Hach BioTector B7000 User Manual

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Catalog Number: 10-MAT-152

BioTector B7000 Online TOC TN Analyzer

USER MANUAL

March 2017, Edition 1

BS4ANP2 2.12d

Original Instructions in English

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Table of Contents

SECTION 1 SAFETY PRECAUTIONS .......................................................................... 5

1.1 INFORMATION AND SAFETY SIGNS USED IN THE MANUAL ....................................................... 5

1.2 PRECAUTIONARY LABELS ATTACHED TO THE INSTRUMENT .................................................... 6

1.3 POTENTIAL SYSTEM SAFETY HAZARDS ................................................................................ 8

1.4 GENERAL SAFETY PRECAUTIONS ...................................................................................... 10

1.4 PRÉCAUTIONS GÉNÉRALES DE SÉCURITÉ ........................................................................... 10

1.4.1 Electrical and Burn Precautions .................................................................................................. 11

1.4.1 Précautions relatives à l’électricité et aux brûlures ..................................................................... 11

1.4.2 Carrier Gas and Exhaust Gas Precautions ................................................................................. 12

1.4.2 Précautions relatives au gaz porteur et d'échappement ............................................................. 12

1.4.3 Chemical Precautions ................................................................................................................. 13

1.4.3 Précautions chimiques ................................................................................................................ 13

1.4.4 Sample Stream Precautions ........................................................................................................ 14

1.4.4 Précautions relatives aux échantillons ........................................................................................ 15

SECTION 2 OPERATOR’S MANUAL ......................................................................... 16

SOFTWARE MENU DIAGRAM ......................................................................................................... 17

2.1 OPERATION MENU ............................................................................................................ 23

Start Stop .................................................................................................................................................. 23

Reagents Setup ........................................................................................................................................ 25

Install New Reagents ............................................................................................................................................ 25

Purge Reagents & Zero ........................................................................................................................................ 26

System Range Data ................................................................................................................................. 26

Manual Program ....................................................................................................................................... 27

Reaction Archive ...................................................................................................................................... 28

Fault Archive ............................................................................................................................................. 28

Time & Date .............................................................................................................................................. 29

Contact Information .................................................................................................................................. 29

2.2 CALIBRATION MENU.......................................................................................................... 30

Zero Calibration ........................................................................................................................................ 30

Span Calibration ....................................................................................................................................... 32

SECTION 3 TECHNICAL SPECIFICATIONS.............................................................. 34

SECTION 4 INTRODUCTION ...................................................................................... 37

4.1 BIOTECTOR MAJOR COMPONENTS .................................................................................... 37

4.1.1 Analysis Enclosure ...................................................................................................................... 37

4.1.2 Electronics Enclosure .................................................................................................................. 39

4.2 BIOTECTOR OPERATION ................................................................................................... 41

4.2.1 BioTector Oxidation Method ........................................................................................................ 41

4.2.2 BioTector Sample Injection ......................................................................................................... 42

4.2.3 BioTector Analysis Types ............................................................................................................ 42

4.2.3.1 TIC & TOC Analysis ........................................................................................................................... 44

4.2.3.2 TC Analysis ........................................................................................................................................ 44

4.2.3.3 VOC Analysis ..................................................................................................................................... 45

4.2.3.4 TC - TIC Analysis ............................................................................................................................... 46

4.2.3.5 TN Analysis ........................................................................................................................................ 47

SECTION 5 INSTALLATION ....................................................................................... 49

5.1 BASIC SYSTEM REQUIREMENTS ........................................................................................ 49

5.2 UNPACKING AND INSTALLATION ......................................................................................... 50

5.2.1 Analyzer Dimensions and Mounting ............................................................................................ 51

5.2.2 Wiring Power and Signal Terminals ............................................................................................ 53

5.2.3 Wiring External Power Disconnection Switch ............................................................................. 55

5.2.4 System Fuse Specifications ........................................................................................................ 56

5.3 CARRIER GAS AND REAGENT CONNECTIONS ...................................................................... 57

5.3.1 Carrier Gas Connection ............................................................................................................... 58

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5.3.2 Reagent Connections .................................................................................................................. 60

5.4 SAMPLE, DRAIN AND EXHAUST CONNECTIONS ................................................................... 62

5.4.1 Sample Inlet Tube Position ......................................................................................................... 62

5.4.2 Drain, Bypass and Exhaust Connections .................................................................................... 64

SECTION 6 REAGENTS AND CALIBRATION STANDARDS.................................... 65

6.1 REAGENTS ....................................................................................................................... 65

6.2 CALIBRATION STANDARDS ................................................................................................ 66

SECTION 7 ANALYZER COMMISSIONING AND STARTUP .................................... 69

SECTION 8 SYSTEM SOFTWARE OPERATION ....................................................... 75

8.1 OPERATION MENU ............................................................................................................ 75

8.2 CALIBRATION MENU.......................................................................................................... 75

8.3 MAINTENANCE MENU ........................................................................................................ 75

8.3.1 DIAGNOSTICS MENU ................................................................................................................ 76

Process Test ......................................................................................................................................................... 77

Oxidation Phase Process Test .............................................................................................................................. 77

Pressure Test .................................................................................................................................................................. 77

Flow Test .......................................................................................................................................................................... 78

Ozone Test ...................................................................................................................................................................... 79

Sample Pump Test ......................................................................................................................................................... 81

pH Test ............................................................................................................................................................................. 82

Liquid Phase Process Test ................................................................................................................................... 86

Purge TN Cell Test ......................................................................................................................................................... 86

Clean TN Cell Test.......................................................................................................................................................... 86

Read DI Water Reference Test ..................................................................................................................................... 87

Read TN Sample Test .................................................................................................................................................... 88

Simulate ................................................................................................................................................................ 89

Oxidation Phase Simulate ............................................................................................................................................. 89

Liquid Phase Simulate .................................................................................................................................................... 93

Signal Simulate ..................................................................................................................................................... 95

Data Output .......................................................................................................................................................... 97

Send Reaction Archive ................................................................................................................................................... 98

Send Fault Archive........................................................................................................................................................ 101

Send Configuration ....................................................................................................................................................... 101

Send All Data ................................................................................................................................................................. 101

Input/Output Status ............................................................................................................................................. 102

Service ................................................................................................................................................................ 103

8.3.2 COMMISSIONING MENU ......................................................................................................... 104

Reaction Time ..................................................................................................................................................... 104

Sample Pump ..................................................................................................................................................... 105

Stream Program ................................................................................................................................................. 105

COD/BOD Program ............................................................................................................................................ 106

New Reagents Program ...................................................................................................................................... 107

Reagents Monitor ............................................................................................................................................... 107

Autocal Program ................................................................................................................................................. 108

4-20mA Program ................................................................................................................................................ 109

Relay Program .................................................................................................................................................... 111

Data Program ..................................................................................................................................................... 112

Information .......................................................................................................................................................... 112

8.3.3 SYSTEM CONFIGURATION MENU ......................................................................................... 113

Analysis Mode .................................................................................................................................................... 114

System Program ................................................................................................................................................. 115

Calibration Data .................................................................................................................................................. 122

Sequence Program ............................................................................................................................................. 122

Average Program .......................................................................................................................................................... 122

Cleaning Program ......................................................................................................................................................... 123

Zero Program................................................................................................................................................................. 124

Span Program ............................................................................................................................................................... 125

Reagents Purge ............................................................................................................................................................ 126

Pressure/Flow Test Program ....................................................................................................................................... 127

Output Devices ................................................................................................................................................... 128

Reaction Check .................................................................................................................................................. 130

Result Integration ................................................................................................................................................ 131

Fault Setup ......................................................................................................................................................... 132

Fault Status ......................................................................................................................................................... 134

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CO2 Analyzer ..................................................................................................................................................... 135

Cooler Program .................................................................................................................................................. 135

Software Update ................................................................................................................................................. 136

Password ............................................................................................................................................................ 137

Language ................................................................................................ ............................................................ 137

Hardware Configuration ...................................................................................................................................... 137

SECTION 9 TROUBLESHOOTING OF SYSTEM FAULTS & WARNINGS .............. 138

9.1 BIOTECTOR FAULT CONDITIONS ...................................................................................... 138

9.2 BIOTECTOR WARNING CONDITIONS ................................................................................. 141

9.3 BIOTECTOR NOTIFICATION CONDITIONS .......................................................................... 146

SECTION 10 SERVICE AND MAINTENANCE ............................................................ 147

10.1 WEEKLY MAINTENANCE .................................................................................................. 147

10.2 SIX AND TWELVE MONTH SERVICE .................................................................................. 148

SECTION 11 SYSTEM REPLACEMENT AND SPARE PARTS .................................. 153

SECTION 12 WARRANTY AND EXCLUSIONS .......................................................... 154

SECTION 13 APPENDICES ......................................................................................... 155

APPENDIX 1 INSTRUCTIONS FOR CONNECTING PRINTER TO BIOTECTOR ................................... 155

APPENDIX 2 SETTING UP WINDOWS TO RECEIVE DATA FROM BIOTECTOR ................................ 156

APPENDIX 3 BIOTECTOR 4-20MA OUTPUT MODES .................................................................. 157

Appendix 3.1 Direct Mode .................................................................................................................. 157

Appendix 3.2 Stream Multiplex Mode ................................................................................................. 158

Appendix 3.3 Full Multiplex Mode ...................................................................................................... 162

Appendix 3.4 Result Update in Stream and Full Multiplex Modes ..................................................... 167

APPENDIX 4 GLOSSARY ......................................................................................................... 168

APPENDIX 5 CONTACT INFORMATION ...................................................................................... 171

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Section 1 Safety Precautions

Please read this manual before unpacking, setting up, or operating the BioTector. BioTector should only be used by qualified trained staff and for the purpose it is intended for. Do not use or

install this equipment in any way other than the methods specified in this manual. The procedures and methods described in this manual are based on assuming the user have basic, fundamental background on electronics, chemistry and analyzer equipment.

If the instructions in this manual are not followed, the operation and protection provided by the equipment may be impaired.

1.1 Information and Safety Signs used in the Manual

When any supplementary information is required and if any hazards exist, the necessary information and safety signs (Information, Caution, Warning and Danger) will be displayed for the corresponding section or procedure in this manual.

Used to indicate supplementary information, to call attention to recommendations, to simplify the operation and to guarantee the correct use of the equipment.

Used when there is a danger of minor damage to the system if the user does not follow precautions.

Used when there is a danger of minor injury or serious damage to the system if the user does do not follow the precautions.

Used when failure to observe a safety precaution may result in serious injury or death.

Caution

WARNING

DANGER

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1.2 Precautionary Labels Attached to the Instrument

The labels and tags attached to the instrument are summarized below. Please read all labels and tags attached to the instrument. If not observed, personal injury or damage to the instrument could occur.

This symbol, when displayed on the instrument, indicates that the user must gather the necessary operation and/or safety information given in the instruction manual.

This symbol, when attached on an enclosure, indicates an existing risk of electrical shock and/or electrocution. Only qualified personnel should open such enclosures and work with hazardous voltages.

This symbol, when displayed on a component, identifies that the component surface can be hot. When it is necessary to work with this component, it should be handled with care.

This symbol, when noted on a product, illustrates the risk of chemical harm due to its corrosive, acidic, caustic or solvent nature. Only qualified and trained staff should handle such chemicals.

This symbol, when noted on an analyzer, illustrates the risk of the presence of toxic ozone gas produced in the analyzer. Only qualified and trained staff should work with this analyzer.

This symbol, when displayed on the instrument, indicates the presence of devices sensitive to Electro-Static Discharge (ESD). Prior to any work with such components, the individual should be grounded via an earth strap to prevent any possible damage.

This symbol, when displayed on the product, indicates that protective eye wear must be used during the maintenance or service of the equipment.

This symbol, when used on the product, identifies the location of the protective earth (ground) connection.

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Electrical equipment marked with this symbol may not be disposed of in European domestic or public disposal systems. Return old or end-of-life equipment to the manufacturer for disposal at no charge to the user.

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1.3 Potential System Safety Hazards

The potential safety hazards, which are associated with a running BioTector system, are as follows:

 Electrical hazards  Potentially hazardous chemicals  Oxygen gas and components generating Ozone gas

Please read the instructions in this manual carefully before installing or starting the BioTector. The manufacturer cannot accept liability for damages due to non-observance of this manual. Use of spare

parts not supplied by the manufacturer will invalidate the warranty. The manufacturer shall not be liable for omissions or errors contained herein or for incidental or consequential damages in connection with the furnishing, performance, or use of this material.

The information contained in this manual is subject to change without notice. The information contained herein is protected by copyright. Reproduction, adaptation, or translation of any

part of this manual without prior written permission is prohibited, except as allowed under the copyright laws. Product names mentioned herein are for identification purposes only and may be trademarks or registered

trademarks of their respective companies. Where manuals are translated into several languages, the source language text is considered as the original.

Maintenance and operation should not be carried out unless personnel have been fully trained in the operation of the BioTector. Prior to working on the inside of the analyzer, the technician should be grounded via an earth strap.

Caution

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Ozone and Toxicity

Ozone is found in gaseous form as a natural ingredient of the earth's atmosphere. Some of the chemical and physical properties of ozone are as follows:

Terms

Properties of Ozone (O3)

Molecule Weight

47.9982 g/g-mol

Boiling Point

-119  0.3 °C

Melting Point

-192.7  0.2 °C

Exposure to even low concentrations of ozone can be damaging to delicate nasal, bronchial and pulmonary membrane. Symptoms of acute ozone toxification appear at a concentration of about 1 ppm by volume. The type and severity of symptoms depend on the concentration and duration of exposure. In mild cases and in the early phases of severe cases, symptoms will include one or more of the following:

 Irritation or burning of the eyes, nose or throat  Lassitude  Frontal headache  Sensation of sub-sternal pressure  Constriction or oppression  Acid taste in mouth  Anorexia

In more severe cases, the symptoms may include dyspnoea, cough, choking sensation, tachycardia, vertigo, lowering of blood pressure, severe cramping, chest pain, and generalized body pain. Pulmonary oedema may develop with delayed onset, usually one or more hours after exposure.

Following severe acute ozone toxification, recovery is slow. In the few severe human cases reported, 10 -14 days of hospitalization were required. In these cases, minimal residual symptoms were present for as long as 9 months, but all cases eventually recovered completely.

The 1983 ACGIH has recommended a Threshold Limit Value (TLV) of 0.1 ppm (0.2 mg/m3) for ozone. The safe level for short human exposure to concentrations of ozone in excess of 0.1 ppm (Threshold Limit Value) is not known with certainty. The atmospheric concentration immediately hazardous to life is likewise not known, but inhalation of 50 ppm for 30 minutes would probably be fatal. The odor threshold of ozone for a normal person is 0.01 - 0.02 ppm by volume in air.

First Aid Treatment

Move the victim to an uncontaminated atmosphere. Control restlessness and pain by the administration of sedatives and anodynes orally. Severe cases may require subcutaneous injections of small doses of meperidine hydrochloride (Demerol) for relief of pain. Give oxygen inhalation by facemask when the acute symptoms have subsided. Severe cases require hospitalization since deferred pulmonary oedema may develop.

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1.4 General Safety Precautions

Please pay attention to all caution, warning and danger statements at all times. Non-observance of the safety instructions can result in serious personal injury, death or damage to the equipment. Therefore observe the following:

 Only engineers trained by the manufacturer should carry out maintenance on the BioTector.  The power supplies contain capacitors that are charged to hazardous voltages. After disconnecting

the main power, allow a minimum of one minute for discharge before opening the control section.

 Never wash or spray the system with water. Do not allow water to enter the interior.  Protect the system from one-sided heat radiation, direct sunlight and vibration. System must be

installed in a dry, dust-free room. Special precautions are required in environments with corrosive gases, vapors or explosion risk.

 Please do not place anything on top of the system.

1.4 Précautions générales de sécurité

Prière d’être toujours attentif à toutes les notices de prudence, d’avertissement ou de danger. Le non respect des instructions de sécurité peut engendrer la blessure grave d’individus, leur décès ou la dégradation du matériel. Pour ces raisons, prière d’observer les règles suivantes:

 Seuls les ingénieurs formés par le fabricant doivent réaliser des travaux de maintenance sur le

BioTector.

 L’alimentation électrique contient des condensateurs qui sont chargés à des tensions dangereuses.

Après avoir débranché l’alimentation électrique, attendre au moins une minute pour permettre la

décharge avant d'ouvrir le boîtier de commande.

 Ne jamais laver ou arroser l’appareil avec de l’eau. Ne pas laisser de l’eau pénétrer à l’intérieur.  Protéger l’appareil des radiations de chaleur sur un seul côté, des rayons directs du soleil et des

vibrations. L’appareil doit être installé dans une pièce sèche et sans poussière. Il est nécessaire de

prendre des précautions particulières dans les environnements contenant des vapeurs ou gaz corrosifs ou ceux à risque d’explosion.

 Prière de ne rien poser sur le dessus de l'appareil.

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1.4.1 Electrical and Burn Precautions

During system installation, maintenance or servicing:

 Isolate the system power lines before starting any work in the electronic enclosure.  All electrical work should be carried out by qualified electrical personnel only.  Comply with all local and national regulations when working with electrical connections.  Make sure the system is properly earthed (grounded) before switching on.  It is required to connect the mains through an external isolator (2-pole disconnection switch), and if

possible connect the mains through an earth leakage circuit breaker.

 When working with hot surfaces, use protective gloves and handle the components with care.

1.4.1 Précautions relatives à l’électricité et aux brûlures

À l’installation de l’appareil, sa maintenance ou son entretien:

 Isoler les fils électriques de l’appareil avant de commencer tout travail dans le boîtier électronique.  Seul le personnel électricien qualifié est habilité à effectuer tous travaux d’électricité.  Se conformer aux règlementations locales et nationales pour tout travail sur un branchement

électrique.

 Avant de l’allumer, veiller à la bonne mise à la terre de l’appareil.  Le branchement sur le courant secteur doit obligatoirement se faire par l'intermédiaire d'un

interrupteur sectionneur externe (interrupteur bipolaire), et prévoyez si possible un disjoncteur différentiel.

 Utiliser des gants de protection pour les travaux sur les surfaces très chaudes et prendre soin en

manipulant les composants.

BioTector contains electrical components operating under high voltages. Contact may result in electric shock and severe or fatal injury.

BioTector contient des composants électriques qui fonctionnent à des tensions élevées. Un contact peut engendrer un choc électrique et des blessures graves ou mortelles.

DANGER

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1.4.2 Carrier Gas and Exhaust Gas Precautions

BioTector uses oxygen (O2) gas as the carrier gas during its operation. The oxygen gas must be free of carbon dioxide (CO2) and nitrogen (N2) gases. The average rate of oxygen consumption in BioTector is 22 L/hour (367 ml/min). Carbon dioxide filtered air, carbon dioxide and nitrogen contaminated oxygen gas are not suitable for BioTector TOC TN analyzer. When handling oxygen:

 The same precautions, which are required for any high pressure or compressed gas system, must be

taken to avoid accidents.

 Comply with all local and national regulations and/or manufacturer's recommendations and guidelines

when working with oxygen.

 If oxygen cylinders are used, they must be transferred safely using appropriate equipment (e.g. carts,

hand trucks etc.)

 If oxygen cylinders are used, they should be labeled clearly for identification and well secured for

storage and transport.

 Avoid the use of extensive number of adaptors and couplers.  Do not allow oxygen to come in direct contact with grease, oil, fat, and other combustible materials. If

uncertain how to handle oxygen cylinders and high concentration oxygen, contact your local oxygen manufacturer.

 If oxygen concentrator is used, take precautions to avoid a fire in the area of the concentrator, install

the concentrator only in a well ventilated area and comply with all local and national regulations.

Vent waste gases to atmosphere or to a well ventilated area making the necessary connections on system exhaust. Under normal operating conditions, waste gases will contain oxygen, traces of carbon dioxide and the traces of volatiles/gases which may exist in the sample stream. Under abnormal conditions, the waste gases may contain traces of ozone.

1.4.2 Précautions relatives au gaz porteur et d'échappement

Pour son fonctionnement, BioTector emploie de l’oxygène (O2) comme gaz porteur. L’oxygène ne doit comporter aucun gaz carbonique (CO2) ni d’azote (N2). Le taux moyen de consommation d’oxygène du BioTector est de 22L/heure (367 ml/min). L’analyseur BioTector TOC TN ne tolère pas l’air filtré de gaz carbonique ni l'oxygène contaminé de gaz carbonique et d'azote. À la manipulation de l’oxygène:

 Afin d’éviter les accidents, prendre les mêmes précautions que pour tout appareil à haute pression ou

gaz comprimé.

 Pour toute opération avec de l’oxygène, se conformer aux règlementations locales et nationales et/ou

aux recommandations et consignes du fabricant.

 S’ils sont employés, les cylindres d’oxygène doivent être transportés en toute sécurité à l’aide du

matériel approprié (chariots, diables, etc.)

 S’ils sont employés, les cylindres d’oxygène doivent être clairement étiquetés pour en permettre

l’identification et bien arrimés pour leur stockage et leur transport.

 Éviter d’utiliser un nombre élevé d’adaptateurs et de dispositifs de couplage.  Ne pas laisser l’oxygène entrer en contact direct avec de la graisse, de l’huile, des matières grasses

ou d’autres matières combustibles. Veuillez contacter votre fabricant local d’oxygène si vous avez des doutes sur la manière de manipuler les cylindres d’oxygène et l’oxygène de haute concentration.

 Dans le cas où un concentrateur est employé, prendre les précautions nécessaires pour éviter un

incendie dans la zone du concentrateur, n’installer le concentrateur que dans un endroit bien ventilé

et se conformer aux règlementations locales et nationales.

Évacuer les gaz usés dans l’atmosphère ou dans un endroit bien ventilé en réalisant les branchements voulus sur l'échappement de l’appareil. Dans des conditions normales de fonctionnement, les gaz usés contiennent de l’oxygène, des traces de gaz carbonique et des traces de composants volatiles/gaz qui peuvent être présents dans l’échantillon. Dans des conditions anormales, les gaz usés peuvent contenir des traces d’ozone.

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1.4.3 Chemical Precautions

A number of chemicals and compounds to be used with BioTector are listed in Section 6 Reagents and Calibration Standards. Some of these compounds are harmful, corrosive, acidic and oxidizing. Appropriate precautions must be taken when handling these chemicals or solutions prepared from these chemicals.

Physical contact with these chemicals and inhalation of any vapors must be minimized using appropriate safety equipment.

1.4.3 Précautions chimiques

La liste de la Section 6 Réactifs et Standards de Calibration énumère un certain nombre de produits chimiques et composés à utiliser avec BioTector. Certains de ces composés sont nocifs, corrosifs, acides et oxydants. Il est essentiel de prendre les précautions appropriées lors de la manipulation de ces produits chimiques ou des solutions dont ils sont la base.

Il est essentiel d’employer l’équipement de sécurité approprié afin de minimiser le contact direct avec ces produits chimiques et l’inhalation de toutes vapeurs.

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1.4.4 Sample Stream Precautions

The user is responsible to establish the potential hazard associated with each sample stream. Necessary precautions must be taken, to avoid physical contact with any harmful sample stream, which may contain chemical or biological hazards.

System components and their composition, which come in contact with the sample liquid and possible volatile gases from the sample, are tabulated in table 1 below. If there are suspected compatibility issues between the sample stream and BioTector components, please contact the manufacturer or the distributor.

Table 1 System components and their composition

Component

Material

Tubing

PFA (Per-fluoro-alkoxy)

Fittings

PFA (Per-fluoro-alkoxy) Stainless Steel (SS-316) PVDF (Poly-vinylidene-flouride)

Pump Tubing

EMPP (Elastomer-modified-poly-propylene)

Connectors

PP (Poly-propylene)

Connector & Valve Tubing

EMPP (Elastomer-modified poly-propylene) Viton

Sample (ARS) Valve

PEEK (Poly-ether-ether-ketone) PVDF (Poly-vinylidene-flouride) Stainless Steel (SS-316)

Reactor

Hastelloy (C-276) Stainless Steel (SS-316) PFA (Per-fluoro-alkoxy) PTFE (Poly-tetra-fluoro-ethylene) Borosilicate Glass

Circulation Pump

Kalrez PVDF (Poly-vinylidene-flouride) Ceramic

Valve Seals

Kalrez Viton

Oxidized Sample Catch-pot/Cleaning Vessel

Borosilicate Glass

NDIR CO2 Analyzer

Hastelloy (C-276) Stainless Steel (SS-316)

NDIR CO2 Analyzer Lens

Sapphire

TN Measuring Cell

Quartz

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1.4.4 Précautions relatives aux échantillons

L’usager assume la responsabilité d’établir le danger possible que représente chaque échantillon. Il est essentiel de prendre les précautions voulues afin d’éviter le contact physique avec tout échantillon nocif qui

pourrait présenter un danger chimique ou biologique. Le tableau 1 ci-dessous présente les composants de l’analyseur (et leur composition) qui entrent en contact

avec l’échantillon liquide et les éventuels gaz volatiles émanant de l’échantillon. Si vous soupçonnez des problèmes de compatibilité entre l’échantillon et les composants BioTector, veuillez contacter le distributeur

ou le fabricant. Tableau 1 Composants de l’analyseur et leur composition

Composant

Équipement

Tuyauterie

PFA (perfluoroalkoxy)

Installations

PFA (perfluoroalkoxy) Acier inoxydable (SS-316) PVDF (polyfluorure de polyvinylidène)

Tuyauterie de la pompe

PPMOD (polypropylène modifié par élastomère)

Connecteurs

PP (polypropylène)

Tuyauterie des connecteurs & vannes

PPMOD (polypropylène modifié par élastomère) Viton

Vanne d’entrée de l’échantillon (sélection

automatique)

PEEK (polyéther éther cétone) PVDF (polyfluorure de polyvinylidène) Acier inoxydable (SS-316)

Réacteur

Hastelloy (C-276) Acier inoxydable (SS-316) PFA (perfluoroalkoxy) PTFE (polytetrafluoroethylene) Verre borosilicaté

Pompe de circulation

Kalrez PVDF (polyfluorure de polyvinylidène) Céramique

Joints des vannes

Kalrez Viton

Bac de récupération/récipient de nettoyage de l’échantillon oxydé

Verre borosilicaté

Analyseur infrarouge non diffuseur de CO2

Hastelloy (C-276) Acier inoxydable (SS-316)

Lentille de l’analyseur infrarouge non diffuseur de CO2

Saphir Cellule de mesure de TN

Quartz

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Section 2 Operator’s Manual

Membrane Keypad

The BioTector is equipped with a built-in microprocessor, which has been programmed to enable the user to control the instrument using just six buttons of its membrane keypad. By pressing the appropriate button, the user can move through the various levels of the software menu.

The functions of the 6 keys on the membrane keypad are described below: The ESCAPE [  ,  ] key, which returns user to the previous screen, can also be used to cancel

programming entries. If the ESCAPE key is pressed for longer than 1 second the user returns to the main menu.

The LEFT [  ,  ] and RIGHT [  ,  ] arrow keys are used for numerical entries and programming the BioTector.

The UP [  ,  ] and DOWN [  ,  ] arrow keys are used for numerical entries and programming the BioTector.

The ENTER [ √ ,  ] key, which advances user to the next screen, is also used to enter programmed settings in the BioTector.

Screen Symbols

Selector. Used to designate the menu item being selected.

Highlighter. Used to highlight an active or ongoing function of the BioTector.

Blinking Cursor. Used to indicate current user position when setting changes are being made.

Menu Levels

There are three main menu levels in BioTector in addition to the reaction graph, reaction data and reagent status screens:

 Level 1 – Operation: This level controls the basic operation of the BioTector and allows access to

the archives.

 Level 2 – Calibration: This level allows the user to run zero and span calibration cycles.  Level 3 – Maintenance: This level allows the user to test the individual components of the BioTector

for diagnostics, to download data, to program the software functions and to program the system specific settings in the BioTector.

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Software Menu Diagram

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Startup State

When the BioTector is powered up, its LCD screen will automatically display the Reaction Data screen after a delay of 60 seconds.

By pressing the ESCAPE key the user moves from the Reaction Data screen to the Reaction Graph screen. Pressing the ENTER key on the Reaction Graph screens brings the user back to the Reaction Data screen.

Pressing ENTER key on the Reaction Data screen will bring up the select level screen, from where the user can select the desired menu level using the UP or DOWN and ENTER keys.

Entry to each menu level can be controlled by numerical passwords. If the passwords are not set, pressing the enter key will bring the user directly to the sub menu screen of the selected level. If the system has been set up with passwords, the Password screen will appear and the password must be entered before access to the selected level is allowed.

In all cases, pressing the ESCAPE key will return the user to the previous screen.

Screen Layout and System Message Priority

The system status messages are displayed on the top left hand side of the Reaction Data and Reagent Status screens. On most other screens, only the screen name is displayed in this location.

System status messages are displayed in the following priority:

1. SYSTEM MAINTENANCE – the BioTector is in Maintenance mode, activated by the maintenance switch.

2. SYSTEM FAULT – There is a fault on the BioTector. System is stopped.

3. SYSTEM WARNING – There is a warning on the BioTector. System is running.

4. SYSTEM NOTE – There is a notification on the BioTector. System is running.

5. SYSTEM CALIBRATION – The BioTector is calibrating. This could be Span Calibration, Span Check, Zero Calibration or Zero Check.

6. System operation status. This could be one of either:

 SYSTEM RUNNING – system is running.  SYSTEM STOPPED – system has been stopped by a fault or from the keypad.  REMOTE STANDBY – system has been put into standby mode remotely. System has stopped

analyzing.

The BioTector time and date is displayed on the top right side of each screen. When a fault/warning/notification is logged in the system, a FAULT LOGGED message will alternate with the time/date in this location until the fault/warning/notification has been corrected.

Changing most system settings are prevented when the BioTector is running.

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Reaction Data

B I O T E C T O R R U N N I N G 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

0 9 : 2 7 : 0 2 1 2 - 0 9 - 0 2 R E A C T I O N S T A R T

T I C & T O C S T R E A M 2 R E A C T I O N T Y P E T O C R E A C T I O N P H A S E 1 R A N G E 2 6 5 s R E A C T I O N T I M E

3 6 0 s R E A C T I O N D U R A T I O N R E A C T I O N R E S U L T T I C m g C / l T O C m g C / l 0 9 : 1 7 : 0 2 1 2 - 0 9 - 0 2 S 1 √ 1 3 0 . 0 5 4 0 . 0 0 9 : 0 7 : 0 2 1 2 - 0 9 - 0 2 S 2 √ 3 . 6 3 . 6 0 8 : 5 7 : 0 2 1 2 - 0 9 - 0 2 S 3 √ 7 . 2 7 . 2 0 8 : 4 7 : 0 2 1 2 - 0 9 - 0 2 S 4 x 1 0 . 7 1 0 . 7 0 8 : 3 7 : 0 2 1 2 - 0 9 - 0 2 S 5 x 1 4 . 3 1 4 . 3

0 8 : 2 7 : 0 2 1 2 - 0 9 - 0 2 C F 0 . 9 7 . 9

The Reaction Data screen is the primary display screen on the BioTector for carbon (TIC, TOC, TC and VOC) analysis.

This screen gives information on:

- The Reaction Start time.

- The Reaction Type, for example a TIC & TOC reaction, TC reaction, Cleaning Reaction.

- The Reaction Phase, for example if the reaction is currently in the TIC, Base Oxidation, TOC phase.

- The Range the BioTector is using to carry out its analysis.

- The Reaction Time, which is the current time in the reaction.

- The Reaction Duration, the overall duration of the reaction. The Reaction Data screen also has an archive of the last 25 reactions. The most recent six reactions are

shown on the screen. In order to access the remaining reactions, use the DOWN or RIGHT keys to scroll down, use the LEFT or UP keys to scroll up.

Each reaction record in the reaction archive contains:

- Start Time - reaction start time.

- Date - reaction date.

- Record Type, using the prefixes below: S1 to S6 – reactions from stream 1 to stream 6. M1 to M6 – reactions from manual sample stream 1 to manual stream 6. √ – sample sensor detected the sample or there is no significant quantity of air bubbles in the

stream/manual grab sample lines.

x – sample sensor detected no sample or there is significant quantity of air bubbles in the

stream/manual grab sample lines.

CF – full cleaning reaction. RW – reactor wash reaction. RS – remote standby reaction. ZC – zero calibration reaction. ZK – zero check reaction. ZM – manual zero adjust. SC – span calibration reaction. SK – span check reaction. SM – manual span factor adjust. A1 to A6 – 24 hours average result from stream 1 to stream 6.

- Reaction Results – reaction results according to the analysis type.

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B I O T E C T O R R U N N I N G 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

0 9 : 2 7 : 0 2 1 2 - 0 9 - 0 2 R E A C T I O N S T A R T T N S T R E A M 2 R E A C T I O N T Y P E S M P L P U R G E R E A C T I O N P H A S E 1 R A N G E 8 5 s R E A C T I O N T I M E 3 6 0 s R E A C T I O N D U R A T I O N R E A C T I O N R E S U L T T N m g N / l

0 9 : 1 7 : 0 2 1 2 - 0 9 - 0 2 S 1 √ 4 1 . 0 0 9 : 0 7 : 0 2 1 2 - 0 9 - 0 2 S 2 √ 4 0 . 1 0 8 : 5 7 : 0 2 1 2 - 0 9 - 0 2 S 3 √ 4 9 . 5 0 8 : 4 7 : 0 2 1 2 - 0 9 - 0 2 S 4 x 4 1 . 1

0 8 : 3 7 : 0 2 1 2 - 0 9 - 0 2 S 5 x 4 0 . 3 0 8 : 2 7 : 0 2 1 2 - 0 9 - 0 2 S 6 3 9 . 9

If BioTector is built as a TOC TN analyzer, the analysis results of the relevant parameters (e.g. TN, COD, BOD etc.) are also displayed on one or more screens.

These screen give information on:

- The Reaction Start time.

- The Reaction Type, for example a TN STREAM 2 reaction.

- The Reaction Phase, for example if the reaction is currently in the SAMPLE PURGE phase etc.

- The Range the BioTector is using to carry out its analysis.

- The current Reaction Time for the corresponding reaction.

- The Reaction Duration for the overall duration of the corresponding reaction.

Reaction Graph

1 0 1 . 5 [ k P a ] 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

T I C m g u 1 2 . 4 9 5 6 C O 2 T O C m g u

1 5 6 . 4

4 3 5 6 C O 2

0 s 1 2 0 s 2 4 0

s 3 6 0 s

1 0 . 0 l / h 2 6 C 5 6 C O 2 i

1 2 C O 2 z 2 6 5 s

The Reaction Graph screen gives information on the current reaction in progress, and allows the user to monitor the progression of the reaction. This screen gives information on:

- The current atmospheric pressure, measured in kPa.

- The un-calibrated data from the reaction, for example TICmgu or TOCmgu without any compensation

for atmospheric pressure.

- The height of the CO2 peaks in each phase of the reaction.

- The current MFC flow in l/h.

- The temperature in the analyzer.

- The CO2 instantaneous value (CO2i) and the CO2 zero value (CO2z) for the reaction.

- The reaction time.

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Reagent Status

B I O T E C T O R R U N N I N G 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

A C I D M O N I T O R 2 5 . 0 l ~ 3 5 D A Y S B A S E M O N I T O R 2 5 . 0 l ~ 3 5 D A Y S H C l W A T E R M O N I T O R 1 0 . 0 l ~ 3 8 D A Y S

T N C L E A N I N G M O N I T O R 2 5 . 0 l ~ 1 5 0 D A Y S D I W A T E R M O N I T O R 2 5 . 0 l ~ 6 0 D A Y S N O T E : D A Y S L E F T I S A N E S T I M A T E B A S E D S Y S T E M C U R R E N T U S E

If the Reagent Status screen has been activated, the estimated number of days left for each reagent type is shown on the display.

If the reagents run low, a LOW REAGENTS fault is activated. This fault has to be cleared by resetting the reagent level in the Install New Reagents menu.

Note that the LOW REAGENTS fault can be set as a warning (where the common fault relay will activate) or a notification, in which case a special programmable relay is required to signal the LOW REAGENTS condition.

Select Level

S E L E C T L E V E L 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < O P E R A T I O N 2 C A L I B R A T I O N 3 M A I N T E N A N C E

This screen allows the user to access the operation, calibration and maintenance menus.

1. Operation. This menu gives access to the basic operation of the BioTector and allows access to the archives. The level can be password protected using the Password menu.

2. Calibration. This menu allows the user to run zero and span calibration cycles. The level can be password protected using the Password menu.

3. Maintenance. This menu allows the user to test the individual components of the BioTector for diagnostics, to download data, to program the software functions and to program the system specific settings in the BioTector. The sub menus in this level can be password protected using the Password menu.

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Enter Password

0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

E N T E R P A S S W O R D F O R O P E R A T I O N S E C U R I T Y D O M A I N

[ 1 2 3 4 ]

The BioTector has separate passwords for all levels/security domains, which are operation, calibration diagnostics, commissioning, system configuration and hardware configuration.

These passwords are programmable, and if a password has been set up for a particular level, then it must be entered before the BioTector will grant access to the password-protected security domains.

Use of a higher-level password also allows access to lower levels/domains.

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2.1 Operation Menu

Operation Menu Diagram

Operation menu allows the user to start and stop the analyzer. Menus related to system operation are also accessed using this menu.

Start Stop

The user can Start or Stop the BioTector using the Start Stop menu.

1. Remote Standby. Remote Standby is an optional function, which is activated from Input 19 (by default) on

the Signal PCB (e.g. from a flow switch). A “REMOTE STANDBY” message is displayed on the top left corner of the main Reaction Data screen to indicate that the BioTector is in remote standby state. When remote standby signal is activated, the BioTector stops analyzing. All menu access and operational functions remain as for BioTector normal running state. The BioTector runs one standby reaction every 24 hours, at the time programmed for the Pressure/Flow Test (at 08:15 AM by default). Sample is not taken during the remote standby reaction (only acid and base reagents are used). This reaction is tagged as “RS” (Remote Standby) in the system reaction archive. The 4-20mA signal or other output devices are not updated. When remote standby signal is deactivated, the BioTector starts analyzing.

When remote standby signal is activated, the “Finish & Stop” or “Emergency Stop” must be selected before using such functions as Install New Reagents, Zero and Span Calibrations, Process Tests etc. If the BioTector is stopped using the “Finish & Stop” or “Emergency Stop” functions or automatically by a system fault, it will not be possible to start the BioTector by the removal of the remote standby signal. The “Start” function must be used to re-start the BioTector. When BioTector is started while the remote standby signal is activated, BioTector goes into remote standby state. The manual grab sample analysis can be carried out normally using the Manual Program menu when the BioTector is in remote standby state.

Maintenance should only be carried out when “SYSTEM STOPPED” message

is displayed on the top left corner of the main Reaction Data screen or when the system is powered down. When “REMOTE STANDBY” or “SYSTEM

RUNNING” message is displayed on the screen, stop the BioTector using the “Finish & Stop” or “Emergency Stop” function.

Caution

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2. Start. This function starts the BioTector. When BioTector is started, the multi-stream operation sequence (if

programmed) is reset. BioTector performs Ozone Purge, Pressure/Flow Test, Reactor Purge and Analyzer Purge sequences automatically before starting its analysis. Ozone Purge sequence purges any residual ozone through the ozone destructor. Pressure/Flow Test sequence confirm that there is no gas leak and there is no gas flow restriction in the BioTector. Reactor Purge sequence purges any liquid from the reactor through the Sample Out Valve. Analyzer Purge sequence purges any CO2 gas from the CO2 Analyzer through the Exhaust Valve.

3. Finish & Stop. When this function is activated from the keyboard, the BioTector stops as soon as its

present reaction is completed. An “*” is displayed to let the operator know the function has been activated.

4. Emergency Stop. When this function is activated the BioTector cancels the execution of the present

reaction and quickly stops operation after the Ozone Purge, Reactor Purge and CO2 Analyzer Purge sequences. The Emergency Stop has highest priority, and always overrules the “Finish & Stop” function.

Quick Startup Function: During maintenance, system testing etc. it may be necessary to quickly start and stop the BioTector to check various parameters. Pressing the ENTER key for the “Start”, when the RIGHT ARROW key is also pressed, bypasses the Pressure/Flow Test sequence, ensuring a quick startup.

When the quick startup function is used, system will log a “28_NO PRESSURE TEST” warning in the fault archive and will start operation. The same warning will also be logged, when the BioTector is started from the Reagents Setup, Manual Program and Calibration menus using this function.

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Reagents Setup

This menu allows the user to access the Reagent menus.

1. Install New Reagents. Menu used to install and prime the reagents in the BioTector. Any “85_Reagents Low” and “20_No Reagents” warnings and notifications can also be reset in this menu.

2. Purge Reagents & Zero. Menu used to purge the reagents, and carryout a zero calibration cycle.

Install New Reagents

I N S T A L L N E W R E A G E N T S 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

C O N F I R M T H E F O L L O W I N G : 1 < N E W A C I D C O N N E C T E D 2 R E S E T A C I D M O N I T O R 2 5 . 0 l ~ 3 5 D A Y S 3 N E W B A S E C O N N E C T E D

4 R E S E T B A S E M O N I T O R 2 5 . 0 l ~ 3 5 D A Y S 5 N E W H C l W A T E R C O N N E C T E D 6 R E S E T H C l W A T E R M . 1 0 . 0 l ~ 3 8 D A Y S

7 N E W T N C L E A N I N G C O N N E C T E D 8 R E S E T T N C L E A N I N G M 2 5 . 0 l ~ 1 5 0 D A Y S 9 N E W D I W A T E R C O N N E C T E D

▼ N O T E : B I O T E C T O R W I L L R E - S T A R T W H E N T H E N E W R E A G E N T S C Y C L E I S C O M P L E T E

I N S T A L L N E W R E A G E N T S 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

C O N F I R M T H E F O L L O W I N G :

 1 0 R E S E T D I W A T E R M O N 2 5 . 0 l ~ 6 0 D A Y S 1 5 N E W Z E R O W A T E R ( D I W ) C O N N E C T E D 1 6 5 0 . 0 m g C / l T I C S T A N D A R D C O N N E C T E D 1 7 3 5 0 . 0 m g C / l T O C S T A N D A R D C O N N E C T E D

1 8 1 0 0 . 0 m g N / l T N S T A N D A R D C O N N E C T E D 2 0 S T A R T N E W R E A G E N T C Y C L E

N O T E : B I O T E C T O R W I L L R E - S T A R T W H E N T H E N E W R E A G E N T S C Y C L E I S C O M P L E T E

The install new reagents procedure is an automatic procedure for installing new reagents, setting the zero offset by Zero Calibration cycle, setting the reaction check levels and checking the span by Span Calibration or Span Check cycles. Span Calibration or Span Check cycles are part of the Install New reagents sequence if SPAN CALIBRATION or SPAN CHECK is activated in New Reagents Program menu. The basic Zero Check/Calibration and Span Check/Calibration parameters (operation ranges, number of reactions, standard solution concentrations etc.) are programmed in Zero Calibration and Span Calibration menus respectively. The comprehensive Zero Check/Calibration and Span Check/Calibration parameters are programmed in Zero Program and Span Program menus respectively.

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To run the Install New Reagents cycle, the BioTector must be stopped. Confirm that all or the corresponding new reagents have been installed on the BioTector, for instance for acid reagent, select New Acid Connected, and press the ENTER key. A tick mark will appear as confirmation that the new acid has been connected. Note that when one or more reagent volumes are updated in Reagents Monitor menu, system automatically resets the new reagents volumes in this menu and also updates the figures displayed in the main Reagents Status screen.

All reagents volumes can be reset while system is running. This function allows the user to top up the reagents, preferably HCl Water (if installed in systems built with FMI Heavy Duty Circulation Pump), TN Cleaning Solution and DI Water, without stopping the system. However, when Acid and/or Base are replaced or topped up, system requires a new Zero Calibration cycle. A “ZERO CALIBRATION REQUIRED” warning will be displayed on the screen when RESET ACID MONITOR and/or RESET BASE MONITOR are selected. Therefore, it is strongly recommended to stop the BioTector and activate the Start New Reagent Cycle or to run the Zero Calibration cycle using the Zero Calibration menu. It is important that Zero Water (DI Water) is

connected to BioTector’s Zero Water port before the Install New Reagent cycle is started. Unlike BioTector

TOC analyzers, in BioTector TOC TN analyzers, Zero Water is required so that the correct zero offset (Zero Adjust) values are set for TN analysis. Failure to do so may have an impact on system zero response and the analysis results.

When all or the necessary reagents have been confirmed to be connected and reset in this menu, and when Start New Reagent Cycle is selected, the Install New Reagents cycle will be executed. It is the responsibility of the user to make sure that all reagent volumes are programmed correctly in Reagents Monitor menu, the reset of the reagents monitoring are carried out correctly in Install New Reagents menu and finally if necessary the Zero Calibration cycle is activated either with the Start New Reagent Cycle function in Install New Reagents menu or with the Run Zero Calibration function in Zero Calibration menu.

The Install New Reagents cycle consists of the following steps:

1. Reagent Purge: System purges and fills all reagent lines with the new reagents.

2. Zero Calibration: The Zero Adjust (zero offset) level is set for all analysis ranges, and the Reaction

Check level for TOC is updated (if the CO2 LEVEL is programmed as AUTO in Reaction Check menu).

3. If Span Calibration or Span Check is activated in New Reagents Program menu, a Span Calibration

or Span Check is carried out.

Once the procedure is completed the BioTector either stops or returns online, depending on the programmed setting of AUTOMATIC RE-START in New Reagents Program menu.

Purge Reagents & Zero

The Purge Reagents & Zero function is an automatic procedure to purge the reagents, to set the zero offset and to set the reaction check levels in the BioTector. The program settings for the Reagent Purge are set up in the Reagents Purge menu.

1. Purge Reagents & Zero. This option allows the user to run the Purge Reagents & Zero cycle.

System Range Data

This menu displays the system specific analysis range data for all measured components (e.g. TIC, TOC, TN, etc.). BioTector can be calibrated with up to 3 analysis ranges for each measured component. When a specific component of a sample (e.g. TOC) is measured at a specific range (e.g. Range 2), the analysis of any other components (e.g. TN etc.) of the sample are also carried out at the same analysis range.

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Manual Program

M A N U A L P R O G R A M 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < R U N A F T E R N E X T R E A C T I O N 2 R U N A F T E R 1 0 : 3 0 3 R E T U R N T O O N - L I N E S A M P L I N G Y E S

4 R E S E T M A N U A L P R O G R A M 5 6 M A N U A L 1 , 4 R A N G E 1 7 M A N U A L 2 , 4 R A N G E 3 8 M A N U A L 3 , 4 R A N G E 2 9 M A N U A L - , - - - R A N G E - 1 0 M A N U A L - , - - - R A N G E - 1 1 M A N U A L - , - - - R A N G E -

1 2 M A N U A L - , - - - R A N G E - 1 3 M A N U A L - , - - - R A N G E - ▼

Manual Program menu allows the user to run system in manual operation mode in order to analyze samples/standards or a sequence of samples/standards manually. This is achieved by one or a set of manual valves installed in the system. The manual analysis sequence can be started at the end of the current reaction, or at a time set by the user. When the manual sequence is complete, the system can be programmed to return online automatically. Note that all cleaning cycle, pressure/flow tests, zero or span cycles are interrupted by the manual operation mode. The Sample Pump reverse operation is also disabled during the manual operation mode by default, unless a Manual Bypass Valve is installed in the system and the REVERSE time is programmed for the corresponding Manual Valve in Sample Pump menu. All items in this menu can be modified when the BioTector is running unless:

- No manual valves have been defined in the Output Devices menu.

- The manual mode is currently running.

- The manual mode is scheduled to start when the current reaction is completed.

Note that the Manual mode always starts at the first programmed valve, and works its way down the programmed sequence.

1. Run After Next Reaction. To start the manual operation mode sequence after the next reaction the

BioTector is currently running, press the ENTER key at this menu item. An “*” will indicate that this

function has been selected. If the BioTector is stopped, then the Manual mode starts immediately. To deactivate this function before the manual operation mode has started, press the ENTER key again, or activate an alternative function. In systems built with the remote control of Manual Program option, the remote signal (Manual Mode Trigger from Input 7) activates the Run After Next Reaction function.

2. Run After 00:00. Similar to menu option 1 above, but the manual operation mode starts after the programmed time.

3. Return to On-line Sampling. This menu item allows the user to specify whether the BioTector should stop or return to online monitoring when the manual operation sequence is complete.

4. Reset Manual Program. Use this function to reset all the programmed settings to their default values.

6. - 30. Manual. In order to analyze one or a number of samples/standards using the manual operation mode,

first connect the sample/standard to the manual port/s outside the BioTector. Then, select the corresponding Manual Valve in this menu (the first setting). Then, enter the number of samples (number of analysis reactions) to be taken through each Manual Valve (the second setting). Finally select the correct analysis range (RANGE 1, 2 or 3) if the concentration levels of the sample/standard are known (see System Range Data menu to view the available system ranges and to select the correct operation range). If the concentration levels of the samples/standards are not known, select AUTO so that BioTector can automatically select the optimum analysis range. When RANGE is programmed as AUTO, a minimum of five analysis reactions is recommended (the second setting) so that BioTector can find the optimum operation range with its automatic exceedance tracking function. When AUTO option is selected, depending on analysis range and system response, the first two or three analysis results may need to be discarded.

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Reaction Archive

The Reaction Archive holds information on TIC, TOC, TC, VOC, COD, BOD, TN, stream valve, reaction range, start time and related analysis information for the last 9999 reactions. If the archive is full, then every new reaction overwrites the oldest one in the archive. As the Reaction Archive contains 9999 events, the user must first enter the date at which the viewing of the archive starts. The Enter Date menu allows the user to specify the date of the first displayed reaction from the archive.

Each reaction record in the reaction archive contains:

- Start Time - reaction start time, which is displayed without seconds in this menu

- Date - reaction date

- Reaction Type - with the prefixes below:

S1 to S6: Reactions from stream 1 to stream 6. M1 to M6: Reactions from manual sample stream 1 to manual stream 6.

√ Sample sensor detected the sample or there is no significant quantity of air

bubbles in the stream/manual grab sample lines.

x Sample sensor detected no sample or there is significant quantity of air

bubbles in the stream/manual grab sample lines. See Sample Status in Fault

Setup section for details. CF: Full cleaning reaction. RW: Reactor wash reaction. RS: Remote standby reaction. ZC: Zero calibration reaction. ZK: Zero check reaction. ZM: Manually input zero adjust. SC: Span calibration reaction. SK: Span check reaction. SM: Manually input span adjust. A1 to A6: 24 hours average result from stream 1 to stream 6.

The user can navigate through the displayed reactions individually by pressing the UP and DOWN keys each time, or can navigate in steps of 10 reactions using the LEFT and RIGHT keys. Depending on system analysis type (e.g. VOC, TC –TIC etc.) and system display options (e.g. COD and/or BOD) settings, BioTector displays additional reaction data held on additional Reaction Archive screens. To access the screens, press the ENTER key, and to return to the previous screen, press the ESCAPE key.

Fault Archive

In the Fault Archive menu, the user can view the last 99 faults/warnings logged in the system, confirm if the faults/warnings are current or not, and acknowledge current faults/warnings. If the archive is full, then every new faults/warnings overwrites the oldest one in the archive. The user can navigate through the displayed reactions individually by pressing the UP and DOWN keys each time, or can navigate in steps of 10 reactions using the LEFT and RIGHT keys.

The faults/warnings archive events are divided into three categories:

- Fault: Faults are categorized as events, which stop BioTector operation. The 4-20mA signals are set to the fault level, and the fault relay is activated. The BioTector cannot be started unless the fault in the archive has been acknowledged.

- Warning: Warning is a minor fault, which does not require the BioTector to stop. The 4-20mA signals are not changed, only the fault relay is activated.

- Notification: A notification is and information (e.g. “86_Power Up”, “87_Service Time Reset” etc.) displayed on the screen.

To acknowledge any current faults/warnings marked with an “*” in the archive, first identify and locate the faults/warnings. See Section 9 Troubleshooting of System Faults and Warnings. Follow the necessary troubleshooting procedures to solve the problem. Acknowledge the fault by pressing the ENTER key in the Fault Archive menu. Please note that there are system faults (e.g. 05_Pressure Test Fail), which cannot be acknowledged by the user. Such faults are reset and acknowledged automatically by the system when system is started, when system is rebooted or when the fault condition is solved.

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Time & Date

This menu allows the system time and date to be set by the user. To change the system time or date (hours, minutes, seconds, day, month and year), press the ENTER key, enter the new time and date and press the ENTER key again.

In order to change the system date format, press the ENTER key, select new date format from the following day, month and year options: DD-MM-YY, MM-DD-YY, YY-MM-DD and press the ENTER key again.

When the time is changed, it is possible for the BioTector to automatically start up if the new time is after the startup time for a scheduled task, for example the startup time for a manual sample sequence in Manual Program menu.

Contact Information

Contact Information menu displays the manufacturer/distributor contact details.

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2.2 Calibration Menu

Calibration menu allows the user to calibrate the analyzer. Zero and Span Calibration menus allow the user to run the zero and span calibration cycles for a single range or for all system ranges available.

Calibration Menu Diagram

Zero Calibration

Z E R O C A L I B R A T I O N 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < T O C Z E R O A D J U S T 1 0 . 0 [ 0 . 0 ] 2 2 0 . 0 [ 0 . 0 ] 3 3 0 . 0 [ 0 . 0 ] 4 T N Z E R O A D J U S T 1 0 . 0 [ 0 . 0 ] 5 2 0 . 0 [ 0 . 0 ] 6 3 0 . 0 [ 0 . 0 ]

1 3 R U N R E A G E N T S P U R G E 1 4 R U N Z E R O C A L I B R A T I O N 1 5 R U N Z E R O C H E C K 1 6 R 1 R 2 R 3

1 7 Z E R O P R O G R A M 6 , 4 , 4 1 8 Z E R O A V E R A G E 4 , 2 , 2 1 9 2 0 - - > Z E R O P R O G R A M

Zero Calibration menu allows the user to enter the suggested Zero Adjust values, to start the Reagent Purge cycle, to start the Zero Calibration and Zero Check cycles and to program the number of zero reactions run at each range.

1.-6. TOC/TN Zero Adjust. The TOC/TN Zero Adjust is used to compensate any organic carbon and nitrogen contamination in the Acid and Base reagents and any absorbed CO2 in the Base reagent. The Zero Adjust values are generated automatically by the system for each range when the zero calibration cycle is completed without any system warnings. Zero Calibration cycle is activated by selecting the RUN ZERO CALIBRATION function in this menu.

The TOC Zero Adjust values are the Zero Offset values in mgC/l measured by the CO2 Analyzer. The TN Zero Adjust values are the Zero Offset Absorbance values measured by the Photometer.

When a Zero Check cycle is run using the RUN ZERO CHECK function, the system only checks the zero

response at each range and displays the suggested Zero Adjust values in brackets “[ ]” for all ranges next

to the current Zero Adjust settings. When a Zero Check cycle is completed, if necessary the suggested Zero Adjust values can be programmed manually by entering the corresponding suggested Zero Offset values for each range (1, 2 and 3) for each parameter in this menu. When the Zero Adjust settings are entered manually, system logs this information in the reaction archive with the prefix “ZM” (Zero Manual).

ENTER PASSWORD CALIBRATION ZERO CALIBRATION

SPAN CALIBRATION

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13. Run Reagents Purge. The RUN REAGENTS PURGE function is used to prime all reagents in the BioTector. If necessary, the pump operation time for Reagent Purge cycle can be increased in the Reagents Purge menu.

14. Run Zero Calibration. Each time BioTector reagents are replaced or topped up and each time a service is carried out, it is strongly recommended to use the RUN ZERO CALIBRATION function so that the system can set the zero offset values automatically. The zero calibration reactions operate in the same manner as a normal reaction, but BioTector takes DI Water through the Zero Water port. To start the zero calibration cycle, first connect Zero Water (DI Water) to the BioTector Zero Port. Press the ENTER key at

this menu item. An “*” will indicate that the function is running. At the end of the Zero Calibration cycle,

the following settings are checked and updated:

1. The TOC Zero Adjust settings for each range are updated automatically by the system using the un-calibrated TOC measurement (not the results seen on the LCD screen). If a Zero Check is

used to check the zero offset, the suggested values are shown in brackets “[ ]” next to the actual

Zero Adjust settings.

2. The TN Zero Adjust settings for each range are updated by using the un-calibrated TN absorbance data (not the results shown on the LCD display). If a Zero Check is used to check the zero setting, the suggested values are shown in brackets “[]” next to the actual TN Zero Adjust settings.

3. If the CO2 LEVEL is set as AUTO for automatic updating in the Reaction Check menu, then the reaction check CO2 Level is also updated automatically.

4. The CO2 Level is also checked against the BASE CO2 ALARM setting in Fault Setup menu. If the measured CO2 Level is greater that the BASE CO2 ALARM value, system generates a “52_HIGH CO2 IN BASE” warning.

15. Run Zero Check. Zero Check cycle is similar to the Zero Calibration above, but BioTector does not update any of the Zero Adjust or CO2 Level settings. System only checks the BASE CO2 ALARM described above.

17. Zero Program. Zero Program function allows the user to program the number of zero reactions run at one or more ranges (R1, R2 and/or R3) for all measured parameters. When the number of zero calibration reactions for one or two of the ranges is set to zero, system runs the zero cycle on the programmed range or ranges and calculates the Zero Adjust values for the other ranges automatically. It is recommended not to modify the factory set Zero Program values unless it is absolutely necessary. Any unnecessary modification in this setting may have an impact on the zero offset values.

18. Zero Average. Zero Average function allows the user to program the number of zero reactions to be averaged for each range (R1, R2 and/or R3) at the end of the zero cycles for all measured parameters. It is recommended not to modify the factory set Zero Average values unless it is absolutely necessary. Any unnecessary modification in this setting may have an impact on the zero offset values.

20.  Zero Program. Zero Program is a link to Maintenance, System Configuration, Sequence Program, Zero Program menu.

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Span Calibration

S P A N C A L I B R A T I O N 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < T I C S P A N A D J U S T 1 1 . 0 0

2 2 1 . 0 0 3 3 1 . 0 0 4 T O C S P A N A D J U S T 1 1 . 0 0 5 2 1 . 0 0

6 3 1 . 0 0 7 T N S P A N A D J U S T 1 1 . 0 0 8 2 1 . 0 0 9 3 1 . 0 0 1 6 R U N S P A N C A L I B R A T I O N 1 7 R U N S P A N C H E C K 1 8 1 9 S P A N P R O G R A M 6

2 0 S P A N A V E R A G E 3 2 1 R A N G E 1 2 2 T I C S T A N D A R D 1 0 0 . 0 m g C / l 2 3 T O C S T A N D A R D 2 5 0 . 0 m g C / l

2 4 T N S T A N D A R D 1 2 5 . 0 m g N / l 2 6 2 7 - - > S P A N P R O G R A M

Span Calibration menu allows the user to enter the Span Adjust values manually, to start the Span Calibration and Span Check cycles and to program the number of span reactions, span operation range and the concentrations of the standard solutions used. Above menu displays the parameters for the TIC & TOC, VOC, TC - TIC Systems. In TC systems, the span calibration menu contains the relevant parameters, which excludes the TIC related parameters.

1.-9. TIC/TOC/TN Span Adjust. This menu item allows the user to set the TIC/TOC/TN span adjust factors manually by entering the STANDARD solution used and the calibrated average reaction RESULT at each range (1, 2 and 3). When the STANDARD and RESULT values are entered, system automatically calculates the corresponding span factors of each parameter for each range. In order to manually set the Span Adjust factors:

First enter the concentration of the standard solution used.

S P A N A D J U S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

S T A N D A R D R E S U L T 1 < T O C S P A N A D J U S T 1 0 0 . 0 2 2 1 . 0 0 3 3 1 . 0 0

Next enter the average result.

S P A N A D J U S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

S T A N D A R D R E S U L T

1 < T O C S P A N A D J U S T 1 0 0 . 0 9 9 . 5 2 2 1 . 0 0 3 3 1 . 0 0

When the ENTER key is pressed again, the new span factor is automatically calculated. In order to set the span adjust factors to 1.00, enter 0.0 values for both standard and result.

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16. Run Span Calibration. This function starts the Span Calibration cycle. The span calibration reactions are run at a single range programmed by the RANGE in this menu below. At the end of the span calibration cycle, BioTector automatically calculates the Span Adjust factors and displays it for Span Adjusts above. Unless it is manually modified, the same Span Adjust factor calculated for the programmed RANGE in this menu is used for the other two ranges as well. The span reactions operates in the same manner as a normal reaction, but the Sample Pump reverse operation is disabled to prevent the contamination of the standard solution connected to calibration/manual port. Span Calibration reactions have the prefix of “SC”.

17. Run Span Check. This function starts the Span Check cycle. The operation is similar to the Span Calibration cycle above, but BioTector does not update any Span Adjust values at the end of the span check cycle. Span Check reactions have the prefix “SK”.

19. Span Program. Span Program function allows the user to program the number of span reactions to be carried out during the Span Calibration and Span Check cycles. It is recommended not to modify the factory set Span Program value unless it is absolutely necessary. Any unnecessary modification in this setting may have an impact on the span adjust values.

20. Span Average. Span Average function allows the user to program the number of reactions to be averaged at the end of the Span Calibration and Span Check cycles. It is recommended not to modify the factory set Span Program value unless it is absolutely necessary. Any unnecessary modification in this setting may have an impact on the span adjust values.

21. Range. Range function allows the user to program the operation range at which the Span Calibration and Span Check reactions are carried out. If the selected range is in conflict with the programmed CALIBRATION STANDARD concentration in this menu, system automatically displays a “Caution! Reaction Range or Standard is Incorrect” warning. See System Range Data menu in order to select the correct operation range or correct standard solution.

22.-24. TIC/TOC/TN Standard. TIC/TOC/TN Standard function allows the user to program the concentrations of the TIC / TOC (mgC/l) and TN (mgN/l) standard solution used in Span Calibration reactions. If the programmed concentration level is in conflict with the programmed RANGE above, system automatically displays a “Caution! Reaction Range or Standard is Incorrect” warning. See System Range Data menu in order to select the correct operation range or correct standard solution. If one or more of the Standard concentrations are programmed as 0.0mg/l, system does not calculate or update any Span Adjust factors and therefore omits any span related warnings defined above. See Section 6 Calibration Standards for the details of BioTector standard solutions and preparation procedures. In VOC and TC – TIC systems, it is recommended to run the TIC and TOC calibrations separately using separate standard solutions.

27.  Span Program. Span Program is a link to Maintenance, System Configuration, Sequence Program, Span Program menu.

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Section 3 Technical Specifications

TYPICAL TECHNICAL DATA

Enclosure: Fiberglass Reinforced Polyester Dimensions (HxWxD): 1250mm x 750mm x 320mm

Enclosure height may increase to 1750mm, depending on system optional

features.

Weight: 90 kg – 120 kg Enclosure weight may change depending on system optional features. Power Consumption: 300 W (VA) Mains Connection: 115V AC, 60Hz or 230V AC, 50Hz (10%) Other power options are available on request. Mains Wire Specification: Number of Cores = 3, Current Rating minimum = 10 Amps, CSA (Cross

Sectional Area minimum) = 1.50mm2

Signal Wire Specification: Number of Cores = 10 (+2 cores per additional signal), Current Rating

minimum = 1 Amp, CSA (Cross Sectional Area minimum) = 0.22mm2.

FEATURES IN DETAIL

Display: High Contrast 40 Character x 16 Line Backlit LCD with CFL Backlight Data Storage: Previous 9999 analysis data on screen in the microcontroller memory and

storage of data archive for the lifetime of the analyzer in the SD/MMC card

Previous 99 fault data on screen in the microcontroller memory and storage

of fault data archive for the lifetime of the analyzer in the SD/MMC card

SD/MMC Card: Flash memory card for data transfer and for software & configuration updates Operation: Microcontroller with Membrane Keyboard Language Options: English, French, German Other language options are available on request.

INPUT & OUTPUT SIGNALS

Standard Output: One programmable 4-20mA output signal (typically for TOC) Maximum impedance: 500 ohms For systems requiring more than six 4-20mA standard outputs, 4-20mA

Output Multiplex option is implemented to provide 4-20mA data for up to 35 output signals.

Digital Output: Two freely programmable system relays (volt free changeover contact with a

current rating of 1Amp at 30V DC)

One system fault relay (volt free changeover contact with a current rating of

1Amp at 30V DC)

Data Transfer Port: SD/MMC Card and serial RS232 Output for Printer, PC or Data Logger

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OPTIONAL FEATURES

Result Output: TIC, TC, VOC, TN, after correlation COD, BOD Remote Control: Input for remote start / standby

Input for remote stream and range selection Input for remote manual grab sample analysis Network Control Unit for remote access over Internet or Intranet connection

using HTTP over TCP/IP protocol

Industrial Interface: Modbus, Profibus, Ethernet (when any of the Modbus, Profibus or Ethernet option is selected, the digital

output signals are sent through the relevant device with its specific communication protocol)

Calibration & Cleaning: Valves for Automatic Calibration and Sample Line Cleaning Multi-stream: Valves for up to 6 streams with up to six 4-20mA signals

The number of available outputs depends on the manual stream

configuration.

Manual stream: Valves for up to 6 manual streams with up to six 4-20mA signals The number of available outputs depends on the multi-stream configuration.

4-20mA Outputs: As individual signal up to maximum of 6 or as multiplex signal up to maximum

of 35. Maximum impedance: 500 ohms.

Hazardous Area: Certification options are available to European Standards (ATEX for Zone 1

and Zone 2) and to North American Standards (Class I Division 1 and Class I Division 2). Other options are available on request.

CONSUMABLES Typical Replacement Frequency & Consumption

Acid & Base: 3 - 10 weeks/25 Liters (application dependent) TN Cleaning Solution: 45 - 90 weeks/10 Liters (application dependent) Deionised Water: 12 - 25 weeks/10 Liters (application dependent) Oxygen: Average consumption is 22 L/hour (367 ml/min)

Integrated and external oxygen concentrator options are available.

Service: 6 Monthly Intervals

ANALYSIS PARAMETERS

Oxidation Method: Patented Two-Stage Advanced Oxidation Process using Hydroxyl Radicals TOC Measurement: NDIR measurement of CO2 after oxidation TN Measurement: Direct photometric analysis of Nitrate after oxidation Measurement Terms: TOC (Total Organic Carbon) including Non-Purgeable Organic Carbon

(NPOC) and Purgeable Organic Carbon (POC) BioTector TIC&TOC mode measures NPOC. BioTector VOC mode measures TOC as NPOC+POC. Measured Components: TOC (NPOC) TOC (NPOC + POC) TIC TC VOC (POC) TOC as TC – TIC TN COD* BOD* * COD & BOD by correlation algorithm incorporating TOC and/or TN measured results

Cycle Time: from 7 minutes, depending on range and application

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MONITORING RANGES: TOC / TN

Standard Range 0-10mg/l up to 0-20,000mg/l Ultra High Range 0-10mg/l up to 0-40,000mg/l

Up to 3 ranges configurable for each component within each range band detailed above. A wide combination of TOC and TN monitoring ranges, including higher ranges, are available on

request.

Exceedance Tracking: Full Exceedance Tracking to Maximum Range Range Selection: Automatic or Manual Range Selection Repeatability: 3% of reading or 0.3mg/l TOC whichever is greater, 3% of reading or 0.2mg/l TN whichever is greater, with Automatic TOC TN Range Selection feature Detection Limit: 0.6mg/l TOC with Automatic Range Selection

0.4mg/l TN with Automatic Range Selection

Sodium Chloride Interference:

TOC

All Ranges None

TN**

0 – 10 mgN/l None below 5% w/v 0 – 100 mgN/l None below 6% w/v 0 – 1000 mgN/l None below 30% w/v 0 – 10000 mgN/l None below 30% w/v 0 – 100000 mgN/l None below 30% w/v

** The sodium chloride interference figures are range dependent and are typically defined for 0.5mm path length TN measuring cell

assuming that the TOC:TN ratio is 1.

SAMPLE & ENVIRONMENTAL CONDITIONS

Sample Volume: Up to 8.0ml Sample Inlet Pressure: Typically ambient (for applications with high sample pressure, optional

sampling systems are available) Drain Pressure: Typically ambient (for applications with high drain pressure, optional systems

are available)

Sample Inlet Temperature: 2°C – 60°C (36°F - 140°F) Sample Flow Rate: Minimum 100ml per sample Sample Particle Size: Up to 2 mm, soft particulates Ambient Temperature: 5°C – 40°C (41°F - 104°F)

Air conditioning and heating options are available.

Humidity: 5% - 85%, non-condensing Ingress Protection: IP44

Optional IP54 with air purge

System Sound: < 60 dBa

The manufacturer has a continuous research and development program. Specifications may therefore be changed without notice. For specification updates, please contact the manufacturer.

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Section 4 Introduction

4.1 BioTector Major Components

4.1.1 Analysis Enclosure

Figure 1 and table 2 below shows the major analysis enclosure components of BioTector TOC TN Analyzer.

Figure 1 BioTector analysis enclosure major components

4 5 6 7 8 1 2

3 9 10

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Table 2 BioTector analysis enclosure major components

Fan

Cooler

Ozone Generator

Exhaust Valve, MV1

Injection Valve, MV7

Purge Valve, MV51

Non-return Valve (Check Valve)

Mass Flow Controller

Ozone Destructor

Oxygen Regulator

Sample Valve (ARS Valve), MV4

Dual Cell Photometer Module (DCP Module)

NDIR CO2 Analyzer

Oxidized Sample Catch-pot/Cleaning Vessel

Acid Valve, MV6

NP Sample Valve, LV3

DI Water Valve, LV2

TN Cleaning Valve, LV1

Circulation Pump (KNF 300), P2

Multi-Component Reactor (MCR)

PFA Glass Beads Chamber

Sample Pump, P1

Acid Pump, P3

Base Pump, P4

N Pump (Nitrogen Pump), LP1

Vent

Sample Out Valve, MV5

Cleaning Valve, MV3

Zero Water Valve (Zero Calibration Valve), MV15

Manual/Calibration Valve (Span Calibration Valve), MV9

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4.1.2 Electronics Enclosure

Figure 2 and table 3 below shows the major electronics enclosure components of BioTector TOC TN Analyzer.

Figure 2 BioTector electronics enclosure major components

Table 3 BioTector electronics enclosure major components

Mains Terminals

Power Supply (for Main Board/Motherboard)

Power Supply (for Pumps and Valves)

Power PCB (Mains PCB)

Main Power Switch

Relay Terminals

4-20mA Isolators

Relay PCB

Stream Alarm Terminals & 4-20mA Terminals

Ozone PCB

Stream Expansion PCB (Auxiliary PCB)

Signal PCB

NP I/O PCB (Nitrogen Phosphorus Input/Output PCB)

RS232 Data Cable

4 5 6

7 8 10

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Figure 3 and table 4 below shows the BioTector main board (motherboard) components.

Figure 3 BioTector main board components

Table 4 BioTector main board components

Main Board (Motherboard)

Processor PCB

MMC/SD Flash Memory Card Slot

Battery (Varta, CR2430, Lithium, 3V, 285mAh)

Hazardous area analyzers may have a special battery. Contact manufacturer for details.

1 2 3

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4.2 BioTector Operation

The BioTector is designed to provide continuous online single-component (e.g. TOC) or multi-component (e.g. TOC & TN & TP) monitoring. The BioTector can operate with unfiltered samples including soft particulates up to 2 mm in diameter, and will give accurate measurements even when fats, high levels of salts and/or calcium is present in the sample.

In BioTector multi-component analyzers, the system can be configured as a;

1) TIC & TOC system to measure the Total Inorganic Carbon (TIC) and Total Organic Carbon (TOC) content of a sample. The TOC result obtained from a TIC & TOC system represents the NonPurgeable Organic Carbon (NPOC). The TIC & TOC system is the standard system for samples which does not contain any volatile organic material or for samples which contains insignificant concentration of volatile organic material.

2) TC system to measure the Total Carbon (TC) content of a sample. The TC result obtained from a TC system represents the sum of TIC, NPOC and Purgeable Organic Carbon (POC) content.

3) VOC system to measure the TIC, TOC, TC and Volatile Organic Carbon (VOC) contents of a sample by means of two analysis reactions in single reactor configuration. VOC result represents the Purgeable Organic Carbon (POC). The TOC result in a VOC system is calculated from the TC and TIC measurements as TC – TIC. Therefore the TOC result includes the VOC (POC) content of the sample. In other words, the TOC result represents the sum of NPOC and POC content.

4) TC - TIC system to measure the TIC, TC and TOC contents of a sample by means of single analysis reaction in a dual reactor configuration. The TOC result in a TC - TIC system is calculated from the TC and TIC measurements as TC – TIC. Therefore the TOC result includes the VOC (POC) content of the sample. In other words, the TOC result represents the sum of NPOC and POC content.

TC, VOC and TC-TIC configurations are system optional features. As a brief introduction, the operation of BioTector analyzers can be summarized as follows:

i. A sample liquid is brought to the analyzer by means of a peristaltic pump. The sample is injected into

the BioTector reactor chamber.

ii. A patented Two Stage Advanced Oxidation process (TSAO) oxidizes the organic material in the

sample.

iii. The carbon dioxide formed in the oxidation process is sparged and measured by a Non-dispersive

Infrared (NDIR) analyzer.

iv. The results are displayed as TIC, TOC, TC and VOC depending on system configuration.

v. The oxidized liquid is discharged and collected in a sample catch-pot and again depending on system

configuration, the Total Nitrogen and/or Total Phosphorus analysis is carried out applying direct photometric and/or colorimetric methods.

vi. The oxidized liquid collected has a pH typically less than 2. This acidic spent liquid, which has a

typical pink/light brown color, is used to wash and purge the sample tubes by running the BioTector peristaltic sample pump in reverse direction.

4.2.1 BioTector Oxidation Method

A patented Two Stage Advanced Oxidation process (TSAO), which uses hydroxyl radicals as the oxidizing agent, is used for the oxidation of the sample.

The hydroxyl radical oxidation is a powerful oxidation technology, which keeps the wetted reactor parts clean in all types of applications. The acidic oxidized liquid at the end of each reaction is used as a sample tube cleaning agent, where the sample lines are washed with an automated reverse wash cleaning cycle. BioTector self cleaning technology using hydroxyl radical oxidation together with the acidic oxidized liquid cleaning of sample lines ensures that the cleaning of the reactor and the replacement of sample tubing are not necessary.

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4.2.2 BioTector Sample Injection

The BioTector analyzes a precise volume of liquid. The Sample Pump injects a pre-programmed number of pulses (half revolutions of pump) of liquid into the reactor for each measurement and therefore the volume of liquid included in each pulse is consistent irrespective of sample source pressure.

Sample is initially drawn from the source by a peristaltic Sample Pump. In standard TIC & TOC systems, Manual/Calibration Valve is activated to isolate any stream pressure or

vacuum coming from the sample lines. Sample Pump rotates forward for 4 pulses by default to remove any pressure/vacuum within the pump tube. Sample Valve rotates 90 degrees clockwise and Sample Pump rotates forward and injects the sample directly into the reactor with the relevant number of pulses appropriate to the range. Sample Valve rotates a further 90° clockwise and the sample volume remaining within the Sample Valve is washed into the BioTector reaction chamber (reactor) by the first TIC acid injection.

In TC systems, the sample injection is carried out similar to the one described for TIC & TOC systems above but the sample volume remaining within the Sample Valve is washed into the reactor by the second base reagent injection.

In VOC systems, BioTector carries out two separate sample injections for the two analysis reactions run consecutively in a single reactor configuration. The first analysis reaction is a TC reaction and the second one is a TIC & TOC reaction. The sample injection takes place as described for the TC systems and for the TIC & TOC systems above.

In TC - TIC systems, BioTector performs two separate sample injections for the two analysis reactions run simultaneously in dual reactor configuration. The analysis reactions, which are run simultaneously, are a TC reaction and a TIC reaction.

4.2.3 BioTector Analysis Types

BioTector multi-component analyzer has typically two analysis phases, which are Oxidation Phase and Liquid Phase analysis. In Oxidation Phase, the sample is oxidized and the carbon contents of the sample (e.g. TIC & TOC) are measured by means of an NDIR CO2 analyzer. In Liquid Phase, the oxidized sample liquid is collected and the relevant sample constituents (e.g. TN & TP) are measured by means of a Photometer.

The Oxidation Phase analysis consists of one or more of the following analysis type options:

1. TIC & TOC Analysis

2. TC Analysis

3. VOC Analysis

4. TC - TIC Analysis

The Liquid Phase analysis consists of one or more of the following analysis type options:

1. TN Analysis

2. TP Analysis

Figure 4 shows the typical oxidation phase analysis (TIC & TOC) layout of a TOC TN analyzer.

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Figure 4 BioTector TOC TN Analyzer oxidation phase analysis layout

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4.2.3.1 TIC & TOC Analysis

1. An unfiltered sample is injected into the BioTector reaction chamber (reactor).

2. An acid reagent is added and the oxygen carrier gas flow is activated to remove the inorganic carbon. The carbon dioxide gas is sparged by the addition of the acid reagent and is carried by the oxygen carrier gas and measured with a nondispersive infrared (NDIR) CO2 analyzer. The result is displayed as Total Inorganic Carbon (TIC). This reaction phase is called TIC phase.

3. Ozone generator is activated. A base reagent is injected and the sample is then oxidized with hydroxyl radicals, a strong oxidizing agent, which is generated by exposing high pH reagents to ozone. This reaction phase is called Base Oxidation phase. The complete oxidation of organic compounds takes place and carbonates are formed.

4. After the Base Oxidation phase, the carbonates are sparged in the form of carbon dioxide gas by the addition of an acid reagent. The carbon dioxide gas is carried by the oxygen carrier gas and measured with the NDIR CO2 analyzer. The result is displayed as Total Organic Carbon (TOC). This reaction phase is called TOC phase. The TOC result obtained from the TIC & TOC analysis type represents the Non-Purgeable Organic Carbon (NPOC).

5. At the end of the reaction, the oxidized sample liquid is discharged from the reactor with increased oxygen flow.

4.2.3.2 TC Analysis

1. The oxygen carrier gas flow and the ozone generator are activated. Base reagent is injected into the reactor and hydroxyl radicals are generated by exposing the base reagent to ozone. This reaction phase is called Pre-Oxidation.

2. The oxygen carrier gas flow is stopped and an unfiltered sample is injected into the reactor of the BioTector.

3. While there is no carrier gas flow, the volatile organic content of the sample is oxidized with hydroxyl radicals. This reaction phase is called VOC Oxidation, as the oxidation of volatile matter is achieved without being sparged.

4. When the VOC Oxidation phase is complete, the oxygen gas flow and the ozone generator is activated and the remaining Non-Purgeable Organic Carbon (NPOC) content in the sample is oxidized by the hydroxyl radicals in Base Oxidation phase. The complete oxidation of organic and inorganic compounds takes place and carbonates are formed.

5. When the oxidation processes are completed, the carbonates are sparged in the form of carbon dioxide gas by the addition of an acid reagent. The carbon dioxide gas is carried by the oxygen carrier gas and measured with the NDIR CO2 analyzer. The result is displayed as Total Carbon (TC). The TC result obtained from the TC analysis type represents the sum of TIC, NPOC and Purgeable Organic Carbon (POC):

TC = TIC + NPOC + POC

6. At the end of the reaction, the oxidized sample liquid is discharged from the reactor with increased oxygen flow.

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4.2.3.3 VOC Analysis

BioTector Volatile Organic Carbon (VOC) analysis type is a combination of TC analysis followed by a TIC & TOC analysis. The VOC result obtained from the VOC analysis type represents the Purgeable Organic Carbon (POC) content of the sample. When both TC and TIC & TOC analysis are complete, the flowing data is available:

 TC result, as measured and displayed from the TC analysis.  TIC result, as measured and displayed from the TIC & TOC analysis. TOC in TIC & TOC analysis

represents the NPOC.

 TOC result including the VOC, which is calculated from the difference between the TC and TIC:

TOCv = TC – TIC The TOC result displayed in VOC analysis type includes the purgeable organic element in the sample. In other words the TOC result displayed is the TOC including VOC, which is the sum of NPOC and POC:

TOCv = NPOC + POC

 VOC (POC) result, as calculated from the difference between the measured TC, from the TC

analysis, and the sum of measured TIC and measured TOC (NPOC), from the TIC & TOC analysis:

VOC (POC) = TC – (TIC + NPOC) The NPOC, as measured from the TIC & TOC analysis, is not displayed, it is only used to calculate the VOC (POC) element in the sample. All displayed results can be programmed in the system and sent as 4-20mA output to an external device.

BioTector analysis types are optional features. In order to be able to utilize VOC analysis type in BioTector, the system must be built with this option. For instance, a system built with TIC & TOC analysis option only cannot be used for VOC analysis type. For VOC analysis to be possible in a TIC & TOC system, mechanical changes and modifications in the system configuration will be required.

BioTectors built with the VOC analysis option can be programmed on site to operate with the TIC & TOC only or TC only analysis types.

BioTector analysis types are optional features. In order to be able to utilize TC analysis type in BioTector, the system must be built with this option. For instance, a system built with TIC & TOC analysis option only cannot be used for TC analysis type. For TC analysis to be possible in a TIC & TOC system, mechanical changes and modifications in the system configuration will be required.

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4.2.3.4 TC - TIC Analysis

BioTector TC - TIC analysis type is a combination of TC analysis and TIC analysis, which are run simultaneously with two separate sample injections, in two different reactors (TC reactor and TIC reactor).

2. The oxygen carrier gas flow is stopped and an unfiltered sample is injected into the TC reactor with the base reagent.

3. While there is no carrier gas flow, the volatile organic content if the sample is oxidized with hydroxyl radicals. This reaction phase is called VOC Oxidation, as the oxidation of volatile matter is achieved without being sparged.

4. While the VOC Oxidation takes place in the TC reactor, an unfiltered second sample is injected into the TIC reactor of the BioTector.

5. An acid reagent is added into the TIC reactor and the oxygen carrier gas flow is activated to remove the inorganic carbon. The carbon dioxide gas is sparged by the addition of the acid reagent and is carried by the oxygen carrier gas and measured with an NDIR CO2 analyzer. The measured result is displayed as TIC.

6. When both TIC phase and the VOC Oxidation phase are complete, the oxygen gas flow is activated and the remaining Non-Purgeable Organic Carbon (NPOC) content of the sample in the TC reactor is oxidized by the hydroxyl radicals during the Base Oxidation phase. The complete oxidation of organic and inorganic compounds takes place and carbonates are formed.

7. When the Base Oxidation phase is completed, the carbonates are sparged in the form of carbon dioxide gas by the addition of an acid reagent. The carbon dioxide gas is carried by the oxygen carrier gas and measured with the NDIR CO2 analyzer. The result is displayed as TC. The TC result obtained from the TC analysis type represents the sum of TIC, NPOC and POC:

TC = TIC + NPOC + POC

8. When the TIC and TC analysis reactions are completed, both oxidized sample liquid in the TC reactor and the sample inside the TIC reactor are discharged from the system with increased oxygen flow.

TOC result including the VOC (POC) is calculated from the difference between measured TC and TIC results:

TOCv = TC – TIC As in the VOC systems, the TOC result displayed in TC - TIC systems includes the purgeable organic element in the sample. In other words the TOC result displayed represents the sum of NPOC and POC:

TOCv = NPOC + POC

BioTector analysis types are optional features. In order to be able to utilize TC - TIC analysis type in BioTector, the system must be built with this option. For instance, a system built with TIC & TOC, TC or VOC analysis options cannot be used for TC TIC analysis type. For TC - TIC analysis type to be possible in such systems, mechanical changes, modifications in system configuration and system software will be required.

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4.2.3.5 TN Analysis

In BioTector, the Total Nitrogen (TN) analysis does not require an additional oxidation cycle because BioTector’s oxidation process breaks down all bound, organic and free nitrogen compounds present in the sample into Nitrate (NO

), which exists as an ion in the oxidized sample liquid in the BioTector reactor.

1. The oxidized sample liquid is discharged from the reactor and collected in the oxidized sample catchpot/cleaning vessel. See figure 5, which shows the typical liquid phase analysis layout of a TOC TN analyzer.

2. This oxidized sample is brought to the Dual Cell Photometer Module (DCP Module) and placed into the TN Measuring Cell by the Nitrogen Pump (N Pump). The DCP Module consists of a TN Measuring Cell, a Xenon Flash Lamp light source, two light beam splitters, two detectors and two optical filters. See figure 6, which shows the layout of the DCP Module below.

3. The Xenon Flash Lamp is turned on. Two of the detectors, which are the signal and the reference detectors, are used during the TN measurement. The primary TN measurement is carried out at 217nm (signal wavelength), where NO

absorbs UV light. In addition to the primary measurement, a secondary reference measurement is carried out at 265nm (reference wavelength). The measured TN result is displayed and sent as a 4-20mA output.

4. When the TN measurement is completed, the oxidized sample is pumped back into the Oxidized Sample Catch-Pot/Cleaning Vessel. The oxidized sample liquid is used as a sample tube cleaning liquid during the Reverse Wash Cleaning Cycle.

5. At regular intervals, an automatic cleaning of the TN Measuring Cell, chambers and lines are carried out, using the TN Cleaning solution. When the TN cleaning cycle is completed, deionised water (DI Water) is used to wash the cleaned chambers and lines.

6. At regular intervals, an automatic reference reading on DI Water is also carried out at the same signal and reference wavelengths used for the TN measurement.

BioTector analysis types are optional features. In order to be able to utilize TN analysis type in BioTector, the system must be built with this option. For instance if a system is built with the TIC & TOC and TN analysis options, this system cannot be used to measure the TC and VOC content of the sample. In order to measure any additional parameters in a system, mechanical changes and modifications in system configuration and software will be required.

Page 48

Figure 5 BioTector TOC TN Analyzer liquid phase analysis layout

Figure 6 BioTector TN Dual Cell Photometer Module

Page 49

Section 5 Installation

5.1 Basic System Requirements

Power and Signal Requirements

 Mains Connection: 115V AC, 60Hz or 230V AC, 50Hz (10%)  Mains Wire Specification: Number of Cores = 3

Current Rating minimum = 10 Amps CSA (Cross Sectional Area minimum) = 1.50mm

 Signal Wire Specification: Number of Cores = 10 (+2 cores per additional signal)

Current Rating minimum = 1 Amp CSA (Cross Sectional Area minimum) = 0.22mm

 Power Consumption: Maximum 300 W (VA)  Electrical Connections: Typically 5 cable glands, PG13.5, clamping range 6 - 12 mm

Carrier Gas and Reagent Requirements

Carrier Gas (Oxygen) Requirements

 Oxygen Quality: Oxygen, free of CO2 , CO, Nitrogen, Hydrocarbons and Water

Typical oxygen purity in the cylinder is greater than >99.5% Typical oxygen purity from the concentrator is 93% (±3%) with balance gas Argon

 Oxygen Supply Pressure: Option A: 1250-2000 mbar from the oxygen concentrator with

instrument air

Option B: Depending on the type, from 550 mbar to 750 mbar from

the oxygen concentrator with compressor

Option C: 1000 mbar from the welding grade oxygen cylinder

 Oxygen Usage: 22 L/hour (367 ml/min) average

Reagent Requirements

 1.8 N Sulfuric Acid (H2SO4),  1.2 N Sodium Hydroxide (NaOH),  0.04 N Hydrochloric Acid Solution (HCl Water for FMI Heavy Duty Circulation Pump systems only),  TN Cleaning Solution (a mixture of 0.5 N Hydrochloric Acid and 0.042 M Sodium Oxalate),  Deionised Water (DI Water).

Sample, Drain and Exhaust Requirements

 Sample Inlet & Outlet Pressure: Ambient  Sample Inlet Temperature: 2°C – 60°C (36°F - 140°F)  Sample Flow Rate: Minimum 100ml per sample  Sample Particle Size: Up to 2 mm Ø, soft particulates  Drain & Exhaust: Ambient

Page 50

5.2 Unpacking and Installation

The BioTector analyzer weighs more than 100kg (220lb). Therefore, appropriate precautions are required for unpacking and installing the BioTector.

The BioTector analyzer is shipped ready to be installed, with a kit of parts including sample tubes, reagent tubes and a selection of spare parts, spare fuses and ferrules.

When the BioTector shipping container is opened, it must be inspected against the shipping list located inside the container. Additionally, it should be confirmed that no damage was caused to the BioTector during shipment.

Any issues must be reported to the manufacturer within 3 days. The BioTector is shipped with a Commissioning and Startup checklist (see Section 7 Analyzer Commissioning

and Startup for details). In order to ensure a quick and trouble free installation, this list should be followed in the correct sequence.

Points to note regarding installation:

 The BioTector should be located as close to the sample point as possible.  The BioTector has an Ingress Protection rating of IP44. It is recommended that the BioTector is

installed in a dry, well ventilated and dust free area.

 The BioTector should be installed where the ambient temperature is between 5 and 40°C. If the

ambient temperature exceeds 40°C, a vortex cooler can be installed to reduce the internal temperature of the BioTector.

 The BioTector should be installed vertically, with the maximum variation on each axis less than 2°.  Ensure that there is enough clearance at the front of the BioTector to allow the door to be opened.  Ensure that there is enough clearance at the right hand side of the BioTector for the tube and

electrical connections. There should be enough clearance at the left hand side for the cooling fan to operate unimpeded.

If there are corrosive gasses in the area, then the BioTector fan should be blanked off, and an instrument air purge system should be fitted.

Caution

Page 51

5.2.1 Analyzer Dimensions and Mounting

The BioTector TOC TN analyzer enclosure is a dual compartment Fiberglass Reinforced Polyester (FRP) cabinet. This enclosure facilitates easy access to all components and thus eases the service and maintenance procedures. Figure 7 and table 5 below gives the dimensions of various BioTector enclosures.

Figure 7 BioTector Dimensions

Page 52

Table 5 Various BioTector Dimensions

Dimension A

Dimension B

Dimension C

Dimension D

BioTector TOC TN Analyzer

500mm

750mm

1025mm

1250mm

BioTector TOC TN Analyzer with integral oxygen concentrator

750mm

1150mm

1500mm

BioTector TOC TN Analyzer with extended lower enclosure

500mm

1000mm

1275mm

1500mm

BioTector TOC TN Analyzer with integral oxygen concentrator and extended lower enclosure

750mm

1000mm

1400mm

1750mm

Figure 8 below illustrates the BioTector door clearance dimensions.

Figure 8 BioTector Door Clearance Dimensions

 When BioTector is being mounted on a wall or a stand, the support has to be strong enough to carry

typically four times of the weight of BioTector (~400 kg).

 The BioTector should be lifted applying a safe method in accordance with local regulations.  The minimum size of the bolts used to hold the BioTector in place should be M8.

Page 53

5.2.2 Wiring Power and Signal Terminals

Figures 9 and 10 below show the typical mains connections for both 230 and 115 volts systems respectively and the 4-20mA signal connections in BioTector. The connection to mains power {230V or 115V AC (10%), 50/60 Hz} should be carried out by a certified electrician, in accordance with site regulations. The mains wire specifications are 3 cores, 10 Amps minimum current rating and 1.50mm2 minimum CSA (Cross Sectional Area). The mains cable should be screened and screen earthed to comply with the Electromagnetic Compatibility Directive (2004/108/EC).

For 4-20mA and any other signal connections, only screened instrument cable, which comply with the EEC directive, should be used. The signal cable should also be screened, and the screen earthed. The specifications for the signal wire are 10 cores (+2 cores per additional signal), 1 Amp minimum current rating,

0.22mm2 minimum CSA (Cross Sectional Area).

Figure 9 Mains and 4-20mA terminal diagram for 230 V systems

BioTector contains electrical components operating under high voltages. Contact may result in electric shock and severe or fatal injury.

DANGER

Page 54

Figure 10 Mains and 4-20mA terminal diagram for 115 V systems

The wiring and earth connections to the analyzer should be carried out in accordance with local regulations, and securely terminated in the phase, neutral and earth terminals in the BioTector. Cable glands must be used to secure the cables when necessary.

All electrical, sample, reagent, drain and exhaust connections should be carried out in accordance with the technical specifications and drawings given in this manual. Errors as a result of non-conformity to these specifications will not be covered by the warranty.

Page 55

5.2.3 Wiring External Power Disconnection Switch

The mains power must be connected through an external 2-pole disconnection switch, so that the power to the analyzer can be isolated without opening the electronics enclosure.

 The external power disconnection switch must be located in an easily accessible location, with a

maximum distance of 2 meters from the analyzer.

 The switch must be clearly marked for its purpose.  The switch must comply with local electrical regulations, and have a breaking capacity of 10 Amps or

greater.

Figure 11 below illustrates the positioning and the installation of the disconnection switch. Figure 11 External Power Disconnection Switch

When the wiring of the system is completed, the power up of the system should be carried out in the order below:

i) While the external disconnection switch is powered off, power on the internal MCB

(miniature circuit breaker) in the BioTector. ii) Close BioTector electronics enclosure. iii) Switch on the external disconnection switch.

The power off of the BioTector should be carried out by switching off with the external disconnection switch followed by the internal MCB.

Page 56

5.2.4 System Fuse Specifications

Table 6 below summarizes the location and specification of the fuses used in BioTector. The locations of the fuses are also displayed in figures 9 and 10 above.

Table 6 System Fuse Specifications

230 V

Systems

115 V

Systems

Location

Name

PCB ID

Number

Interrupt

Rating

Type

Material

Fuse

Number

Current

Rating

Current

Rating

Power PCB

(Mains PCB)

81204030-02

H-250V

Miniature

5x20mm

Ceramic

T 1.25A

T 2.50A

T 500mA

T 1.00A

T 1.60A

T 2.50A

T 2.00A

T 3.15A

T 500mA

Relay PCB

81204001-01

L-250V

Miniature

5x20mm

Glass

T 2.50A

T 500mA

T 1.00A

T 500mA

T 1.00A

Stream

Expansion

PCB

81204040-02

L-250V

Miniature

5x20mm

Glass

T 1.00A

Signal PCB

81204010-02

L-250V

Miniature

5x20mm

Glass

T 1.00A

T 500mA

Main Board

(Motherboard)

81204022-02

L-250V

Miniature

5x20mm

Glass

T 500mA

Cooler DIN

Rail

Terminal 47

L-250V

Miniature

5x20mm

Glass

T 2.5A

24V DC

Circulation

Pump DIN

Rail

Terminal 42

L-250V

Miniature

5x20mm

Glass

T 2.5A

NP I/O PCB

(TNTP Board)

81204290-01

L-250V

Miniature

5x20mm

Glass

T 630mA

T 1.00A

KEY A: Amperes DIN: German Institute for Standardization (Deutsches Institut für Normung e.V.)

F: Fuse H: High Interrupt ID: Identification L: Low Interrupt

mA: Milli-amperes PCB:Printed Circuit Board T: Time Lag (Time Delay) V: Volts

BioTector contains electrical components operating under high voltages. Contact may result in electric shock and severe or fatal injury.

All electrical work should be carried out by qualified electrical personnel only. When any fuse replacement is required in the system, please refer to table 6

below.

DANGER

Page 57

5.3 Carrier Gas and Reagent Connections

The orientation of the ferrules inside each fitting of BioTector is critical for the correct operation of the system. Incorrect ferrule orientation may create gas/liquid leak and/or introduce air bubbles into the system lines. Therefore, the ferrules on all carrier gas, reagents, drain, exhaust and vent fittings have to be fitted with the correct orientation. Failure to do so will have an impact on the system operation and analysis responses.

Figure 12 shows the fitting side and the nut side of SS-316 (stainless steel), PFA and PVDF fittings and their corresponding correct ferrule orientation.

Figure 12 The correct ferrule orientation of SS-316, PFA and PVDF fittings on BioTector

When tightening brand new stainless steel fittings, first fully insert the tube into the fitting, tighten the nut initially finger tight, then tighten a further 1¼ turns using an appropriate size spanner or an adjustable wrench. Stainless steel fittings used on 1/8” PFA tubing should be tightened only a further ¾ turns after finger tight. When re-tightening stainless steel fittings, which were already tightened during reassembly or after service, initially tighten the nut up to the point it was tightened previously, then tighten slightly more using an appropriate size spanner or an adjustable wrench.

When tightening brand new PFA fittings, first fully insert the tube into the fitting, tighten the nut initially finger tight, then tighten a further ½ turn using an appropriate size spanner or an adjustable wrench. When retightening PFA fittings, which were already tightened during reassembly or after service, initially tighten the nut up to the point it was tightened previously, then tighten slightly more using an appropriate size spanner or an adjustable wrench.

Page 58

5.3.1 Carrier Gas Connection

The recommended carrier gas for BioTector is Oxygen (O2), free of Carbon dioxide (CO2), Carbon monoxide (CO), Nitrogen (N2), Hydrocarbons and Water. In BioTector TOC TN analyzers, the carrier gas has to be Nitrogen free Oxygen gas.

The oxygen gas can be supplied to BioTector from;

A) An oxygen concentrator with instrument air B) An oxygen concentrator with compressor C) A welding grade oxygen cylinder

Typical oxygen purity in the oxygen concentrator is 93% (±3%) with balance gas Argon. Typical oxygen purity in the oxygen cylinder is greater than >99.5%.

When welding grade oxygen cylinder is used, a 50 liter oxygen cylinder is recommended. The oxygen cylinder should be installed in accordance with site regulations and/or your oxygen supplier's recommendations. The cylinder should be well secured. Before connecting the pressure regulator, check that there is no moisture, dirt or grease at the connection. Connect the pressure regulator according to the manufacturer's specifications.

The oxygen supply pressure to the analyzer is typically;

A) 1250-2000 mbar from the oxygen concentrator using instrument air B) Depending on the type, from 550 mbar to 750 mbar from the oxygen concentrator with compressor

C) 1000 mbar from the welding grade oxygen cylinder BioTector uses an average of 22 L/hour (367 ml/min) oxygen during online operation. Figure 13 below illustrates the three options for oxygen supply: A) Oxygen concentrator with instrument air, B)

Oxygen concentrator with compressor and C) Welding grade oxygen cylinder.

Do not allow oxygen to come in direct contact with grease, oil, fat and other combustible materials, as it may explode. If uncertain how to handle oxygen cylinders or high concentration oxygen, contact your local oxygen dealer.

Oxygen generators or cylinders can be supplied by BioTector distributors as an extra option.

WARNING

Page 59

Figure 13 BioTector oxygen supply options

Page 60

5.3.2 Reagent Connections

Special precautions are needed when working with chemical reagents, both when renewing reagents and when dealing with leaks or spills. Some reagents can cause chemical burns and may cause injury or death if swallowed. Please refer to the symbols and codes on the reagent containers.

Use of 25 liter containers is recommended for each BioTector reagents. Figure 14 below shows the setup and typical connection ports of BioTector TOC TN analyzer reagents: Acid (1.8N Sulfuric Acid), Base (1.2N Sodium Hydroxide), TN Cleaning Solution, DI Water, and Zero Water (DI Water for Zero Calibration). See Section 6 Reagents and Calibration Standards for further details.

Figure 14 BioTector reagent setup and connections

DANGER

Page 61

As can be seen in the figure 14 above, unlike all other reagents, base reagent container does not contain any vent (breathing) hole. The breathing air into the base container is supplied through the CO2 filter, which must be fitted on the base container lid.

Figure 15 below shows the detailed connections on BioTector base reagent. The purpose of the CO2 filter is to prevent the base reagent coming in contact with atmospheric CO2 present in the air. The soda lime inside the CO2 filter absorbs the atmospheric CO2 and prevents the base reagent getting contaminated. If any vent hole is accidentally drilled on the lid of the base container and if the fittings are not connected correctly on the base reagent, contamination will occur and the background CO2 readings will increase.

Figure 15 BioTector base reagent dip tube setup

All other reagent containers’ (except the base reagent container) lids must contain a 3mm vent hole. Failure

to do so may cause the container to collapse and leak. The length of the dip tubes in all reagent containers should be adjusted correctly for the optimum usage of the

reagents. Stainless steel (SS-316) weights should not be used in any reagent which contains HCl acid (e.g. TN Cleaning Solution). The recommended weights for such reagents are PFA.

Page 62

5.4 Sample, Drain and Exhaust Connections

5.4.1 Sample Inlet Tube Position

BioTector operates on unfiltered samples, the setup of the sampling point is important for the correct operation of the system. BioTector can handle soft particulates up to 2mm in diameter, however hard particulates (e.g. sand) will damage the analyzer and should be removed from the sample. The vertical distance between the water surface at the sample intake and the bottom of the BioTector enclosure can be up to 4 meters. The overall length of the sample tube is typically 4 meters. BioTector in fact can draw samples from distances greater than 4 meters however, such distances may have an impact on the Sample Pump tubing life. The point where the sample is taken from should not be pressurized. The sample inlet and outlet should be at ambient pressure. The sample temperature should be between 2°C and 60°C (36°F - 140°F). The minimum sample flow rate is 100ml per sample. The sample bypass tube should be placed to a well ventilated area at ambient pressure and it should not be subjected to any back pressure as this may result in measurement errors. Figure 16 below illustrates the correct positioning of the BioTector sample tube in various/optional sampling systems.

Figure 16 BioTector sample tube position in various sampling systems

For the fittings to remain leak proof, they must be kept clean and should not be over tightened. Over tightening of the fittings will damage them and cause eventual leakage.

Caution

Page 63

Page 64

5.4.2 Drain, Bypass and Exhaust Connections

The BioTector should be installed in a well-ventilated area with the exhaust port piped to an external vent. The installation should be carried out in accordance with Section 1 Safety Precautions.

All BioTector drain tubing must be positioned correctly so that any liquid pumped will drip freely into a larger drain chamber. The correct positioning and setup of the drain ports prevent liquid accumulation and measurement errors. All drain ports should be directed to a well ventilated area as oxygen and other gases may be released during the analysis. The drain tubes should be at atmospheric pressure and should not be subjected to any back pressure as this may result in measurement errors. The exhaust tube should be piped out to a well ventilated area as oxygen and other gases will be released during the analysis. The end of this tube should be positioned in a downward position so that water condensation and freezing will not occur during winter months. Figure 17 illustrates BioTector drains, sample bypass and exhaust connections.

The PVC-U drain pipe, installed outside the BioTector, is supplied for convenience. PVC-U is a durable material, which survives in environments containing acids, caustics, oxidizing agents etc. However, if the sample contains specific high concentration solvents such as Benzene, Toluene etc., it is recommended to check the compatibility of PVC-U tubing against the specific organic solvents present in the sample. If necessary, the drain pipe can be replaced with an alternative pipe. If such change is carried out, it is important that the sample bypass port is connected to the new pressure free drain pipe at the same height with the original pipe.

Figure 17 BioTector drain, sample bypass and exhaust connections

WARNING

Page 65

Section 6 Reagents and Calibration Standards

6.1 Reagents

BioTector TOC TN analyzer uses following reagents:

I. Acid: 1.8 N Sulfuric Acid (H2SO4) Reagent containing 40mg/l Manganese Sulfate Monohydrate

II. Base: 1.2 N Sodium Hydroxide (NaOH) Reagent

III. TN Cleaning: 0.5 N HCl and 0.042 M Sodium Oxalate (NaOx) mixture solution

IV. DI Water: Deionized Water (0.1 – 0.5 µS/cm)

BioTectors built with FMI Heavy Duty Circulation Pump require HCl Water, which is 0.04N Hydrochloric Acid solution. If there is no HCl WATER IN/OUT ports on BioTector, HCl Water solution is not required. Reagents should not contain high levels of organics, nitrates and phosphates. Ideally, the level of organics, nitrate and phosphate should be less than 100 g/l (ppb) in the deionized water used to prepare TOC TN analyzer reagents. Phosphoric acid or Nitric acid cannot be used as an alternative acid in BioTector TOC TN analyzer.

Acid, Base and HCl Water reagents are stable up to 1 year. TN Cleaning solution is stable up to 2 years. Table 7 below summarizes the total days each BioTector TOC TN Analyzer reagents lasts at various system configurations:

Table 7 BioTector TOC TN Analyzer Reagent Consumption

TOTAL DAYS REAGENT LASTS

REAGENTS

Container Size

(Liters)

Low Ranges*

( < 500 mgC/l)

(15 pulses) +

Medium Ranges*

(500 – 2000 mgC/l)

(23 pulses) +

High Ranges*

( > 2000 mgC/l)

(31 pulses) +

Acid

Base

TN Cleaning

657

DI Water

193

*Low Ranges are typically less than 500 mgC/l. Medium Ranges are between 500 and 2000 mgC/l. High Ranges are typically greater than 2000 mgC/l.

The number of pulses acid and base reagents is injected every analysis cycle.

Above table is derived from several online operation parameters such as 100% online time. Note that TN Cleaning, DI Water and HCl Water consumptions are independent of BioTector range. A 10 liters HCl Water solution container typically lasts 38 days.

Recommended bunds (reagent spill trays) to contain above quantity reagents are 1x 50 Liters and 1x 25 Liters. If HCl Water solution is used, instead of the 25 Liters reagent spill tray, a 50 Liters tray is recommended.

Page 66

6.2 Calibration Standards

The following compounds can be used to prepare calibration standard solutions in BioTector.

To prepare a 1000mgC/l Total Organic Carbon (TOC) standard solution, use one of the following:

 Potassium Hydrogen Phthalate, C8H5KO4, 2.13g (99.9% purity) in one liter of deionised water. Water

solubility: 80 g/L at 20°C.

 Acetic acid, C2H4O2, 2.51g (99.8% purity) in one liter of deionised water. Water solubility: Miscible in

all proportions.

 Glucose, C6H12O6, 2.53g (99% purity) in one liter of deionised water. Water solubility: 512g/L at 25°C.

To prepare a 1000mgC/l Total Inorganic Carbon (TIC) standard solution, use one of the following:

 Sodium Carbonate, CNa2O3, 8.84g (99.9% purity) in one liter of deionised water.

 Sodium Hydrogen Carbonate, CHNaO3, 7.04g (99.5% purity) in one liter of deionised water.

 Potassium Carbonate, CK2O3, 11.62g (99.0% purity) in one liter of deionised water.

To prepare a 1000mgN/l Total Nitrogen (TN) standard solution, use one of the following:

 Nitric Acid, HNO3, 6.43g (70% purity) in one liter of deionised water.

 Cesium Nitrate, CsNO3, 14.05g (99% purity) in one liter of deionised water.

 Sodium Nitrate, NaNO3, 6.07g (99% purity) in one liter of deionised water.

All hygroscopic chemicals in crystal form should be dried in an oven set at 105°C for 3 hours to remove any traces of absorbed water. All prepared solutions must be mixed thoroughly with a magnetic stirrer or inverted manually at least ten times or until all crystals are completely dissolved inside the solution.

The quantity of concentrated chemical required to prepare stock calibration solutions will change with the % purity of the chemical used. If the purity of the chemical is different than the figures displayed above, the necessary quantity needs to be recalculated from the purity of the chemical. See example in the following page.

Depending on the system analysis ranges (see System Range Data menu), every BioTector requires specific calibration standard solutions. The required concentration of the calibration standard solutions can be identified in Span Calibration menu. As the sample pressure normalization (line equalization function) is not activated for Calibration/Manual Valve, it is recommended that the calibration standard solution flask is placed at the same height with the Sample Pump.

Caution

Page 67

The calculation of the quantities required to prepare Potassium Hydrogen Phthalate (KHP) standard solutions with various purities are given as an example below:

Name: Potassium Hydrogen Phthalate

Formula: C8H5KO4

Carbon, 12 x8 = 96 Oxygen, 16 x4 = 64 Potassium, 39 x 1 = 39 Hydrogen, 1 x5 = 5____________ Total weight = 204.22 g/mol

47% of KHP is Carbon. Purity of the KHP is 99.9%. Therefore, to prepare a 1000 mgC/l standard solution, add 2.13g of KHP in a flask and add enough deionised water to make it exactly 1 liter solution.

Note that the quantities required change with the % purity of the chemical used. Table 10 below gives the KHP quantities required at various % purity for the preparation of 1000mgC/l calibration standard.

Table 10 Quantity of KHP required to prepare 1000 mgC/l standard at various purities.

% Purity of KHP

Quantity of KHP (grams)

to prepare 1000 mgC/l Standard

100

2.127

99.9

2.129

99.5

2.138

99.0

2.149

95.0

2.239

90.0

2.364

To prepare standard solutions containing more than 1000 mgC/l, the required solvent can be mixed directly with deionised water. Table 11 below gives the required quantity of KHP for various concentration standard solutions to be mixed with deionised water and added enough deionised water to make the solution exactly 1 liter.

Table 11 Quantity of KHP required to prepare various concentration TOC standard solutions.

TOC Standard Solution

Concentration (mgC/l)

Quantity of 99.9% KHP (grams)

to be added 1 Liter DI Water

1000

2.129

1250

2.661

1500

3.194

2000

4.258

5000

10.645

10000

21.290

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Preparation of Calibration Standard Solutions:

Use eye protection and gloves.

Standards solutions greater than 1000mg/l can be prepared directly without any dilution by simply mixing the necessary quantity solvent or salt with deionised water. Standard solutions below 1000mg/l concentration should be prepared by dilution technique. First a 1000mg/l standard stock solution should be prepared, and then the required lower concentration standard solution should be prepared by applying the necessary dilution procedures:

 For example, to prepare a 50mgC/l TOC only standard solution, first weigh 50 grams of the

1000mgC/l stock standard. Add 50 grams of the 1000mgC/l standard into a one-liter flask and add enough deionised water to make the solution exactly 1 liter.

 For example, to prepare a 50mgC/l TOC and 10 mgN/l TN mixture standard, add 50 grams of the

1000mgC/l standard and 10 grams of the 1000mgN/l standard together into a one-liter flask, and add enough deionised water to make the solution exactly 1 liter.

 For increased accuracy, standard solutions below 5mg/l (ppm) concentration should be prepared with

two or more steps dilution. For example, to prepare a 1mgC/l standard, first prepare a 100mgC/l standard by adding 100 grams of the 1000mgC/l standard into a one-liter flask and by adding enough deionised water to make it exactly a 1 liter solution. Then add 10 grams of the 100mgC/l standard into a one-liter flask and add enough deionised water to make it exactly 1 liter.

 Standard solutions at μg/l (ppb) levels should be prepared with several dilution steps. For instance, a

1mgC/l (1000 μg/l) standard should be prepared with two or more steps dilution as described above.

To prepare a 50μg/l standard, add 50 grams of the 1000μg/l standard into a one-liter flask, and add enough deionised water to make it exactly 1 liter.

Shelf Life and Storage of Calibration Standard Solutions:

 TOC standards prepared from Potassium Hydrogen Phthalate is typically stable for a month once it

is kept in a closed glass container and refrigerated at 4°C.

 All other standards such as TOC prepared from Acetic Acid, TIC and TN standard solutions are

recommended to be used within 48 hours of manufacture.

Page 69

Section 7 Analyzer Commissioning and Startup

The check list below must be used to ensure that the installation has been properly carried out. Please proceed through the check list in the given order. If the BioTector analyzer is certified for hazardous areas, carefully read the hazardous area documentation supplied with the analyzer. This documentation contains important information for compliance with explosion protection regulations. Understanding this information is essential for the safe operation of the equipment.

Confirm the mains supply voltage and the frequency are correct.

_____

Connect the oxygen cylinder/oxygen concentrator to the BioTector’s OXYGEN port. Option A: The pressure on the oxygen concentrator with instrument air should be between

1250 and 2000 mbar. Option B: Depending on the type, the pressure on the oxygen concentrator with compressor should be between 550 mbar and 750 mbar.

Option C: The pressure on the welding grade oxygen cylinder should be 1000 mbar.

_____

Reconnect the tube linking the Ozone Generator to the acid TEE, at the TEE. Reconnect the tube linking the Cooler and CO2 analyzer, at the top of the Cooler. Reconnect the tubing leaving the Circulation Pump, at the discharge side of the Circulation Pump. Reconnect the tube linking the Ozone Destructor to the Exhaust Valve (MV1), at the top of the Ozone Destructor.

_____

Connect the EXHAUST port with ¼” PFA tube to a safe and well ventilated area or to open atmosphere. The tube must have no restrictions and it must be placed so that any condensation and liquid buildup in the tubing is prevented. The maximum length of ¼” PFA tubing installed in Exhaust line is 10 meters. If tubing longer than 10 meters is required, the use of a larger ID tubing or pipe is recommended.

The end of the exhaust tubing should have a slight downward slope so that any condensation or liquid at the outlet of the tubing cannot freeze at night or during cold weather.

_____

Remove the tapes, which are used to seal the ends of the supplied CO2 filter. Fit the CO2 filter to the Base container and seal the Base container tightly.

_____

Connect the Acid (1.8N H2SO4) and Base (1.2N NaOH) containers to the BioTector’s ACID and BASE ports with ¼” PFA tube. 25 liter containers are recommended.

_____

In systems built with FMI Heavy Duty Circulation Pump, connect the HCl Water solution

container to the BioTector’s HCl WATER IN port with 1/8” PFA tube. Minimum of 10 liter

containers are recommended.

_____

In systems built with FMI Heavy Duty Circulation Pump, connect the HCl WATER OUT port to a pressure free drain using the 1/8” PFA tube supplied. The tube should be fitted so that it cannot freeze in cold weather.

_____

Confirm the sample or samples are at ambient pressure. If the sample is under pressure, then the system must be designed to isolate the sample in

the event of a tube leak within the BioTector, for example a system consisting of a liquid leak detector and automatic isolation valve (this valve must be located outside the BioTector) must be installed. Note that the maximum allowed sample pressure is 500mbar.

_____ Connect the sample stream or streams to the BioTector with ¼” PFA tube. These ports are

marked SAMPLE 1…6.

_____

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If a SAMPLER has been supplied with the system, connect the sampler in accordance with the drawings and instructions in the sampler manual.

_____

Connect the PVC-U Drain Pipe (installed outside the BioTector) to a well ventilated pressure free drain using the supplied 1” braided hose.

_____

Confirm the SAMPLE OUT port is connected to the PVC-U Drain Pipe. If the PVC-U Drain Pipe is not used, connect the SAMPLE OUT with ¼” PFA tube to well ventilated pressure free drain. The tube should be fitted so that it cannot freeze in cold weather.

_____

Confirm the sample BYPASS port is connected to the PVC-U Drain Pipe. If the PVC-U Drain Pipe is not used, connect the sample BYPASS port with ¼” PFA tube to a large diameter tube, as shown in drawing 81104041. The end of the sample bypass tube should be level with the centre of the Sample (ARS) Valve. The large diameter tube should be connected to a pressure free drain. The end of the sample bypass line should not be under the surface of the water in the drain at any time. The tube should be fitted so that it cannot freeze in cold weather.

_____

If BioTector is built as a TC - TIC system, confirm the TIC DRAIN port is connected to the PVC-U Drain Pipe. If the PVC-U Drain Pipe is not used, connect the TIC DRAIN port (TIC

Sample Out port) with ¼” PFA tube to well ventilated pressure free drain. The tube should be

fitted so that it cannot freeze in cold weather.

_____

If fitted, connect ¼” PFA tube to the MANUAL or CALIBRATION ports. Remove all tapes placed around the fittings for shipment.

_____

If the BioTector is supplied as a “purge ready” system (i.e. if the BioTector is supplied without any fan

and vent ports), connect the -20°C dew point, oil, water and dust free purge air to the BioTector.

The purge air is instrument air which is typically at 100 L/min flow, and filtered with a 40 microns or smaller filter. Drill and connect the air inlet port to the top left hand side of the upper enclosure. Drill and install an air outlet port “vent” to the bottom left hand side of the lower enclosure.

_____

Additional requirements for the TN system (next 5 items):

Confirm the TN DRAIN port is connected to the PVC-U Drain Pipe. If the PVC-U Drain Pipe is not used, connect the TN DRAIN port with 1/8” PFA tube to a suitable pressure free drain. The drain must be connected so that the end of the tube is never under the surface of the liquid in the drain. The tube should be fitted so that it cannot freeze in cold weather.

_____

Confirm the TN BYPASS port is connected to the PVC-U Drain Pipe. If the PVC-U Drain Pipe is not used, connect the TN BYPASS port with 1/8” PFA tube to a suitable pressure free drain. It is recommended to keep this tubing as short as possible. The drain must be connected so that the end of the tube is never under the surface of the liquid in the drain. The tube should be fitted so that it cannot freeze in cold weather.

_____

Connect the TN Cleaning solution (consisting of a mixture of 0.5N HCl and 1000mgC/l

sodium oxalate) to the BioTector’s TN CLEANING port using 1/8” PFA tube. TN Cleaning

solution is used to clean the measuring cells and lines. A 25 liter container will last approximately 150 days.

_____

Connect Deionised Water to the BioTector’s DI WATER port using 1/8” PFA tube. DI Water is used to wash the measuring cells, and to get a DI Water reference reading at regular intervals.

_____

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Connect Deionised Water to the BioTector’s ZERO WATER port using ¼” PFA tube. The BioTector TOC TN analyzers require Zero Water to adjust the zero offset during the zero calibration cycle. This is different than the BioTector TOC analyzers, where only acid and base reagents are required. The reason is that the TN measurements are made in the liquid phase, so the makeup of the liquid must be the same for the zero calibration and online readings. Therefore, every time a zero calibration is carried out in the BioTector TOC TN analyzer, Zero Water must be connected. . Failure to do so may have an impact on system zero response and the analysis results. The deionised water usage is <500ml per zero calibration cycle.

_____

Check the electrical connections within the BioTector.

_____

In systems built with FMI Heavy Duty Circulation Pump, insert the fuse for the Circulation Pump on the Power PCB (Mains PCB).

_____

Reconnect the tube rails/tubing for the Sample, Acid and Base Pumps. Reconnect the tube rails/tubing for the Nitrogen Pump (N Pump).

_____ Check the Swagelok/PFA tube connections within the BioTector.

_____

Power up the analyzer. Go to Operation, Time & Date menu and adjust the time and the date.

_____

Using the Simulate, Oxidation Phase Simulate menu, check the following:

Check the purity of Oxygen: Turn on the oxygen concentrator or the oxygen supply if a cylinder is used. When an oxygen concentrator is used, let the concentrator run for at least 10 minutes before the oxygen purity test is carried out.

In the Simulate menu, test the oxygen purity by turning on the MFC with a setting of 10 l/hr, and flowing gas through the CO2 analyzer for 5 minutes. At the end of this period, the CO2 analyzer zero reading should be within ± 0.5% of full scale of the CO2 analyzer range, which is typically ± 50ppm CO2. Record the CO2 analyzer zero reading.

If the CO2 analyzer zero reading is outside the specifications, confirm that there is no CO2 in the oxygen by connecting the CO2 filter (used with the base container) between the oxygen source and BioTector oxygen inlet and set the MFC to 10 l/h in the same Simulate menu. As the size of the CO2 filter is small, keep the 10 l/h gas flow running for at least for 5 minutes and record the CO2 readings at the end of the 5 minute period. If the CO2 readings do not drop significantly with the CO2 filter in place, this will indicate that there is no CO2 contamination in the oxygen supply.

_____

Check that the peristaltic pumps are pumping correctly. The pump rate measurements are used to confirm that the correct tubing has been installed in the appropriate pump. Any variation between tube batches is corrected when the zero and span calibration is carried out. The pump rates can be measured by supplying DI Water or tap water to the pump at the inlet port using a small container.

Confirm the Acid Pump is pumping correctly by removing the fitting at the pump outlet port and using a 10ml graduated cylinder (at 20 pulses, the measured volume should be between

3.9ml and 4.9ml in ~13 seconds).

_____

Confirm the Base Pump is pumping correctly (at 20 pulses, the measured volume should be between 3.9ml and 4.9ml in ~13 seconds).

_____

Important Note: For the correct operation of the system, the measured Acid and Base Pump rates must be identical or as close as possible. The maximum allowable difference in the measured volumes for acid and base injections above is typically 5% or ~0.2ml. This figure is based on standard system operation conditions and may not cover systems built with specific configurations.

Page 72

Confirm the HCl Water Pump (if fitted for FMI Circulation Pump) is pumping correctly. The pump rate should be between 8.5ml and 11.5ml in ~18 seconds.

_____

Confirm the WMM60 Sample Pump is pumping correctly. The pump rate at 16 pulses should be between 5.5ml and 7.5ml in ~8 seconds.

_____

Confirm that the Exhaust, Sample Out, TOC Acid and Base Valves are working. Note that the Base Valve is optional.

_____

Confirm that the Sample (ARS) Valve is working.

_____

Confirm the MFC is working and pressure on the BioTector oxygen regulator is 350 mbar at 20 l/hr.

_____

Additional requirements for the TN system (next 2 items): Using the Simulate, Liquid Phase Simulate menu, check the following:

Confirm the WMM60 Nitrogen Pump (N Pump) is pumping correctly. The pump rate at 16 pulses should be between 6.5ml and 7.5ml in ~8 seconds. The pump rate can be measured by supplying DI Water or tap water to the pump at the inlet port using a small container.

_____

Confirm that all installed valves in the TN system are operating correctly, using the Liquid Phase Simulate menu.

_____

Go to Operation, Reagents Setup, Install New Reagents menu, confirm the menu items and select the “START NEW REAGENT CYCLE” function for the system to prime the reagents and set the Zero Adjust (zero offset) values automatically.

_____ Confirm that the automatic pressure/flow test is passed when analyzer is started up.

_____

When the Zero Calibration cycle is completed, go to Operation, Start Stop menu and stop the analyzer. Run 5 reactions on DI Water using the manual sample port. If manual port is not available, use the input point for stream 1, but first set the Sample Pump REVERSE time to 0 seconds in Sample Pump menu. Confirm that the zero response is correct. If the BioTector

has been in storage for a long period, a second “Install New Reagents” cycle may be

required.

_____

If the zero readings and CO2 peaks are correct, items from 1 to 6 below can be skipped.

_____

Confirm that the pH in the reactor is correct, using the test sequence in the pH Test menu. See pH Test section in BioTector user manual for details.

_____

Check for a pH of 0 during the TIC phase.

_____

Check for a pH of 14 during the Base Oxidation phase.

_____

Check for a pH of 0 during the TOC phase.

_____

Run a further 2 reactions on DI Water.

_____

Run an “Install New Reagents” cycle on the system to adjust the zero offset.

_____

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Using the Commissioning menus, follow below procedures:

In Reaction Time menu, program the INTERVAL time depending on the required sample analysis frequency.

_____

In Sample Pump menu, confirm that the Sample Pump FORWARD and REVERSE times are correct. In order to test the Sample Pump forward and reverse times, go to Process Test, Sample Pump Test menu and select the PUMP FORWARD TEST and PUMP REVERSE TEST. Sample Pump times can be set individually for each stream in Sample Pump menu. Adjust the Sample Pump FORWARD times and confirm that sample liquid coming from each stream bypasses the system and drips into the drain pipe on the side of the BioTector.

If the SAMPLER is used, then the default sampler time is 100s. This default time must not be changed unless the time programmed in the PLC of the sampler is also changed. See sampler user manual for details.

_____

In Stream Program menu, set the required multi-stream parameters (stream operation sequence, number of reactions to run at each stream and operation range for each stream). Automatic range change function should not be used in multi-stream systems.

_____

In COD/BOD program menu, if COD and/or BOD parameter is required, program DISPLAY with the required parameter. Install the necessary STREAM and TOC, TN, NO3 FACTORS for each stream. If required, the factors for each stream can be obtained following the procedures described in information sheet “I030. TOC to COD or BOD Correlation Method”.

_____

In Reagents Monitor menu, if required, activate/deactivate the reagent monitoring function, program the reagent volumes and set the relevant reagent warnings.

_____

In Autocal Program menu, if required, program the automatic zero and span calibration cycles.

_____

In 4-20ma Program menu, set the required parameter for each stream and set the full scale of each 4-20mA channel. In order to program the correct full scale of each 4-20mA channel, see System Range Data screen and Stream Program menu.

_____

In Relay Program menu, if installed, set the required ALARM levels for each stream. Set the required idle state and the fault conditions of the COMMON FAULT relay.

_____

In Data Program menu, if required, program the relevant configuration parameters for the specific output device communication port.

_____

Program the concentration(s) of the standard solution in the Span Calibration menu (see Section 2.2 Calibration Menu). The concentration of the calibration standard used must be typically greater than 50% of the full scale of the RANGE the calibration is carried out. In order to see BioTector calibrated ranges, see System Range Data screen. (To prepare a

standard solution, see procedures described in Section 6 Calibration Standards or information sheet “R009. Standard Solutions for BioTector Multi-component Analyzer”.)

_____

Connect the standard solution to the MANUAL/CALIBRATION port. If these ports are not available, use the SAMPLE 1 port. Avoid the manual purging of the calibration, manual grab sample and sample lines using the Simulate menu, because the system reactor may get contaminated during the automatic sample valve and pump synchronization process. To purge these lines, it is recommended to use PUMP FORWARD TEST and PUMP REVERSE TEST functions in the Sample Pump Test menu. It is recommended that the standard solution is located at the same height as the sample pump. Run the Span Calibration cycle using the RUN SPAN CALIBRATION function in Span Calibration menu. A minimum of five complete analysis cycles is recommended for the span calibration.

_____

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Download BioTector “All Data” in text format into the MMC/SD card or into a PC/Laptop using

the SEND ALL DATA function in Data Output menu to record all changes made in the system configuration.

_____

Go to Start Stop menu and start the BioTector. When the BioTector is running online, carefully observe the first two or three reactions and confirm that the CO2 peaks are correct.

_____

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Section 8 System Software Operation

8.1 Operation Menu

Operation menus are covered in Section 2 Operator’s Manual.

8.2 Calibration Menu

Calibration menus are covered in Section 2 Operator’s Manual.

8.3 Maintenance Menu

Maintenance Menu Diagram

MAINTENANCE ENTER PASSWORD DIAGNOSTICS PROCESS TEST PRESSURE TEST

FLOW TEST OZONE TEST SAMPLE PUMP TEST pH TEST PURGE TN CELL TEST CLEAN TN CELL TEST READ DIW REF TEST

READ TN SAMPLE TEST

SIMULATE OXIDATION PHASE SIMULATE

LIQUID PHASE SIMULATE SIGNAL SIMULATE DATA OUTPUT SEND REACTION ARCHIVE

SEND FAULT ARCHIVE

SEND CONFIGURATION

SEND ALL DATA

INPUT / OUTPUT STATUS DIGITAL INPUT

DIGITAL OUTPUT

ANALOG INPUT

ANALOG OUTPUT SERVICE

ENTER PASSWORD COMMISSIONING REACTION TIME

SAMPLE PUMP STREAM PROGRAM COD / BOD PROGRAM NEW REAGENTS PROGRAM REAGENTS MONITOR AUTOCAL PROGRAM 4-20mA PROGRAM RELAY PROGRAM DATA PROGRAM PRINTER

MMC / SD CARD

INFORMATION CONTACT INFORMATION

SOFTWARE

IDENTIFICATION

ENTER PASSWORD SYSTEM CONFIGURATION ANALYSIS MODE DEMO MODE DEMO MODE CO2 DATA

SYSTEM PROGRAM OXIDATION PROGRAM 1

OXIDATION PROGRAM 2

OXIDATION PROGRAM 3

LIQUID PHASE PROGRAM

CALIBRATION DATA TOC CALIBRATION 1

TOC CALIBRATION 2

TOC CALIBRATION 3

TIC CALIBRATION 1

TIC CALIBRATION 2

TIC CALIBRATION 3

TN CALIBRATION 1

TN CALIBRATION 2

TN CALIBRATION 3

SEQUENCE PROGRAM AVERAGE PROGRAM

CLEANING PROGRAM

ZERO PROGRAM

SPAN PROGRAM

REAGENTS PURGE

PRESSURE / FLOW TEST OUTPUT DEVICES REACTION CHECK RESULT INTEGRATION FAULT SETUP FAULT STATUS O2 FLOW

RELAY PCB FAULT

OZONE PCB FAULT

CO2 ANALYZER FAULT

BIOTECTOR TEMPERATURE

COOLER TEMPERATURE

CO2 ANALYZER CO2 ANALYZER CAL COOLER PROGRAM SOFTWARE UPDATE PASSWORD LANGUAGE

ENTER PASSWORD HARDWARE CONFIGURATION

Page 76

8.3.1 DIAGNOSTICS MENU

This menu allows the user to access the Process Test, Simulate, Data Output, Input/Output Status and Service menus for diagnostic purposes.

Diagnostics Menu Diagram

ENTER PASSWORD DIAGNOSTICS PROCESS TEST PRESSURE TEST

FLOW TEST OZONE TEST SAMPLE PUMP TEST pH TEST PURGE TN CELL TEST CLEAN TN CELL TEST READ DIW REF TEST

READ TN SAMPLE TEST

SIMULATE OXIDATION PHASE SIMULATE

LIQUID PHASE SIMULATE SIGNAL SIMULATE DATA OUTPUT SEND REACTION ARCHIVE

SEND FAULT ARCHIVE

SEND CONFIGURATION

SEND ALL DATA

INPUT / OUTPUT STATUS DIGITAL INPUT

DIGITAL OUTPUT

ANALOG INPUT

ANALOG OUTPUT SERVICE

Page 77

Process Test

This menu allows the user to simulate the: i) Oxidation Phase Process Tests, which are Pressure Test, Flow Test, Ozone Test, Sample Pump Test

and pH Test routines.

ii) Liquid Phase Process Tests, which are Purge TN Cell Test, Clean TN Cell Test, Read DI Water

Reference Test and Read TN Sample Test.

Oxidation Phase Process Test

Pressure Test

P R E S S U R E T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < * P R E S S U R E T E S T 2 P R E S S U R I Z E R E A C T O R 3 T I C P R E S S U R E T E S T

4 P R E S S U R I Z E T I C R E A C T O R T I M E 6 0 s M F C S E T P O I N T 8 0 . 0 l / h M F C F L O W 7 4 . 3 l / h S T A T U S T E S T I N G

P R E S S E S C T O A B O R T T H E T E S T

This menu enables the user to simulate the Pressure Test. The menu also shows the current status of the Mass Flow Controller. Any settings made by the user in this menu are automatically reset when the user exits this menu.

1. Pressure Test. Use this function to simulate the Pressure Test. When the Pressure Test is activated, an “*” will be shown, and a small menu will display the following data: Time: The time for the pressure test is 60 seconds. This time shows the time left to the end

of the test. MFC Setpoint: This is the BioTector mass flow controller setting for the pressure test. MFC Flow: This is the actual flow from the mass flow controller. Initially the setpoint and flow will

match, and if there is no gas leak, after about 25 seconds the flow will fall to close to

zero. Status: At the end of the test, the status below is shown:

TESTING: Test in progress.

PASS: The Pressure Test finished its cycle with a flow below the Pass

(Pressure Test Warning) level.

WARNING: The Pressure Test finished its cycle with a flow above the Pass

(Pressure Test Warning) level, but below the Fail (Pressure Test Fault) level.

FAIL: The Pressure Test finished its cycle with a flow above the Fail

(Pressure Test Fault) level.

2. Pressurize Reactor. This is similar to the Pressure Test above, but its time has been extended to 999s, allowing the user to locate any leak there may be on the system. Pass, Warning and Fail are automatically shown on the screen, depending on the status of the test.

3. TIC Pressure Test. In TC - TIC systems only, use this function to simulate the Pressure Test, which includes TIC reactor. In TC - TIC systems, Pressure Test function above includes the TC reactor in the test.

4. Pressurize TIC Reactor. In TC - TIC systems only, use this function to pressurize the TIC reactor. In TC

- TIC systems, Pressurize Reactor function above pressurizes the TC reactor in the test.

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Flow Test

F L O W T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < * E X H A U S T T E S T

2 E X H A U S T F L O W 3 S A M P L E O U T T E S T 4 S A M P L E O U T F L O W

T I M E 3 0 s M F C S E T P O I N T 8 0 . 0 l / h M F C F L O W 7 4 . 3 l / h S T A T U S T E S T I N G

P R E S S E S C T O A B O R T T H E T E S T

This menu enables the user to simulate various Flow Tests through the system. The menu also shows the current status of the Mass Flow Controller. Note that the items displayed in this menu change with the system analysis type. For instance, The TIC Exhaust and Sample Out Test/Flow are only displayed in TC - TIC systems. Any settings made by the user in this menu are automatically reset when the user exits this menu.

1. Exhaust Test. Use this function to simulate the flow through the Exhaust Valve. When the Exhaust Test is activated, an “*” will be shown, and a small menu will display the following data: Time: The time for the flow test is 30 seconds. This time shows the time left to the end of

the test. MFC Setpoint: This is the BioTector mass flow controller setting for the flow test. MFC Flow: This is the actual flow from the mass flow controller. If there is no blockage in the

lines, then the setpoint should match the flow. Status: At the end of the test, the status below is shown: TESTING: Test in progress.

PASS: The Exhaust Test finished its cycle with a flow above the Pass (Flow

Warning) level.

WARNING: The Exhaust Test finished its cycle with a flow below the Pass level,

but above the Fail (Low O2 Flow) fault level.

FAIL: The Exhaust Test finished its cycle with a flow below the Fail (Low

O2 Flow) fault level.

2. Exhaust Flow. This is similar to the Exhaust Test menu, but its time has been extended to 999s, allowing the user to locate any blockage in the system. Pass, Warning and Fail are automatically shown on the screen, depending on the status of the test.

3. Sample Out Test. This is similar to the Exhaust Test, but for the Sample Out Valve.

4. Sample Out Flow. This is similar to the Exhaust Flow, but for the Sample Out Valve.

Page 79

Ozone Test

The ozone test uses the procedure described in information sheet “T006, Procedure to check the ozone level”. The user must read and understand the

processes described in this sheet, and have all the correct parts listed before carrying out the test.

General overview of the operation of the ozone test:

Phase 1: Install the tester according to information sheet T006, and start the test from the menu. Phase 2: The BioTector carries out a pressure test, to ensure that the system is leak tight. Phase 3: The ozone generator is switched on, and when the o-ring in the tester breaks, press the stop

test menu item.

Phase 4: There is a purge period that purges any traces of ozone from the ozone tester, and the result

of the test is shown on the screen.

Phase 5: The purge of the tester is complete, and the result remains on the screen.

Ozone Test, Phase 1:

O Z O N E T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < * S T A R T T E S T 2 S T O P T E S T

This menu enables the user to test the concentration of ozone generated by the BioTector.

1. Start Test. This starts the ozone test.

2. Stop Test. This stops the ozone test. It should be activated when the o-ring in the tester breaks, or at any

time to stop the ozone test.

Ozone Test, Phase 2:

P R E S S U R E T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

T I M E 3 5 s M F C S E T P O I N T 4 0 . 0 l / h

M F C F L O W 2 2 . 0 l / H

S T A T U S T E S T I N G

P R E S S E S C T O A B O R T T H E T E S T

This menu enables the user to monitor the progress of the ozone test. To abort the ozone test, press the ESCAPE key on the keyboard.

WARNING

Page 80

Ozone Test, Phase 3:

O Z O N E T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 * S T A R T T E S T 2 < S T O P T E S T T I M E 5 s S T A T U S T E S T I N G O Z O N E G E N E R A T O R I S O N ! ! ! D O N O T O P E N O Z O N E T E S T E R

The ozone test has now started. DO NOT OPEN THE OZONE TESTER. The user should now move the cursor down to line 2, and press the ENTER key as soon as the o-ring in the ozone tester breaks. The time will be calculated automatically.

Ozone Test, Phase 4:

O Z O N E T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 S T A R T T E S T 2 < * S T O P T E S T T I M E 1 2 s

S T A T U S P A S S D O N O T O P E N O Z O N E T E S T E R U N T I L P U R G E O F O Z O N E T E S T E R C O M P L E T E

When the user sees the o-ring break, he should immediately select Stop Test and press the ENTER key. The ozone generator is now switched off, but there will still be traces of ozone in the tester. Therefore the BioTector will purge the tester for 30s to remove these traces of ozone. DO NOT OPEN THE OZONE TESTER until the warning message is removed.

The time for the o-ring to break is shown on the screen, as well as the PASS, LOW OZONE or FAIL message. Note that the maximum allowed time for the ozone test is 60s, after which the FAIL message is displayed.

Ozone Test, Phase 5:

O Z O N E T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 S T A R T T E S T 2 < * S T O P T E S T T I M E 1 2 s S T A T U S P A S S

The test is complete. The time for the o-ring to break is shown on the screen, as well as the PASS, LOW OZONE or FAIL message. The Pass, Low Ozone or Fail setting is factory set in the Fault Setup menu.

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Sample Pump Test

S A M P L E P U M P T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 V A L V E S T R E A M 1

2 < * P U M P F O R W A R D T E S T 3 P U M P R E V E R S E T E S T 4 5 - - > S A M P L E P U M P

T I M E 6 s S T A T U S T E S T I N G P R E S S E S C T O A B O R T T H E T E S T

This menu enables the user to test the Sample Pump forward and reverse times. Any settings made by the user in this menu are automatically reset when the user exits this menu.

1. Valve. Valve allows the user to select the stream or manual sample ports the Sample Pump Test is going to be carried out. The valve selection may have an effect on the Sample Pump forward time measured with the Pump Forward Test below, unless all sample lines are at the same length.

2. Pump Forward Test. This function starts the Sample Pump running in the forward direction. When the sample has been correctly transported to the BioTector, through the Sample (ARS) Valve and as far as the recommended sample transport point or until it drips out into the drain, press ESCAPE. This stops the timer, and provides the user the correct FORWARD times to be programmed for each stream and manual sample in the Sample Pump menu.

3. Pump Reverse Test. This is the same as the Pump Forward Test above, only this time Sample Pump operates reverse to empty the sample lines and the oxidized sample catch-pot/cleaning vessel (if installed) back into the corresponding stream selected with the Valve above.

5.  Sample Pump. Sample Pump is a link to the Maintenance, Commissioning, Sample Pump menu.

Page 82

pH Test

The user must understand the procedure for testing the pH in the BioTector. Use eye protection and gloves. Have all the relevant parts for this test ready (primarily beaker and pH paper) before carrying out the test.

For the pH test to be accurate, the previous reaction should have finished normally, so that any liquid carried over from that reaction will not affect the pH test. Significant volume of liquid loss, during the pH test phases 1, 2, 3 or 4, may have an impact on the consecutive pH tests. In such cases, the test must be stopped at that specific phase, where the significant volume of liquid is lost, and re-started from pH Test Phase 1 below. When the pH test is re-started, the corresponding pH measurements can be skipped for the previous valid tests.

General overview of the operation of the pH test, the description below is for the TIC & TOC mode:

Phase 1: Prepare the test equipment, and start the test. Phase 2: The BioTector carries out a normal startup operation, including ozone purge, reactor purge,

pressure test and flow test to ensure that the system is purged and leak tight.

Phase 3: The sample and TIC acid are added to the reactor, mixed and then the program pauses, to

allow the pH to be tested.

Phase 4: The base is added to the solution in the reactor, and then the program pauses, to allow the

pH to be tested.

Phase 5: The TOC acid is added to the solution in the reactor, and then the program pauses, to allow

the pH to be tested.

Phase 6: The reactor and CO2 analyzer are purged.

pH Test, Phase 1:

P H T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < R A N G E , V A L V E 1 , S T R E A M 1 2 M O D E T I C + T O C 3 S T A R T T E S T 4 T A K E S A M P L E

5 C O N T I N U E T O N E X T P H A S E 6 S T O P T E S T

This menu enables the user to test the pH in the BioTector.

1. Range, Valve. Select the range and the stream or manual sample point the pH test is going to run on. This function has an effect on the volume of sample, acid and base used for the test.

2. Mode. Depending on the analysis type of the BioTector, the test mode can be selected as TIC+TOC mode, TC mode or TIC REACTOR mode. In TIC & TOC systems, the only available test mode is TIC + TOC. In TC systems, the only available test mode is TC. If the BioTector is a VOC system, the user can choose to run the test in either TIC+TOC or TC modes.

In TC - TIC systems, the user can choose to run the test in either TC mode or TIC REACTOR mode. The TC mode allows the pH test to be carried out in the TC reactor and the additional TIC REACTOR mode allows the test to be carried out in the TIC reactor of the system.

WARNING

Page 83

3. Start Test. This starts the ph test routine, which goes through the 6 phases described above.

4. Take Sample. Not applicable until the test is running.

5. Continue to next phase. Not applicable until the test is running.

6. Stop Test. When the test is running, activating this control will stop the test. Note that some phases have

to be completed before the stop can be used.

P H T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < R A N G E , V A L V E 1 , S T R E A M 1 2 M O D E T I C + T O C 3 S T A R T T E S T 4 T A K E S A M P L E

5 C O N T I N U E T O N E X T P H A S E 6 S T O P T E S T C O N F I R M P R E V I O U S R E A C T I O N F I N I S H E D C O R R E C T L Y . P R E S S E N T E R T O C O N F I R M , E S C T O E X I T

For the pH test to be accurate, the previous reaction should have finished normally, so that any liquid carried over from that reaction will not affect the pH test. Therefore, when the start test menu item has been activated, a confirmation will be required. If the previous reaction did not finish normally, then liquid remaining in the reactor may interfere with the test and give incorrect pH test results.

pH Test, Phase 2:

P H T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < R A N G E , V A L V E 1 , S T R E A M 1

2 M O D E T I C + T O C 3 S T A R T T E S T 4 T A K E S A M P L E 5 C O N T I N U E T O N E X T P H A S E 6 S T O P T E S T

T I M E 1 5 s P H A S E O Z O N E P U R G E M F C = 3 9 . 3 l / h C O 2 = 1 5 0 . 8 p p M

W A I T T E S T P H A S E T O C O M P L E T E

After the pH test has been started, the BioTector carries out a normal startup operation, including ozone purge, reactor purge, pressure test and flow test to ensure that the system is purged and leak tight. This phase cannot be stopped, and requires about 210 seconds to run.

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pH Test, Phase 3:

P H T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < R A N G E , V A L V E 1 , S T R E A M 1 2 M O D E T I C + T O C 3 S T A R T T E S T 4 T A K E S A M P L E 5 C O N T I N U E T O N E X T P H A S E 6 S T O P T E S T T I M E 0 s

P H A S E P A U S E D M F C = 0 . 0 l / h C O 2 = 1 5 0 . 8 p p M T E S T T I C p H . E X P E C T E D p H < 2 .

W H E N F I N I S H E D , S E L E C T N E X T A C T I O N F R O M M E N U .

At this phase, the sample and TIC acid are added to the reactor and mixed together. The system then pauses to allow the pH to be tested. The user now has 3 options:

4. Take Sample. It can be difficult to take the sample, so to aid this, press this menu item once to pulse the Sample Out Valve for 0.1s. This will allow a small volume of sample to pass through the valve, and this can be tested with a pH paper. Several activations of the valve may be required to purge the Sample Out Valve of any old sample, and get a fresh sample for the test.

5. Continue To Next Phase. If this is selected, the program continues to the next phase.

6. Stop Test. If this is selected, the program jumps to the reactor purge phase.

pH Test, Phase 4:

P H T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < R A N G E , V A L V E 1 , S T R E A M 1 2 M O D E T I C + T O C

3 S T A R T T E S T 4 T A K E S A M P L E 5 C O N T I N U E T O N E X T P H A S E 6 S T O P T E S T

T I M E 0 s P H A S E P A U S E D M F C = 0 . 0 l / h C O 2 = 1 5 0 . 8 p p M

T E S T B A S E p H . E X P E C T E D p H > 1 2 .

W H E N F I N I S H E D , S E L E C T N E X T A C T I O N F R O M M E N U .

At this phase, the base is added to the solution in the reactor and mixed together. The program then pauses to allow the pH to be tested. The user now has 3 options, which are the same as in the previous phase.

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pH Test, Phase 5:

P H T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < R A N G E , V A L V E 1 , S T R E A M 1 2 M O D E T I C + T O C 3 S T A R T T E S T 4 T A K E S A M P L E 5 C O N T I N U E T O N E X T P H A S E 6 S T O P T E S T T I M E 0 s

P H A S E P A U S E D M F C = 0 . 0 l / h C O 2 = 1 5 0 . 8 p p M T E S T T O C p H . E X P E C T E D p H < 2 .

W H E N F I N I S H E D , S E L E C T N E X T A C T I O N F R O M M E N U .

At this phase, the TOC acid is added to the solution in the reactor and mixed together. The system then pauses to allow the pH to be tested. The user now has 3 options. Option 4 is used to take the sample as before, but both options 5 and 6 below will end the test, as the TOC acid check is the last phase in the cycle.

5. Continue To Next Phase. If this is selected, the program continues to the next phase, which is the reactor purge phase.

6. Stop Test. If this is selected, the program jumps to the reactor purge phase.

As the next phase is the reactor purge phase, the user is prompted to confirm that all tubes have been reconnected before the BioTector starts this phase.

P H T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < R A N G E , V A L V E 1 , S T R E A M 1 2 M O D E T I C + T O C

3 S T A R T T E S T 4 T A K E S A M P L E 5 C O N T I N U E T O N E X T P H A S E 6 S T O P T E S T C O N F I R M A L L T U B E S R E - C O N N E C T E D C O R R E C T L Y . P R E S S R I G H T A R R O W T O C O N F I R M .

pH Test, Phase 6:

P H T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < R A N G E , V A L V E 1 , S T R E A M 1 2 M O D E T I C + T O C 3 S T A R T T E S T 4 T A K E S A M P L E 5 C O N T I N U E T O N E X T P H A S E 6 S T O P T E S T

T I M E 0 s P H A S E C O M P L E T E M F C = 0 . 0 l / h C O 2 = 1 5 0 . 8 p p M

The pH test is complete. The BioTector will purge the reactor and the CO2 analyzer. The user can either exit the menu or start the pH test again.

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Liquid Phase Process Test

Purge TN Cell Test

P U R G E T N C E L L T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < * S T A R T T E S T 2 S T O P T E S T

T I M E 1 4 s P H A S E C E L L S P U R G E W A I T F O R T E S T P H A S E T O C O M P L E T E

The objective of the Purge TN Cell Test is to simulate and test the cell purge operation in Liquid Phase analysis. This phase is carried out by running the Nitrogen Pump, emptying the oxidized sample catchpot/cleaning vessel (OSCP) and emptying the TN measuring cell’s deionised water (DI Water) content.

1. Start Test. This function starts the Purge TN Cell Test.

2. Stop Test. This function stops the Purge TN Cell Test.

When escape key is pressed during the test, only STOP is activated. Note that at the end of this test, the measuring cell is not filled with DI Water and left empty. The user can leave this menu only when Liquid Phase analysis is stopped and escape key is pressed.

Clean TN Cell Test

C L E A N T N C E L L T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < * S T A R T T E S T 2 S T O P T E S T

T I M E

1 4 s

P H A S E C L E A N I N G W A I T F O R T E S T P H A S E T O C O M P L E T E

The objective of the Clean TN Cell Test is to simulate and test the cell cleaning operation of Liquid Phase analysis as it occurs in normal reaction. The test starts with the oxidized sample catch-pot/cleaning vessel and measuring cell purge. Then the cleaning liquid is brought into the cell and sample lines between the cell and cleaning vessel are cleaned. After this phase, the measuring cell and the lines are washed with DI Water.

1. Start Test. This function starts the Clean TN Cell Test.

2. Stop Test. This function stops the Clean TN Cell Test.

When escape key is pressed during the test, only STOP TEST is activated. The user can leave this menu only when the test is stopped and escape key is pressed.

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Read DI Water Reference Test

R E A D D I W R E F T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < * S T A R T T E S T 2 S T O P T E S T T I M E 1 6 s

P H A S E D I W M E A S U R E X E N O N L A M P O F F O N N S I G 2 7 0 3 4 0 0 0 0 8 5 %

N R E F 3 4 0 3 3 0 0 0 0 7 5 % S / R R A T I O 1 . 0 0 W A I T F O R T E S T P H A S E T O C O M P L E T E

The purpose of Read DI Water Reference Test is to simulate and test the reference reading cycle on DI Water and to display the intensity readings at both signal (SIG) wavelength, which is at 217nm, and reference (REF) wavelength, which is at 265nm for Nitrogen.

The test starts with cell purge. DI Water is brought to the TN measuring cell and measured in the Dual Cell Photometer (DCP) module. The Nitrogen Signal (N SIG) and Nitrogen Reference (N REF) values are updated as soon as the readings are available. The Signal and Reference Ratios (S/R Ratio) are displayed for Nitrogen. The % intensity values, which are calculated from the current readings and the readings obtained in factory, are also displayed. The % signal and reference intensity values should be within the fault threshold, which is typically greater than 50% and less than 150%. The % intensity values greater than 50% indicate that the DI Water, the TN measuring cell and all corresponding lines are clean. The test measurement is carried out the same way it is carried out in a normal reaction. When DI Water measurement is finished, the system completes the test by purging the TN measuring cell.

1. Start Test. This function starts the Read DI Water Reference test.

2. Stop Test. This function stops the Read DI Water Reference test.

When escape key is pressed during the test, only STOP TEST is activated. The user can leave this menu only when the test is stopped and escape key is pressed.

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Read TN Sample Test

R E A D T N S M P L T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < * S T A R T T E S T 2 S T O P T E S T T I M E 1 6 s

P H A S E S A M P L E M E A S U R E X E N O N L A M P O F F O N N S I G 2 8 0 1 4 0 0 0 0 0 %

N R E F 3 3 0 1 3 0 0 0 0 0 % S / R R A T I O 1 . 0 8 W A I T F O R T E S T P H A S E T O C O M P L E T E

The purpose of this test is to simulate and test the TN sample reading cycle and to display the intensity readings at both signal (SIG) and reference (REF) wavelengths.

In order to make a representative TN reading on the sample, BioTector must be stopped using the Finish & Stop function in the Start Stop menu. If BioTector is stopped using Emergency Stop function, the liquid will be discharged from the reactor directly without the completing of the oxidation process. As the discharged liquid may be coming from various stages of the reaction (e.g. TIC phase, Base Oxidation phase, TOC phase etc.), any sample reading carried out on such liquids may not be representative.

The test starts with the cell purge. The sample in oxidized sample catch-pot/cleaning vessel (OSCP) is brought into the TN measuring cell and measured in the Dual Cell Photometer module. The Nitrogen Signal (N SIG) and Nitrogen Reference (N REF) values are updated as soon as the readings are available. The Signal and Reference ratio (S/R Ratio) is also displayed. Unlike the Read DI Water Reference test, the % intensity values are not updated and only the default 0% intensity values are displayed. The sample measurement is carried out the same way it is carried out in a normal reaction. When sample measurement is completed, the system ends the test by purging the TN measuring cell.

1. Start Test. This function starts the Read TN Sample Test.

2. Stop Test. This function stops the Read TN Sample Test.

When escape key is pressed during the test, only STOP TEST is activated. The user can leave this menu only when the test is stopped and escape key is pressed.

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Simulate

Oxidation Phase Simulate

O X I D A T I O N P H A S E S I M 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

M F C = 1 0 . 0 l / h C O 2 = 3 5 . 0 p p m 1 < * M F C 1 0 . 0 l / h

2 O Z O N E G E N E R A T O R O F F 3 A C I D P U M P O F F , 1 4 A C I D V A L V E O F F 5 B A S E P U M P O F F , 1

6 B A S E V A L V E O F F 7 S A M P L E V A L V E S E N 1 8 S A M P L E P U M P O F F , 1 9 I N J E C T I O N V A L V E O F F 1 0 C I R C U L A T I O N P U M P O F F ▼

O X I D A T I O N S I M U L A T E 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

M F C = 1 0 . 0 l / h C O 2 = 3 5 . 0 p p m  1 1 H C l W A T E R P U M P O F F 1 2 S A M P L E O U T V A L V E O F F 1 3 E X H A U S T V A L V E O F F

1 4 C L E A N I N G V A L V E O F F 1 5 C A L I B R A T I O N V A L V E O F F 1 6 S T R E A M V A L V E O F F 1 7 M A N U A L V A L V E O F F

1 8 C O O L E R A U T O , 5 . 0 C 1 9 L E A K D E T E C T O R O F F 2 0 F A N A U T O , 2 0 . 0 C 2 1 S A M P L E R F I L L O F F ▼

O X I D A T I O N S I M U L A T E 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

M F C = 1 0 . 0 l / h C O 2 = 3 5 . 0 p p m  2 2 S A M P L E R E M P T Y O F F 2 3 S A M P L E D E T E C T O R O F F 2 4 T I C S M P L I N V A L V E O F F 2 5 T I C S M P L O U T V A L V E O F F

2 6 T I C S P A R G E V A L V E O F F 2 7 T I C A N A L Y S I S V A L V E O F F 2 8 T I C P U R G E V A L V E O F F 2 9

3 0 - - > I N P U T / O U T P U T S T A T U S

The Oxidation Phase Simulate menu enables the user to test Oxidation Phase system components such as pumps, valves, MFC etc. installed in BioTector. The menu also shows the current status of all devices when the BioTector is running. Note that the Oxidation Phase Simulate screen may change slightly depending on system settings. Any settings made by the user in this menu are automatically reset when the user exits this menu. The line below the time and date shows the MFC flow in l/h and actual CO2 analyzer reading in ppm.

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Each time a component is activated, the BioTector will interlock additional devices to ensure that the component being tested can be checked in a manner that will not cause consequential damage to the overall system. It is recommended that each test is evaluated carefully, for although the interlocks are extensive, it may still be possible to damage the system. In simulate menus, most items require a minimum of 6 l/h oxygen flow set on the Mass Flow Controller (MFC) to operate. This is a system safety interlock, which is implemented to prevent the system from flooding.

1. MFC. Use this function to set the MFC set point. Press the ENTER key, set the required set point, and press the ENTER key again. The actual flow is shown at the top of the screen. An “*” is shown when the MFC has been activated. If the flow is 0.0 l/h, then the MFC is switched off.

2. Ozone Generator. Use this function to test the ozone generator. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

Ozone will be generated when the ozone generator is turned on.

Before the Ozone Generator is switched on, a pressure test procedure is executed automatically to detect

any gas leakage in the system for safety. If this test fails then the ozone generator will not be switched on.

3. Acid Pump. Use this function to test the Acid Pump. To turn the pump on, press the ENTER key, and select ON. Press ENTER again, input the number of pulses (½ revolutions), press ENTER and the pump will run. If the reactor type of the system is multi-component reactor (MCR) and if the Acid Valve is activated, the maximum allowable number of pulses is 10. When the pump is running the actual (outside brackets) and programmed pulse time (inside brackets) is shown. The pump will stop when the required number of pulses is complete, or to manually stop the pump, press ENTER, select OFF, and press ENTER again.

4. Acid Valve. Use this function to test the Acid Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

5. Base Pump. Use this function to test the Base Pump. To turn the pump on, press the ENTER key, and select ON. Press ENTER again, input the number of pulses (½ revolutions), press ENTER and the pump will run. When the pump is running the actual (outside brackets) and programmed pulse time (inside brackets) is shown. The pump will stop when the required number of pulses is complete, or to manually stop the pump, press ENTER, select OFF, and press ENTER again.

6. Base Valve (if configured in the system). Use this function to test the Base Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

WARNING

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7. Sample Valve. Use this function to test the Sample (ARS) Valve. The valve has three positions, SEN1 (Sample Pump to Bypass), SEN2 (Sample Pump to Reactor), and SEN3 (TIC Acid/TC Base to Reactor). To position the valve in different positions, press the ENTER key, select the required position, and press ENTER again.

8. Sample Pump. This function can be used to test the Sample Pump. The pump has four operation modes: FWR (forward), REV (reverse), P-FWR (pulse control forward) and P-REV (pulse control reverse). To run the pump in the required mode, press ENTER, and select the operation mode. When P-FWR or P-REV modes are selected, the number of pulses (½ revolution of the pump roller) must be entered. When the pump is running, the actual pulse time (outside the brackets) and programmed pulse time (inside the brackets) are displayed. The pump stops when the programmed number of pulses is completed. To stop the pump manually, press ENTER, select OFF, and press ENTER again.

9. Injection Valve. Use this function to test the Injection Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

10. Circulation Pump. Use this function to test the Circulation Pump. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

11. HCl Water Pump (if configured in the system). Use this function to test the HCl Water Pump. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

12. Sample Out Valve. Use this function to test the Sample Out Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

13. Exhaust Valve. Use this function to test the Exhaust Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

14. Cleaning Valve (if configured in the system). Use this function to test the Cleaning Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

15. Calibration Valve (if configured in the system). Use this function to test the Zero and Span Calibration Valves. To change the state of the device, press the ENTER key, set the device to ZERO/SPAN/OFF, and press the ENTER key again. When the relevant device is on, it will be marked with an “*”.

16. Stream Valves (if configured in the system). Use this function to test the Stream Valves. To test a Stream Valve, press the ENTER key and select the number of the valve to be tested. Press the ENTER key again and the valve will be activated. To turn the valve off, select OFF. These valves can be driven either from programmable relays or from the Stream Expansion (Auxiliary) PCB. Note that only one Stream Valve can be switched on at any given time.

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17. Manual Valves (if configured in the system). Use this function to test the Manual Valves. To test a Manual Valve, press the ENTER key and select the number of the valve to be tested. Press the ENTER key again and the valve will be activated. To turn the valve off, select OFF. Note that only one Manual Valve can be switched on at any given time.

18. Cooler. This device is normally automatically controlled by the system. To test the Cooler relay, press the ENTER key and select device state option: ON, OFF, AUTO. If the device is on, it will be marked with an “*”. The actual cooler temperature in degrees centigrade (°C) is also shown in this menu.

19. Leak Detector (if configured in the system). This device is input only and therefore its state cannot be changed from this menu. It only indicates the state of the BioTector Liquid Leak Detector alarm input.

20. Fan. This device is normally automatically controlled by the system. To test the Fan relay, press the ENTER key and select device state option: ON, OFF, AUTO. If the device is on, it will be marked with an “*”. The actual BioTector temperature in degrees centigrade (°C) is also shown in this menu. In AUTO mode, if the temperature of the system is below the default set point temperature, which is 25°C, BioTector switches the fan off in order to stabilize the temperature using its own internal heat. If the temperature is above the set point temperature, fan keeps operating continuously.

21. Sampler Fill (if configured in the system). Signal to fill the BioTector sampler. This signal remains on until turned off.

22. Sampler Empty (if configured in the system). Signal to empty the BioTector sampler. This signal is a 5 second pulse.

23. Sample Sensor (if configured in the system). This device is an input only and therefore its state cannot be changed from this menu. It only indicates the state of the Sample Sensor.

24. TIC Sample Valve. In TC - TIC systems only, use this function to test the TIC Sample Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

25. TIC Sample Out Valve. In TC - TIC systems only, use this function to test the TIC Sample Out Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

26. TIC Sparge Valve. In TC - TIC systems only, use this function to test the TIC Sparge Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

27. TIC Analysis Valve. In TC - TIC systems only, use this function to test the TIC Analysis Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

28. TIC Purge Valve. In TC - TIC systems only, use this function to test the TIC Purge Valve. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

30.  Input/Output Status. Input/Output Status is a link to Maintenance, Diagnostics, Input/Output Status menu.

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Liquid Phase Simulate

L I Q U I D P H A S E S I M 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

N I T R O G E N :

S / R R A T I O = 1 . 8 1 7 S = 6 2 5 0 0 0 R = 3 4 4 0 0 0

1 L I Q U I D P H A S E C O M P O N E N T S 2 X E N O N L A M P O F F 3 N P S A M P L E V A L V E O F F 1 0 D I W A T E R V A L V E O F F 1 1 T N C L E A N I N G V A L V E O F F 1 2 N P U M P O F F , 1 1 8 D C P L E A K D E T E C T O R O F F 1 8

1 9 ▼

L I Q U I D P H A S E S I M 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

 2 0 O X I D A T I O N P H A S E C O M P O N E N T S 2 1 C L E A N I N G V A L V E O F F

2 2 S A M P L E P U M P O F F , 1 2 3 2 4 - - > I N P U T / O U T P U T S T A T U S

The Liquid Phase Simulate menu enables the user to test Liquid Phase system components and also the relevant Oxidation Phase system components such as pumps, valves, lamp, boilers etc. installed in BioTector. The menu also shows the current status of all devices when the BioTector is running. Note that the Liquid Simulate screen may change slightly depending on system settings. Any settings made by the user in this menu are automatically reset when the user exits this menu.

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The menu status lines, which are the lines below the time and date, show the following information:

S/R RATIO - Signal and reference Ratio S - Actual reading of signal intensity R - Actual reading of reference intensity The intensity and ratio readings for Nitrogen only update when system is running and when the detectors in the Dual Cell Photometer are used. Any settings carried out by the user in this menu are automatically reset when the user exits the menu.

1. Liquid Phase Components

2. Xenon Lamp. Use this function to activated/deactivate the Xenon light source. To change the state of the

device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

3. NP Sample Valve. Use this function to test the NP Sample Valve. To change the state of the device,

press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

10. DI Water Valve. Use this function to test the DI Water Valve. To change the state of the device, press the

ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

11. TN Cleaning Valve. Use this function to test the TN Cleaning Valve. To change the state of the device,

press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

12. N Pump. Use this function to test the Nitrogen Pump. The pump has two operation modes: P-FWR (pulse

control forward) and P-REV (pulse control reverse). Select the required operation mode, press the ENTER key, enter a number of pulses (½ revolutions of pump roller) to be tested, press the ENTER key again and the pump will run the number of programmed pulses in the selected mode.

18. DCP Leak Detector. The Dual Cell Photometer (DCP) Liquid Leak Detector (if installed) is an input only

and therefore its state can not be changed from this menu. This function only indicates the state of the DCP Leak Detector alarm input. In other words, when there is a liquid leak inside the Dual Cell Photometer module, or during the testing of the leak detector, the system changes the state of the device as ON, which is the leak and the fault condition or OFF, which is the default state without any leak and fault condition.

20. Oxidation Phase Components

21. Cleaning Valve. This function can be used to test the BioTector Cleaning Valve. To change the state of

the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

22. Sample Pump. This function can be used to test the BioTector Sample Pump. The pump has four

operation modes: FWR (forward), REV (reverse), P-FWR (pulse control forward) and P-REV (pulse control reverse). To run the pump in the required mode, press the ENTER key and select the operation mode. When P-FWR or P-REV mode is selected, the number of pulses (½ revolutions of pump roller) must be entered. When the pump is running, the actual pulse time (outside the brackets) and programmed pulse time (inside the brackets) are displayed. The pump stops when the programmed number of pulses is completed. To stop the pump manually, press the ENTER key, select OFF, and press the ENTER key again.

24.  I/O Status. I/O Status is a link to Maintenance, Diagnostics, Input/Output Status menu.

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Signal Simulate

S I G N A L S I M U L A T E 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 C O M M O N F A U L T O F F 2 < * A L A R M O N 3 C H A N N E L 1 4 . 0 m A 4 . . . . . . . . . . . . . . . 9 C H A N N E L 7 4 . 0 m A 1 0 S T M A L A R M 1 O F F

1 1 . . . . . . . . . . . . . . . 1 5 S T M A L A R M 6 O F F 1 6 S A M P L E F A U L T 1 O F F 1 7 S Y N C R E L A Y O F F

1 8 S A M P L E S T A T U S O F F 1 9 C A L S I G N A L O F F 2 0 M A I N T S I G N A L O F F 2 1 S T O P O F F ▼

S I G N A L S I M U L A T E 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

 2 2 F A U L T O F F 2 3 F A U L T O R W A R N O F F 2 4 W A R N I N G O F F 2 5 N O T E O F F 2 6 M A N M O D E T R I G O F F 2 7 4 - 2 0 m A C H N G O F F

2 8 4 - 2 0 m A C H N G 1 O F F

3 2 . . . . . . . . . . . .

3 3 4 - 2 0 m A C H N G 6 O F F 3 4 4 - 2 0 m A R E A D O F F

3 5 3 6 - - > I N P U T / O U T P U T S T A T U S

This menu enables the user to test the Common Fault relay, the available 4-20mA outputs, the programmed output signals and if installed, the Stream Alarm relays and any other optional outputs in the BioTector. Any settings made by the user in this menu are automatically reset when the user exits this menu.

1. Common Fault. By pressing the ENTER key on this menu item the user can activate the Fault Relay.

When activated, an “*” will be displayed on the screen. Note that if the normal state of the relay is energized, then when activated the relay will de-energize. Alternatively, if the normal state of the relay is de-energized, then when activated the relay will energize. The default state of the Fault Relay is programmed in Relay Program menu. To reset the relay back to its default state, press the ENTER key again.

2. Alarm (if configured in the system). Use this function to test the Alarm relay. To change the state of the

device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

3. - 9. Channel 1-7. This allows the user to test the function of the 4-20mA signals. Press the ENTER key,

use the arrow keys to set the required 4-20mA signal, and press the ENTER key again to test the 4-20mA signal. Channel 7, which is for future use only, requires specific system components in order to be used.

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10. - 15. Stm Alarm 1-6 (if configured in the system). This allows the user to test the function of the Stream

Alarms if they are programmed in Output Devices menu. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.

16. Sample Fault 1 (if configured in the system). Use this function to test the Sample Fault 1 output signal.

To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”.See Output Devices section for details.

17. Sync Relay (if configured in the system). Use this function to test the Synchronization relay. To change

the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”. See Output Devices section for details.

18. Sample Status (if configured in the system). Use this function to test the Sample Status output. To

change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”. See Output Devices section for details.

19. Cal Signal (if configured in the system). Use this function to test the Calibration Signal output. To

20. Maint Signal (if configured in the system). Use this function to test the Maintenance Signal output. To

21. Stop (if configured in the system). Use this function to test the Stop output. To change the state of the

device, press the enter key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”. See Output Devices section for details.

22-24. Fault, Fault or Warning, Warning (if configured in the system). Use these functions to test the

Fault and Warning outputs. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”. See Output Devices section for details.

25. Note (if configured in the system). Use this function to test the system Notification output. To change

the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”. See Output Devices section for details.

26. Man Mode Trig (if configured in the system). Use this function to test system Manual Mode Trigger

output. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”. See Output Devices section for details.

27-33. 4-20mA Chng 1-6 (if configured in the system). Use these functions to test system 4-20mA Change

outputs for single stream or for specific streams from Stream 1 to Stream 6. To change the state of the device, press the ENTER key, set the device to ON/OFF, and press the ENTER key again. If the device is on, it will be marked with an “*”. See Output Devices section for details.

34. 4-20mA Read (if configured in the system). Use this function to test system 4-20mA Read output. To

36.  Input/Output Status. Input/Output Status is a link to Maintenance, Diagnostics, Input/Output Status

menu.

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Data Output

D A T A O U T P U T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < O U T P U T D E V I C E M M C / S D C A R D 2 S E N D R E A C T I O N A R C H I V E 3 S E N D F A U L T A R C H I V E 4 S E N D C O N F I G U R A T I O N 5 S E N D A L L D A T A 6 7 - - > D A T A P R O G R A M

This menu enables the user to select the communication port and to download the contents of the system reaction, fault archives, system specific configuration and all data for diagnostics purposes.

1. Output Device. This item allows the user to select communication port configuration profile. Available

options are PRINTER, PC and MMC/SD CARD. See Data Program menu for specific output device settings. In order to receive data from BioTector, see appendices for the instructions on connecting the output devices to BioTector.

2. Send Reaction Archive. Sub menu used to download the reaction archive to the selected output device.

3. Send Fault Archive. Sub menu used to download the fault archive to the selected output device.

4. Send Configuration. Sub menu used to download the system configuration to the selected output

device.

5. Send All Data. Sub menu used to download system all data, which includes system configuration, fault

archive, reaction archive and system diagnostics information.

7.  Data Program. Data Program is a link to Maintenance, Commissioning, Data Program menu. When external MMC/SD memory card is used as the output device, the data is downloaded into the card in

text format. Note that;  Any text data (reaction and fault archive, configuration and all data) can be downloaded into the card

while BioTector is running.

 The card can be removed when BioTector is running.  The card should not be removed before the data transfer is completed.  If the data download into the card is successful, the files, which can be accessed in the memory card

in text format, are reaction archive, fault archive, configuration and/or all data.

 Other files which are located in the in system’s external memory card by default are system firmware

(sysfrmw.hex) and system configuration (syscnfg.bin) both of which are in binary formats. Binary files

can only be opened and viewed by specific computer programs. Therefore the user should not

attempt to open or access these files.

 The memory card used in BioTector can be an MMC/SD card formatted with FAT, FAT12/16 or

FAT32 file systems. Most SDHC cards are also supported and can also be used.

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Send Reaction Archive

S E N D R E A C T I O N A R C H I V E 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0

1 < S T A R T D A T E 0 1 - 0 9 - 0 2 2 N U M B E R O F E V E N T S 1 2 3 3 S T A R T S E N D I N G

4 P A U S E S E N D I N G 5 * S T O P S E N D I N G O U T P U T # 1 2 3 I T E M S

This menu is used to download the reaction archive. The communication port parameters used are those set up in the Data Program menu.

1. Start Date. This is the start date of the first item to be downloaded. The default date is the current date on

the BioTector, which can be changed by the user. The newest event is downloaded first when downloading data.

2. Number of Events. This is the number of events to be downloaded. The default is the number of events

in the reaction archive, which can be edited by the user.

3. Start Sending. Press the ENTER key to start downloading the data.

4. Pause Sending. Press the ENTER key to interrupt the downloading of data. Press again to continue

downloading. If the downloading is interrupted for more than 60 seconds, then the downloading is automatically resumed.

5. Stop Sending. Press the ENTER key to stop downloading the data. OUTPUT ITEMS is the number of events currently downloaded. The maximum amount of events is 9999.

When external MMC/SD memory card is being used as the output device, the reaction archive will be saved into the card in text format and named as “RARCH.TXT” by default.

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The meaning of the abbreviations used in the downloaded reaction data in both standard and engineering modes (see Print Mode in Data Program, Printer, PC, MMC/SD Card menus) are as follows:

Standard Mode:

TIC & TOC Analysis:

TIME The time the reaction started. DATE The date the reaction started. S1:2 Reaction type and range. TICmgC/l The calibrated TIC value in mgC/l. TOCmgC/l The calibrated TOC value in mgC/l (TOC represents NPOC). TNmgN/l The calibrated TN value in mgN/l. COD/BODmgO/l The calculated COD and/or BOD value in mgO/l (if activated in COD/BOD Program menu).

TC Analysis:

TIME The time the reaction started. DATE The date the reaction started. S1:2 Reaction type and range. TCmgC/l The calibrated TC value in mgC/l (TC represents TIC + NPOC + POC). TNmgN/l The calibrated TN value in mgN/l.

VOC Analysis:

TIME The time the reaction started. DATE The date the reaction started. S1:2 Reaction type and range. TCmgC/l The calibrated TC value in mgC/l (TC represents TIC + NPOC + POC). TICmgC/l The calibrated TIC value in mgC/l. TOCmgC/l The calculated TOC value in mgC/l (TOC is calculated as TC – TIC). VOCmgC/l The calculated VOC value in mgC/l (VOC is calculated as TC – TIC – NPOC). TNmgN/l The calibrated TN value in mgN/l.

TC - TIC Analysis:

TIME The time the reaction started. DATE The date the reaction started. S1:2 Reaction type and range. TCmgC/l The calibrated TC value in mgC/l. TICmgC/l The calibrated TIC value in mgC/l. TOCmgC/l The calculated TOC value in mgC/l (TOC is calculated as TC – TIC). TNmgN/l The calibrated TN value in mgN/l.

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Engineering mode (TIC & TOC analysis):

TIME The time the reaction started. DATE The date the reaction started. S1:2 Reaction type and range. CO2z CO2 analyzer zero adjust for the current reaction.

TICmgu The un-calibrated TIC value in mgC/l. TICmgc The calibrated TIC value in mgC/l. CO2p The height of the TIC CO2 peak.

TOCmgu The un-calibrated TOC value in mgC/l. TOCmgc The calibrated TOC value in mgC/l (TOC represents NPOC). CO2p The height of the TOC CO2 peak.

TNmgu The un-calibrated TN absorbance value. TNmgc The calibrated TN value in mgN/l.

COD/BODmgc The calculated COD and/or BOD value in mgO/l (if activated in COD/BOD Program menu). DegC BioTector temperature in Degrees Centigrade (°C). Atm Atmospheric pressure in kPa.

SAMPLE Sample quality (%) from Sample Sensor signal, which is used to activate SAMPLE STATUS output. SMPL PUMP The five items, which are number coded or a number data, gives information on the Sample Pump:

1) operation mode (0=time mode or 1= pulse mode),

2) number of pulses during operation such as injection,

3) total time (milliseconds) taken for total number of pulse operation (see point 2 above),

4) the time (milliseconds) taken for the last pulse operation (see point 2 above),

5) error counter (ranges from 0 to 6). When a pulse is missed or not detected, the pump switches into time mode for that specific operation (for instance, injection, synchronization, etc). System only generates a pump warning and logs into fault archive if there are 6 consecutive failures.

ACID PUMP Similar information on Acid Pump operation (see five items listed for SMPL PUMP above). BASE PUMP Similar information on Base Pump operation (see five items listed for SMPL PUMP above).

N PUMP The Nitrogen Pump error counter, which operates similar to the Sample Pump error counter above. TNSS0 The intensity reading on TN sample at Nitrogen signal wavelength when the light source is OFF.

TNSS1 The intensity reading on TN sample at Nitrogen signal wavelength when the light source is ON. TNSR0 The intensity reading on TN sample at Nitrogen reference wavelength when the light source is OFF. TNSR1 The intensity reading on TN sample at Nitrogen reference wavelength when the light source is ON.

NWS0 The intensity reading on DI Water at Nitrogen signal wavelength when the light source is OFF. NWS1 The intensity reading on DI Water at Nitrogen signal wavelength when the light source is ON. NWR0 The intensity reading on DI Water at Nitrogen reference wavelength when the light source is OFF. NWR1 The intensity reading on DI Water at Nitrogen reference wavelength when the light source is ON.

The default signal and reference wavelengths for Nitrogen measurements are 217nm and 265nm respectively.

The COD and/or BOD result is added into the reaction screens and reaction archives if the COD and/or BOD is activated in COD/BOD Program menu.

Hach BioTector B7000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual