Cartridge
Extractor Tool, and Capacitive Sensor Calibration Tool, Reagents Pressure Hose
1.6 Other Items Needed
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Vent Hose, 4" Diameter
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Vacuum Source (vacuum connection should be an Industrial-Shape Quick Connection 0.25" Socket in
order to connect to the bottle harness)
•
Power Supply (specified page 7)
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Sample Jars (Environmental Express Catalog # ESS09500050)
•
Nitrogen Source (70 psi minimum / 110 psi maximum). Other inert gases are acceptable. (Supply hoses
must be an Industrial-Shape Quick Connect 0.25" Socket in order to connect to unit).
•
Containers – All with GL38 threads
- N-Hexane Waste Container – 1 Liter
- n-Hexane Reagent Bottle - 4 Liter
- DI Water Bottle - 1 Liter
- Methanol - 1 Liter
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2.0 Getting Started
2.1 Unpacking Your Unit
•
When unpacking your unit, remove the rubber plug from the filter adapter. Care should be taken not to allow
particulate matter to get into the filter adapter or it may cause damage to the station valves. Save the rubber
plug to be used in long periods of non-use. Always lift the SPE-Express from the bottom, with one person on
each side of the unit. Avoid lifting from the front of the unit.
2.2 Setting Up the Hardware
Please read the system requirements and electrical requirements on page 7 of the manual.
2.2.1 Electrical Connections
Secure the following connections:
• SPE-Express Power Cord to Power Source
• USB Port to PC
• Serial Cable to Bottle Rack (if equipped with Smart Bottle Rack)
He
x
a
n
e
Deionized Water
M
et
h
a
n
ol
Vacuum Source
Water Miscible Waste
Hexane Waste
Close Up, Reagent Tubing
Kit Connections
Figure 4
Figure 2
Nitrogen - from source
Nitrogen - to reagents
Hexane
Deionized Water
Methanol
Exhaust Fan
Power Cord
Serial Cable to Additional
SPE-XPress Unit
Power Indicator Light
Serial Cable to
Bottle Rack
USB Port
to PC
Vacuum Source
Water Miscible Waste
Hexane Waste
Vent Fan
Air Intake for
Exhausting
Unit
Power Switch
Figure 3
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2.2.2 Reagent Tubing Kit
Securely connect each tubing line to the appropriate port on the back of the unit (see detail diagram, page
8). Ensure the 3 luer fittings are tight by twisting the blue portion counterclockwise. Use the Fastener Tool
provided with the SPE-Express unit to tighten the Hexane, DI Water and Methanol lines.
•
Hexane
•
Deionized Water
•
Methanol
•
Vacuum
•
Water Miscible Waste
•
Hexane Waste
WARNING: Fluid connection, pressure must always be removed before disconnecting bottle harness from unit
to prevent leakage of chemicals. (Reference “Detaching the Bottle Harness” section for instructions for safe
removal of the bottle harness).
Replace reagents and waste container caps with the appropriate caps within the Bottle Harness. Ensure
Bottle Harness caps are tight on reagent bottles to prevent leaking.
Attach the Reagents Hose provided to the Bottle Harness manifold labeled “Pressure”.
Attach the Vacuum source to the Bottle Harness manifold labeled “Vacuum”.
Do not place reagents higher than the SPE-Express as it will affect spray volume performance.
Place reagents level with the SPE-Express or within 36" below.
CAUTION: Reagent bottles are under pressure while Nitrogen is supplied to the unit and reagents hose is
attached; never loosen reagent caps with Nitrogen supplied.
2.2.3 Nitrogen Ports
Ports are provided to control your Nitrogen flow.
Nitrogen from Source
The “Nitrogen - from Source” uses a hose with an Industrial-Shape Hose Quick Connect 0.25" Socket. The
other end should connect to the Nitrogen supply.
Nitrogen to Reagents
Connect the Reagents Pressure Hose Plug (opposite from the end connected to the “Pressure” manifold of
the Bottle Harness).
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2.2.4 Filter O-Ring
Place a filter O-Ring (15 are supplied with the unit) into the groove in the filter adapter of each station.
This O-Ring ensures the disposable filters seal to the unit during a test.
The o-ring is not a disposable item and can be reused in multiple tests.
2.2.5 Exhaust Duct
A hose adapter with a diameter of approximately 4" should be placed around the SPE-Express exhaust
duct and connected to a fume hood or other available exhaust ducting.
The exhaust duct with fan may be interchanged between the two sides of the unit depending on your
venting preference. To switch the exhaust fan and ducting to the alternate side of the unit:
•
Use a 5/64" Allen wrench to remove the 4 screws on each of the two side panels.
•
The exhaust fan will be plugged to a cable within the internal channel of the unit. Remove the
exhaust fan plug from the cable receptacle.
•
Plug exhaust fan plug into the cable receptacle on the alternate side of the unit.
•
Replace 4 screws into each of the two side panels. Care should be taken to fully insert the cable
and wiring into the internal channel in order to prevent tangling the wiring into the fan.
Tangling the wires in the blades will cause a fan fault in the software and prevent the Operator
Test Screen from running.
2.2.6 Flow Control Valve
A flow control valve is located within the SPE-Express unit which can be adjusted to supply a portion of the
Nitrogen source into the electronics chamber. The flow control valve is shipped set in the OFF position.
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If the unit is in a highly acidic or corrosive environment it is recommended that the flow control valve be
turned on. Note that when the flow control valve is on it will continue to supply Nitrogen as long as the
source Nitrogen is supplied to the back of the unit even if power is off. To adjust the flow control valve:
•
Ensure the SPE-Express power switch is in the OFF position.
•
Remove supply pressure from the unit by unfastening the supply hoses on the back of the unit.
•
Remove the back cover of the unit by unscrewing the thumbscrews.
•
Locate the flow control valve on the middle wall of the unit. It will be within the right fluids
chamber and has a tube which connects to a barb within the wall leading to the left electronics
chamber.
•
Loosen the lock nut on the front of the valve and adjust the metering needle counterclockwise
using a 3/32" Allen wrench. The valve SHOULD NOT be adjusted past a ¾ turn counterclockwise.
•
Tighten the lock nut toward the body of the valve to reduce the probability of unwanted
adjustment.
•
Replace the back cover of the SPE-Express unit with the thumbscrews.
•
Reattach the Nitrogen supply hoses.
2.2.7 Connecting Two Units
When operating two SPE-Express units from one computer use the G8050 Dual Unit Assembly Kit to make
the following modifications. The kit includes an additional reagent tubing kit and a dual unit coupler
panel.
•
Reagent Tubing – This kit will attach to the standard reagent tubing kit, and includes a “Y”
connector to attach both units. Follow the instructions in 2.2.2 to connect each of the three ends
to the standard reagent tubing kit and the instruments.
•
Exhaust Port and Fan – Both instruments must have the same exhaust fan/outlet configuration.
Use the dual unit coupler panel to connect the two units together. Use a 5/64" Allen wrench to
remove the blocking cover that is between the two units. Attach the dual unit coupler panel in
place of the removed blocking cover. Slide the two units together so that the exhaust from the
second unit is inside the dual unit coupler.
Additional Steps:
•
USB Cable – Connect each SPE-Express to the computer using a separate USB cable to a separate
USB port on the computer. Do not use USB cables longer than 10 feet.
•
Nitrogen Source – Both units can be run from a single nitrogen source. Use a “T” fitting (not
included) to split the line to provide a connection to each instrument. Only one unit should be
used to supply nitrogen to the reagents. The other unit should have this connection left unused.
•
If the software previously operated a single unit you must rerun the Configuration option in order
to set up for two units. Always use the system on the left as unit 1 and the system on the right as
unit 2.
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2.3 Setting Up the SPE-Express Software
To set up your software, insert the Flash Drive provided and follow the screen prompts.
Click on the SPE-Express Installer file to start the script.
•
This "installation in progress" screen will appear. This window must stay open throughout the
program installation.
•
The script will install the USB to Serial Converter driver from the FTDI Software Folder. This
"installing driver" command prompt will appear.
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•
After the driver is installed a prompt for National Instruments software will appear.
This installs the SPE-Express program and NI Software from the NI Software folder.
o
Navigate through the windows by pressing the "Next" button to install the software
o
After the software Is installed a shortcut to the SPE-Express Program will appear on the
Desktop
•
After installation is complete, restart the computer.
Welcome to the Environmental Express SPE-Express Software.
•
“Log In/Log Out”: Press to open the Log In dialog box.
•
“Exit”: Press to exit the SPE-Express software, or press the Escape key.
•
The date and time is shown in the upper left hand corner.
•
The software version is shown in the upper right hand corner.
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