HACH BioTector B3500C Online TOC Analyzer USER MANUAL

Catalog Number: 10-MAT-452 BioTector B3500C Online TOC Analyzer USER MANUAL November 2012, Edition 1 BS5AX 2.02.01a © Copyright BioTector 2012. All rights reserved. Printed by BioTector. Printed in the Republic of Ireland. Table of Contents SECTION 1 1.1 1.2 1.3 1.4 SAFETY PRECAUTIONS .......................................................................... 5 INFORMATION AND SAFETY SIGNS USED IN THE MANUAL ....................................................... 5 PRECAUTIONARY LABELS ATTACHED TO THE INSTRUMENT .................................................... 6 CERTIFICATION MARKS ATTACHED TO THE INSTRUMENT ....................................................... 7 POTENTIAL SYSTEM SAFETY HAZARDS ................................................................................ 8 1.4.1 1.4.2 1.5 1.5 Ozone and Toxicity .........................................................................................................................9 First Aid Treatment .........................................................................................................................9 GENERAL SAFETY PRECAUTIONS ...................................................................................... 10 PRÉCAUTIONS GÉNÉRALES DE SÉCURITÉ ........................................................................... 10 1.5.1 1.5.1 1.5.2 1.5.2 1.5.3 1.5.3 1.5.4 1.5.4 Electrical and Burn Precautions .................................................................................................. 11 Précautions relatives à l’électricité et aux brûlures ..................................................................... 11 Carrier Gas and Exhaust Gas Precautions ................................................................................. 12 Précautions relatives au gaz porteur et d'échappement ............................................................. 12 Chemical Precautions ................................................................................................................. 13 Précautions chimiques ................................................................................................................ 13 Sample Stream Precautions........................................................................................................ 14 Précautions relatives aux échantillons ........................................................................................ 15 SECTION 2 OPERATOR’S MANUAL ......................................................................... 16 2.1 SOFTWARE SCREENS AND SOFTWARE MENU DIAGRAM ............................................................ 16 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.2 Startup State................................................................................................................................ 18 System Status Messages ............................................................................................................ 18 Analysis Data Screen .................................................................................................................. 19 Analysis Graph Screen ................................................................................................................ 20 Reagent Status Screen ............................................................................................................... 20 Select Level Menu ....................................................................................................................... 21 Enter Password Menu ................................................................................................................. 21 OPERATION MENU ............................................................................................................ 22 2.2.1 2.2.2 Start Stop..................................................................................................................................... 22 Reagents Setup ........................................................................................................................... 24 2.2.2.1 2.2.2.2 2.2.3 2.2.4 2.2.5 2.2.6 2.2.7 2.2.8 2.2.9 2.3 Install New Reagents ......................................................................................................................... 24 Purge Reagents & Zero ..................................................................................................................... 25 System Range Data Screen ........................................................................................................ 25 Manual Program Menu ................................................................................................................ 26 Reaction Archive Screen ............................................................................................................. 27 Fault Archive Menu ..................................................................................................................... 27 Time & Date Menu ...................................................................................................................... 28 Contact Information ..................................................................................................................... 28 LCD Adjust .................................................................................................................................. 28 CALIBRATION MENU.......................................................................................................... 29 2.3.1 2.3.2 Zero Calibration ........................................................................................................................... 29 Span Calibration .......................................................................................................................... 31 SECTION 3 TECHNICAL SPECIFICATIONS.............................................................. 34 SECTION 4 INTRODUCTION ...................................................................................... 37 4.1 BIOTECTOR MAJOR COMPONENTS .................................................................................... 37 4.1.1 4.1.2 4.2 Analysis Enclosure ...................................................................................................................... 37 Motherboard Enclosure ............................................................................................................... 40 BIOTECTOR OPERATION ................................................................................................... 42 4.2.1 4.2.2 4.2.3 4.2.4 BioTector Oxidation Method ........................................................................................................ 42 BioTector Sample Injection ......................................................................................................... 43 BioTector Oxygen Concentrator .................................................................................................. 45 BioTector Analysis Types ............................................................................................................ 47 4.2.4.1 4.2.4.2 TIC & TOC Analysis ........................................................................................................................... 47 TC Analysis........................................................................................................................................ 47 Page 2 4.2.4.3 VOC (POC) Analysis ......................................................................................................................... 48 SECTION 5 INSTALLATION ....................................................................................... 49 5.1 5.2 BASIC SYSTEM REQUIREMENTS ........................................................................................ 49 UNPACKING AND INSTALLATION ......................................................................................... 50 5.2.1 5.2.2 5.2.3 5.2.4 5.3 Analyzer Dimensions and Mounting ............................................................................................ 51 Wiring Power and Signal Terminals ............................................................................................ 53 Wiring External Power Disconnection Switches .......................................................................... 55 System Fuse Specifications ........................................................................................................ 57 AIR SUPPLY AND REAGENT CONNECTIONS......................................................................... 58 5.3.1 5.3.2 5.4 Air Supply Connection ................................................................................................................. 59 Reagent Connections .................................................................................................................. 60 SAMPLE, DRAIN AND EXHAUST CONNECTIONS ................................................................... 62 5.4.1 5.4.2 Sample Inlet Tube Position ......................................................................................................... 62 Drain and Exhaust Connections .................................................................................................. 64 SECTION 6 6.1 REAGENTS AND CALIBRATION STANDARDS.................................... 65 REAGENTS ....................................................................................................................... 65 6.1.1 6.1.2 6.2 Sulfuric Acid Reagent .................................................................................................................. 66 Sodium Hydroxide Reagent ........................................................................................................ 68 CALIBRATION STANDARDS ................................................................................................ 70 SECTION 7 ANALYZER COMMISSIONING AND STARTUP .................................... 73 SECTION 8 MAINTENANCE MENU ........................................................................... 78 8.1 DIAGNOSTICS MENU .................................................................................................... 79 8.1.1 Process Test................................................................................................................................ 80 8.1.1.1 8.1.1.2 8.1.1.3 8.1.1.4 8.1.1.5 8.1.2 8.1.3 8.1.4 Simulate ....................................................................................................................................... 89 Signal Simulate............................................................................................................................ 93 Data Output ................................................................................................................................. 95 8.1.4.1 8.1.4.2 8.1.4.3 8.1.4.4 8.1.5 8.1.6 8.1.7 8.2 Pressure Test .................................................................................................................................... 80 Flow Test ........................................................................................................................................... 81 Ozone Test ........................................................................................................................................ 82 Sample Pump Test ............................................................................................................................ 84 pH Test .............................................................................................................................................. 85 Send Reaction Archive ...................................................................................................................... 96 Send Fault Archive ............................................................................................................................ 99 Send Configuration ............................................................................................................................ 99 Send All Data ..................................................................................................................................... 99 Input/Output Status ................................................................................................................... 100 Oxygen Controller Status .......................................................................................................... 101 Service ....................................................................................................................................... 102 COMMISSIONING MENU ............................................................................................ 103 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.2.9 8.2.10 8.2.11 8.3 Reaction Time ........................................................................................................................... 103 Sample Pump ............................................................................................................................ 104 Stream Program ........................................................................................................................ 104 COD/BOD Program ................................................................................................................... 105 New Reagents Program ............................................................................................................ 106 Reagents Monitor ...................................................................................................................... 106 Autocal Program ........................................................................................................................ 107 4-20mA Program ....................................................................................................................... 107 Alarm Program .......................................................................................................................... 109 Data Program ........................................................................................................................ 110 Information ............................................................................................................................ 110 SYSTEM CONFIGURATION MENU ............................................................................. 111 8.3.1 8.3.2 8.3.3 8.3.4 Analysis Mode ........................................................................................................................... 112 System Program ........................................................................................................................ 113 Calibration Data ......................................................................................................................... 118 Sequence Program ................................................................................................................... 118 8.3.4.1 8.3.4.2 8.3.4.3 8.3.4.4 Average Program ............................................................................................................................. 118 Zero Program................................................................................................................................... 119 Span Program.................................................................................................................................. 120 Reagents Purge ............................................................................................................................... 122 Page 3 8.3.4.5 8.3.5 Pressure/Flow Test Program ........................................................................................................... 122 Output Devices .......................................................................................................................... 123 8.3.5.1 8.3.5.2 8.3.6 8.3.7 8.3.8 8.3.9 8.3.10 8.3.11 8.3.12 8.3.13 8.3.14 8.3.15 8.3.16 System Outputs ............................................................................................................................... 123 Programmable Outputs .................................................................................................................... 125 Reaction Check ......................................................................................................................... 126 Result Integration ...................................................................................................................... 127 Fault Setup ................................................................................................................................ 128 Fault Status ............................................................................................................................... 131 CO2 Analyzer ........................................................................................................................ 132 Cooler Program ..................................................................................................................... 133 Ozone Destructor Program ................................................................................................... 134 Software Update ................................................................................................................... 135 Password .............................................................................................................................. 136 Language .............................................................................................................................. 136 Hardware Configuration ........................................................................................................ 136 SECTION 9 TROUBLESHOOTING OF SYSTEM FAULT, WARNING AND NOTIFICATION EVENTS ................................................................................................ 137 9.1 9.2 9.3 BIOTECTOR FAULT EVENT EXPLANATION AND REMEDIAL ACTION ...................................... 137 BIOTECTOR W ARNING EVENT EXPLANATION AND REMEDIAL ACTION ................................. 141 BIOTECTOR NOTIFICATION EVENT EXPLANATION AND REMEDIAL ACTION .......................... 149 SECTION 10 10.1 10.2 SERVICE AND MAINTENANCE ............................................................ 150 WEEKLY MAINTENANCE .................................................................................................. 150 SIX MONTH SERVICE ...................................................................................................... 151 SECTION 11 SYSTEM REPLACEMENT AND SPARE PARTS .................................. 155 SECTION 12 GENERAL INFORMATION .................................................................... 158 12.1 12.2 12.3 DECLARATION OF CONFORMITY AND CERTIFICATION ........................................................ 158 DECLARATION OF COMPLIANCE ....................................................................................... 159 WARRANTY AND EXCLUSIONS ......................................................................................... 160 SECTION 13 APPENDICES ......................................................................................... 161 APPENDIX 1 APPENDIX 2 GLOSSARY OF TERMS AND ABBREVIATIONS .......................................................... 161 CONTACT INFORMATION ...................................................................................... 164 Page 4 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. Caution Used when there is a danger of minor injury or serious damage to the system if the user does do not follow the precautions. WARNING Used when failure to observe a safety precaution may result in serious injury or death. DANGER Page 5 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 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. This symbol, when displayed on the instrument, indicates that the user must follow the necessary local, state and federal laws during the disposal of the display. Page 6 1.3 Certification Marks Attached to the Instrument The certification marks attached to the instrument and their meanings are summarized below. This mark, which stands for European Conformity "Conformité Européene", indicates that “The instrument complies with the European product directives, health, safety and environmental protection legislations”. See Section 12.1 Declaration of Conformity and Certification for details. If these marks are displayed on the instrument, they indicate that “This product has been tested to the Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use; Part 1: General Requirements of ANSI/UL 61010-1 and CAN/CSA-C22.2 No. 61010-1, second edition, 12 July 2004 including revision 22 July 2005”. Intertek ETL listed mark, which stands for Electrical Testing Laboratories, identifies that the product has been tested by Intertek, found in compliance with accepted national standards, and it meets the minimal requirements required for sale or distribution. Page 7 1.4 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 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 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. If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. 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. Page 8 1.4.1 Ozone and Toxicity Ozone is found in gaseous form as a natural ingredient of the earth's atmosphere. It is not a poisonous chemical but a strong oxidizing chemical. Some of the chemical and physical properties of ozone are as follows: Terms Molecule Weight Boiling Point Melting Point Properties of Ozone (O3) 47.9982 g/g-mol -119  0.3 °C -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. 1.4.2 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. Page 9 1.5 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:      1.5 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. 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. Page 10 1.5.1 Electrical and Burn Precautions BioTector contains electrical components operating under high voltages. Contact may result in electric shock and severe or fatal injury. DANGER 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 recommended 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. 1.5.1 Précautions relatives à l’électricité et aux brûlures 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 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. Il est recommandé de brancher l’alimentation électrique de réseau par le biais d’un isolateur externe (commutateur bipolaire de découplage) et si possible, brancher l'alimentation de réseau en la faisant passer par un disjoncteur de fuite à la terre. Utiliser des gants de protection pour les travaux sur les surfaces très chaudes et prendre soin en manipulant les composants. Page 11 1.5.2 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 29 l/h (483 ml/min). Carbon dioxide filtered air, carbon dioxide and nitrogen contaminated oxygen gas are not suitable for BioTector TOC 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. 1.5.2 Précautions relatives au gaz porteur et d'échappement Pour son fonctionnement, BioTector emploie de l’oxygène (O 2) 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 29L/heure (483 ml/min). L’analyseur BioTector TOC 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. Page 12 1.5.3 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. 1.5.3 Précautions chimiques La liste de la Section 6 Réactifs et Standards de Calibration (Section 6 Reagents and Calibration Standards) 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. Page 13 1.5.4 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) Vinyl Reinforced Silicon Reinforced PVC (Poly-vinyl-chloride) PFA (Per-fluoro-alkoxy) Stainless Steel (SS-316) PVDF (Poly-vinylidene-flouride) Brass EMPP (Elastomer-modified-poly-propylene) PP (Poly-propylene) HDPE (High-density-poly-ethylene) EMPP (Elastomer-modified poly-propylene) Viton / FKM (Fluoro-elastomer) Fittings Pump Tubing Connectors Connector & Valve Tubing Sample Valve Reactor Valve Seals Oxidized Sample Catch-pot/Cleaning Vessel NDIR CO2 Analyzer NDIR CO2 Analyzer Lens PEEK (Poly-ether-ether-ketone) PVDF (Poly-vinylidene-flouride) Stainless Steel (SS-316) EMPP (Elastomer-modified poly-propylene) Hastelloy (C-276) Stainless Steel (SS-316) PFA (Per-fluoro-alkoxy) PTFE (Poly-tetra-fluoro-ethylene) Kalrez / FFKM (Perfluoro-elastomer) Viton / FKM (Fluoro-elastomer) NBR (Nitrile-butadiene-rubber) Borosilicate Glass Hastelloy (C-276) Stainless Steel (SS-316) Sapphire Page 14 1.5.4 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 Matière Tuyauterie PFA (perfluoroalkoxy) Vinyle Silicone renforcé PVC renforcé (poly-chlorure de vinyle) PFA (perfluoroalkoxy) Acier inoxydable (SS-316) PVDF (polyfluorure de polyvinylidène) Laiton PPMOD (polypropylène modifié par élastomère) PP (polypropylène) HDPE (polyéthylène haute densité) PPMOD (polypropylène modifié par élastomère) Viton / FKM (élastomère fluoré) Raccords Tuyauterie de la pompe Connecteurs Tuyauterie des connecteurs & vannes Vanne d’entrée de l’échantillon Réacteur Joints des vannes Bac de récupération/récipient de nettoyage de l’échantillon oxydé Analyseur infrarouge de CO2 Lentille de l’analyseur infrarouge de CO2 PEEK (polyéther éther cétone) PVDF (polyfluorure de polyvinylidène) Acier inoxydable (SS-316) PPMOD (polypropylène modifié par élastomère) Hastelloy (C-276) Acier inoxydable (SS-316) PFA (perfluoroalkoxy) PTFE (polytetrafluoroethylene) Kalrez / FFKM (élastomère perfluoré) Viton / FKM (élastomère fluoré) NBR (caoutchouc nitrile butadiène) Verre borosilicaté Hastelloy (C-276) Acier inoxydable (SS-316) Saphir Page 15 Section 2 Operator’s Manual 2.1 Software Screens and Software Menu Diagram 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 [ BioTector.  ,  ] and RIGHT [  ,  ] arrow keys are used for numerical entries and programming the The UP [  , BioTector.  ] and DOWN [  ,  ] arrow keys are used for numerical entries and programming the The ENTER [  , √ ] key, which advances user to the next screen, is also used to enter programmed settings in the BioTector. The symbols used on BioTector LCD screen and their meanings are as follows: < 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. There are three main menu levels in BioTector in addition to the analysis graph, analysis 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. Page 16 Software Menu Diagram Page 17 2.1.1 Startup State When the BioTector is powered up, its LCD screen will automatically display the Analysis Data screen after a delay of 60 seconds. By pressing the ESCAPE key the user moves from the Analysis Data screen to the Analysis Graph screen. Pressing the ENTER key on the Analysis Graph screens brings the user back to the Analysis Data screen. Pressing ENTER key on the Analysis 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 menu 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. 2.1.2 System Status Messages The system status messages are displayed on the top left hand side of the Analysis 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. 3. SYSTEM CALIBRATION – The BioTector is calibrating. This could be Span Calibration, Span Check, Zero Calibration or Zero Check. 4. Running 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. The BioTector time and date is displayed on the top right side of each screen. When a fault is logged in the system, a FAULT LOGGED message will alternate with the time/date in this location until the fault has been corrected. Changing most system settings are prevented when the BioTector is running. Page 18 2.1.3 Analysis Data Screen B I O T E C T O R R U N N I N G 0 9 : 1 7 : 2 8 0 9 : 1 3 : 0 2 1 2 - 0 9 - 0 2 T I C & T O C S T R E A M 2 T O C 1 2 6 6 s 3 6 0 s R R R R R R E E E A E E A A A N A A C C C G C C R 0 0 0 0 0 0 S S S S S C 1 2 3 4 5 F √ √ √ x x T I C m g C 1 3 0 3 7 1 0 1 4 0 E 9 9 8 8 8 8 A : : : : : : C 0 0 5 4 4 3 T 7 1 5 9 3 7 I : : : : : : O 0 0 0 0 0 0 N 2 2 2 2 2 2 R 1 1 1 1 1 1 E 2 2 2 2 2 2 S - U 0 0 0 0 0 0 L 9 9 9 9 9 9 T - 0 0 0 0 0 0 2 2 2 2 2 2 T T T E T T 1 2 - 0 9 - 0 2 I O N I O N I O N S T A R T T Y P E P H A S E I O N I O N T I M E D U R A T I O N / . . . . . . l 0 6 2 7 3 9 T O C m g 5 4 0 3 7 1 0 1 4 7 C . . . . . . / l 0 6 2 7 3 9 The Analysis Data screen is the default display screen on the BioTector for carbon (TIC, TOC, TC and VOC) analysis. When the user moves through the various levels of the software menu, BioTector returns to this screen automatically after 15 minutes if there is no further activity on the membrane keypad. 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 operation Range (e.g. Range 1, 2 or 3) the BioTector is using to carry out its analysis. - The Reaction Time, which is the elapsed time (seconds) since the analysis start. - The Reaction Duration, which is the overall duration (seconds) of the analysis. The Analysis 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 S3 – reactions from stream 1 to stream 3. M1 to M3 – reactions from manual sample stream 1 to manual stream 3. √ – sample sensor detected the sample and liquid quality is greater than the threshold value. x – sample sensor detected no sample or liquid quality is less than the threshold value. 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 A3 – 24 hours average result from stream 1 to stream 3. - Analysis Results – analysis results according to the analysis type (e.g. TIC, TOC in mgC/l). Page 19 2.1.4 Analysis Graph Screen 1 0 1 . 5 [ k P a ] 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 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 1 0 . 0 l / h 0 s 2 6 C 1 2 0 s 5 6 C O 2 i 2 4 0 s 1 2 C O 2 z 3 6 0 s 2 6 5 s The Analysis Graph screen gives information on the current analysis in progress, and allows the user to monitor the progression of the analysis. This screen gives information on: - The current atmospheric pressure, measured in kPa (e.g. 101.5 kPa). - The milligram per liter un-calibrated (mgu) data from the analysis, for example TICmgu or TOCmgu without any compensation for atmospheric pressure. - The height of the CO2 peaks in each phase of the reaction (e.g. 956ppm CO2). - The current MFC flow in l/h (e.g. 10.0 l/h). - The temperature of the analyzer in °C (e.g. 26°C). - The CO2 instantaneous value (e.g. 56ppm CO2i) and the CO2 zero value (e.g. 12ppm CO2z) of the reaction. - The elapsed time (e.g. 265s) since the start of the analysis. 2.1.5 Reagent Status Screen B I O T E C T O R A C I D B A S E N O T E : R U N N I N G M O N I T O R M O N I T O R D A Y S L E F T I S B A S E D S Y S T E M 0 9 : 1 7 : 2 8 1 9 . 0 l 1 9 . 0 l 1 2 - 0 9 - 0 2 ~ 2 1 0 ~ 2 1 0 D A Y S D A Y S A N E S T I M A T E 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. Page 20 2.1.6 Select Level Menu S E L E C T 1 < 2 3 L E V E L 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 O P E R A T I O N C A L I B R A T I O N M A I N T E N A N C E The Select Level 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. 2.1.7 Enter Password Menu 0 9 : 1 7 : 2 8 E N T E R P A S S W O R D O P E R A T I O N [ S E C U R I T Y 1 2 3 4 1 2 - 0 9 - 0 2 F O R D O M A I N ] 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 in Password menu (see Section 8.3.14 Password for details), then it must be entered before the BioTector will grant access to the password-protected security domains. Use of a higher menu level password also allows access to lower levels/domains. Page 21 2.2 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. 2.2.1 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 2 (by default) on the Power and Input/Output Board (e.g. from a flow switch). A “REMOTE STANDBY” message is displayed on the top left corner of the main Analysis 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 Analysis 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 Page 22 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 Reactor Valve.  Analyzer Purge sequence purges any CO2 gas from the CO2 Analyzer through the Exhaust Valve. An “*” is displayed to let the operator know the function has been activated. If there is a fault in the system, it will not be possible to start the analyzer until the fault has been rectified. 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 CO 2 Analyzer Purge sequences. An “*” is displayed to let the operator know the function has been activated. 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. Page 23 2.2.2 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. 2.2.2.1 Install New Reagents I N S T A L L N E W C O N F I R M R E A G E N T S 0 9 : 1 7 : 2 8 T H E F O L L O W I N G : 1 < 2 3 4 1 0 1 0 C C I C A S g C W N E R N E R T O S T W A C I D E S E T A W B A S E E S E T B C 2 0 0 m A R T N E O D O E , R N N M N N M T I E A E O E O C G C N C N T I T I 5 E N E T E T 0 T D 3 5 0 m g O R 2 5 . D O R 2 5 . m g C C O N C Y C L E 1 2 - 0 9 - 0 2 / l M n S O 4 . H 2 O 0 l ~ 2 6 0 D A Y S 0 l ~ 2 6 0 N E C T E D D A Y S N O T E : B I O T E C T O R W I L L S T O P 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 (see Section 2.3 Calibration Menu for details). The comprehensive Zero Check/Calibration and Span Check/Calibration parameters are programmed in Zero Program and Span Program menus respectively (see Section 8.3.4.2 Zero Program and 8.3.4.3 Span Program for details). 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 without stopping the system. However, when acid and/or base reagents 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. Failure to do so may have an impact on system zero response and the analysis results. Page 24 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 (see Section 8.2.5 New Reagents Program for details). 2.2.2.2 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. 2.2.3 System Range Data Screen This menu displays the system specific, factory calibrated, analysis range data for all measured components (e.g. TIC, TOC, TC). 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. TIC etc.) of the sample are also carried out at the same analysis range. Page 25 2.2.4 Manual Program Menu M A N U A L 1 1 1 1 1 < 2 3 4 5 6 7 8 9 0 1 2 3 ▼ P R O G R A M 0 9 : 1 7 : 2 8 R R R R U U E E N A F T E R N E X T R E A C T I O N N A F T E R T U R N T O O N - L I N E S A M P L I N G S E T M A N U A L P R O G R A M M M M M M M M M A A A A A A A A N N N N N N N N U U U U U U U U A A A A A A A A L L L L L L L L 1 2 3 - , , , , , , , , 4 4 4 - - - R R R R R R R R A A A A A A A A N N N N N N N N 1 2 - 0 9 - 0 2 0 0 : 0 0 Y E S G G G G G G G G E E E E E E E E 1 3 2 - Manual Program menu allows the user to run system in manual operation mode in order to analyze grab 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 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 will start 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 (with NO setting) or return to online monitoring (with YES setting) 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 screen (see Section 2.2.3 System Range Data Screen for details) 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. Page 26 2.2.5 Reaction Archive Screen The Reaction Archive holds information on TIC, TOC, TC, VOC, COD, BOD, 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 S3: M1 to M3: √ x RS: ZC: ZK: ZM: SC: SK: SM: A1 to A3: Reactions from stream 1 to stream 3. Reactions from manual sample stream 1 to manual stream 3. Sample Sensor detected the sample and the liquid quality is greater than the threshold value for stream and manual samples. Sample Sensor detected no sample or the liquid quality is less than the threshold value for stream and manual samples. See Sample Status in section 8.3.8 Fault Setup for details. Remote standby reaction. Zero calibration reaction. Zero check reaction. Manually input zero adjust. Span calibration reaction. Span check reaction. Manually input span adjust. 24 hours average result from stream 1 to stream 3. 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. 2.2.6 Fault Archive Menu In the Fault Archive menu, the user can view the last 99 faults/warning/notification events logged in the system, confirm if these events are current or not, and acknowledge the current events. If the archive is full, then every new event 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. See Section 9 Troubleshooting of System Fault, Warning and Notification Events for a list of all systems fault, warning and notification events. The faults 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 event, 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 an information (e.g. “86_Power Up”, “87_Service Time Reset” etc.) displayed on the screen. To acknowledge any current events marked with an “*” in the archive, first identify and locate the faults/warnings/notification. Follow the necessary troubleshooting procedures to solve the problem. See Section 9 Troubleshooting of System Fault, Warning and Notification Events for details. 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. If an event cannot be acknowledged when the system is running, a “SYSTEM RUNNING” message is displayed on screen. Page 27 2.2.7 Time & Date Menu 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. 2.2.8 Contact Information Contact Information menu displays the manufacturer/distributor contact details. 2.2.9 LCD Adjust LCD Adjust menu allows the user to adjust the LCD screen’s contrast and backlight level. The default contrast and backlight setting is 50%. The adjustment is carried out by entering to the relevant setting and making the necessary change using the UP or DOWN arrow keys. When the UP/DOWN key is pressed and kept pressed, BioTector displays the relevant adjustment in real time. When the adjustment is completed, press the ENTER key to accept the new setting or press ESCAPE key to return back to the previous setting. Page 28 2.3 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 ENTER PASSWORD CALIBRATION ZERO CALIBRATION SPAN CALIBRATION 2.3.1 Zero Calibration Z E R O 1 < 2 3 4 5 6 7 8 9 1 0 1 1 C A L I B R A T I O N Z E R O R U N R U N R U N Z E R O Z E R O - - > A D J U S T 0 9 : 1 7 : 2 8 1 2 3 R E A G E N T S P U R G E Z E R O C A L I B R A T I O N Z E R O C H E C K P R O G R A M A V E R A G E Z E R O 0 . 0 0 . 0 0 . 0 R 1 6 4 , , 1 2 - 0 9 - 0 2 [ 0 . 0 ] [ 0 . 0 ] [ 0 . 0 ] R 2 4 2 , , R 3 4 2 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.-3. Zero Adjust. The Zero Adjust is used to compensate any organic 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. 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) 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). 4. 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. 5. 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 does not take any sample. To start the zero calibration, 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: Page 29 1. The Zero Adjust settings for each range are updated automatically by the system using the uncalibrated 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. 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. 3. 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. 6. 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. 8. 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). 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. 9. 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. 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. 11.  Zero Program. Zero Program is a link to Maintenance, System Configuration, Sequence Program, Zero Program menu. See Section 8.3.4.2 Zero Program. Page 30 2.3.2 Span Calibration S P A N 1 1 1 1 1 1 1 1 1 1 2 2 1 < 2 3 4 5 6 0 1 2 3 4 5 6 7 8 9 2 3 C A L I B R A T I O N T O C S P A N T I C S P A N R U N R U N S P A N S P A N S S R T T T T P P A O O I I A N P R O A N A V E N G E C C A L C C H E C C C A L C C H E C - - > S P A N 0 9 : 1 7 : 2 8 A D J U S T 1 2 3 A D J U S T 1 2 3 C A L I B R A T I O N C H E C K G R A M R A G E S T D K S T D S T D K S T D 1 1 1 1 1 1 . . . . . . 0 0 0 0 0 0 0 0 0 0 0 0 6 4 1 1 0 5 1 2 6 0 0 5 0 . . . . 0 0 0 0 1 2 - 0 9 - 0 2 m m m m g g g g C C C C / / / / l l l l 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 systems. In TC and VOC systems, the relevant parameters, identified below, are displayed in this menu. 1.-3. TOC Span Adjust. This menu item allows the user to set the TOC 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 TC and VOC systems, this function is named as TC Span Adjust. In order to manually set the Span Adjust factors: First enter the concentration of the standard solution used. S P A N 1 < 2 3 4 A D J U S T T O C S P A N A D J U S T T I C S P A N A D J U S T 0 9 : 1 7 : 2 8 S T A N D A R D 1 0 0 . 0 2 1 . 0 0 3 1 . 0 0 1 1 . 0 0 1 2 - 0 9 - 0 2 R E S U L T 0 9 : 1 7 : 2 8 S T A N D A R D 1 0 0 . 0 2 1 . 0 0 3 1 . 0 0 1 1 . 0 0 1 2 - 0 9 - 0 2 R E S U L T 9 9 . 5 Next enter the average result. S P A N 1 < 2 3 4 A D J U S T T O C S P A N A D J U S T T I C S P A N A D J U S T 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. Page 31 4.-6. TIC Span Adjust. This menu item allows the user to set the TIC span adjust factors manually for each range as described for TOC Span Adjust above. 10. 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”. 11. 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”. 13. 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. 14. 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. 15. 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 screen (see Section 2.2.3 System Range Data Screen for details) in order to select the correct operation range or correct standard solution. 16. TOC Cal Std. TOC Calibration Standard function allows the user to program the concentration (mgC/l) of the TOC 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 screen in order to select the correct operation range or correct standard solution. If TOC Calibration Standard is programmed as 0.0mgC/l, system does not calculate or update any Span Adjust factors and therefore omits any span related warnings defined above. See Section 6.2 Calibration Standards for the details of BioTector standard solutions and preparation procedures. In TC systems, this parameter is named as TC Calibration Standard. 17. TOC Check Std. TOC Check Standard function allows the user to program the concentration (mgC/l) of the TOC standard solution used in Span Check reactions. If TOC Check Standard is programmed as 0.0mgC/l, any span related warnings are omitted. In TC systems, this parameter is named as TC Check Standard. 18. TIC Cal Std. TIC Calibration Standard function allows the user to program the concentration (mgC/l) of the TIC standard solution used in Span Calibration reactions. If TIC Calibration Standard is programmed as 0.0mgC/l, any span related warnings are omitted. In VOC and TC – TIC systems, it is recommended to run the TIC and TOC calibrations separately using separate standard solutions. 19. TIC Check Std. TIC Check Standard function allows the user to program the concentration (mgC/l) of the TIC standard solution used in Span Check reactions. If TIC Check Standard is programmed as 0.0mgC/l, any span related warnings are omitted. Page 32 20. TC Cal Std. In VOC systems, the sum of the TIC and TOC Calibration Standard solution is displayed as TC Calibration Standard. When TOC Calibration Standard is programmed as 0.0mgC/l, and when a concentration of TIC Calibration Standard is programmed above, BioTector displays the TC Calibration Standard as 0.0mgC/l on purpose. This allows the calibration of TIC without any effect on the TC calibration. See definitions for TOC Calibration Standard above, Section 8.3.4.3 Span Program and Section 6.2 Calibration Standards for further details. 21. TC Check Std. In VOC systems, the sum of the TIC and TOC Check Standard solution is displayed as TC Check Standard. When TOC Check Standard is programmed as 0.0mgC/l, and when a concentration of TIC Check Standard is programmed above, BioTector displays the TC Check Standard as 0.0mgC/l on purpose. This allows the check of TIC without any effect on the TC check. 23.  Span Program. Span Program is a link to Maintenance, System Configuration, Sequence Program, Span Program menu (see Section 8.3.4.3 Span Program). Page 33 Section 3 Technical Specifications TYPICAL TECHNICAL DATA Enclosure: Dimensions (HxWxD): Weight: Power Consumption: Mains Connection: Mains Wire Specification: Signal Wire Specification: Fiberglass Reinforced Polyester 750mm x 500mm x 320mm Typically 46 kg 100 W (VA) 115V AC, 60Hz or 230V AC, 50Hz (10%) Other power options are available on request. Number of Cores = 3, Current Rating minimum = 10 Amps, CSA (Cross 2 Sectional Area minimum) = 1.50mm Number of Cores = 6 (+2 cores per additional signal), Current Rating 2 minimum = 1 Amp, CSA (Cross Sectional Area minimum) = 0.22mm FEATURES IN DETAIL Display: Data Storage: SD/MMC Card: Operation: Language Options: High Contrast 40 Character x 16 Line Backlit LCD with LED Backlight Previous 9999 Analysis Data on screen and more than 2 years old Analysis Data archive in flash memory card Previous 99 Fault Data on screen and more than 2 years old Fault Data archive in flash memory card Flash memory card for data transfer and for software & configuration updates Microcontroller with BioTector OS3 Software and Membrane Keyboard English, French, German Other language options are available on request. INPUT & OUTPUT SIGNALS Standard Output: Digital Output: Data Transfer Port: One programmable 4-20mA output signal (typically for TOC) per sample input channel Maximum impedance: 500 ohms Optionally expandable up to four programmable 4-20mA output signals Two freely programmable system relays (volt free changeover contact with a current rating of 1Amp at 30V DC) One of the relays is preprogrammed as system fault relay as standard. SD/MMC Card OPTIONAL FEATURES Result Output: Digital Output: Remote Control: Industrial Interface: Calibration: TIC, TC, VOC, after correlation COD, BOD Up to 4 additional digital output signals (volt free normally open contact with a current rating of 1Amp at 30V DC) Input for remote start / standby Input for remote stream and range selection (up to 2 online streams) Input for remote manual grab sample analysis Modbus, Profibus, Ethernet Automatic Calibration is available. Calibration is not necessary between every 6 month service intervals. Multi-stream: Up to 2 sample input channels, which can be used for online streams Manual stream: Manual grab sample channel, which can be used for automatic calibration. Sample input channels may be configured as manual grab sample channels. 4-20mA Outputs: As individual signal up to maximum of 4 or as multiplex signal up to maximum of 35. Maximum impedance: 500 ohms. EExp/Z purge: Certification options are available to European Standards (ATEX, Zone 2) and to North American Standards (Class 1, Div 2). Page 34 CONSUMABLES Typical Replacement Frequency & Consumption Acid & Base: Instrument Air: 26 weeks/19 Liters (based on standard range and 6 minute analysis cycle) 1.5 bar, - 20°C dew point (free of water, oil and dust) 3 Average consumption is less than 5.4 m /hour. Filter pack is recommended and available to meet the air quality specification. BioTector Air Compressor is available for air supply. Service: 6 Monthly Intervals ANALYSIS PARAMETERS Oxidation Method: TOC Measurement: Patented Two-Stage Advanced Oxidation Process using Hydroxyl Radicals NDIR measurement of CO2 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) COD* BOD* * COD & BOD by correlation algorithm incorporating TOC measured results Cycle Time: TOC typically 6 minutes MONITORING RANGES: Standard Range Accuracy and Repeatability Detection Limit TOC 0-5mgC/l or 0-25mgC/l 3% of reading or 0.03mgC/l, whichever is greater 0.06mg/l Second Range (Optional for Exceedance Tracking) 0-100mgC/l (5% of reading or 0.5mgC/l, whichever is greater) Range Selection: Automatic or Manual (up to 2 ranges configurable) Page 35 SAMPLE & ENVIRONMENTAL CONDITIONS Sample Volume: Sample Inlet Pressure: Drain Pressure: Sample Inlet Temperature: Sample Flow Rate: Sample Particle Size: Ambient Temperature: Humidity: Ingress Protection: System Sound: Up to 12.0ml Ambient (for applications with high sample pressure, sampling systems are available) Ambient (for applications with high drain pressure, optional systems are available) 2°C – 60°C (36°F - 140°F) Minimum 100ml per sample Up to 100 microns 5°C – 45°C (41°F - 113°F) Cooling and heating options are available. 5% - 85%, non-condensing IP54, standard fan cooled, maximum ambient temperature 45°C (113°F) IP65, air cooled, maximum ambient temperature 35°C (95°F) IP 65, vortex cooled, maximum ambient temperature 50°C (122°F) < 80 dBa The manufacturer has a continuous research and development program. Specifications may therefore be changed without notice. For specification updates, please contact the manufacturer. Page 36 Section 4 4.1 Introduction BioTector Major Components 4.1.1 Analysis Enclosure Figure 1, figure 2 and table 2 below shows the typical major analysis enclosure components of BioTector TOC Analyzer. Figure 1 BioTector analysis enclosure major components (typical TIC & TOC system) 1 2 3 4 5 6 8 7 9 11 10 13 12 14 15 Page 37 Figure 2 BioTector oxygen concentrator enclosure major components 16 18 17 19 20 23 22 24 21 25 27 26 10 11 28 29 14 30 31 32 33 Page 38 Table 2 BioTector major components 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Power and Input/Output Board NDIR CO2 Analyzer Ferrite Acid Pump, P3 Base Pump, P4 Main Power Switch Cooler Ozone Generator Sample Pump, P1 Manual Grab Sample/Calibration Valve, MV5 or Multi-stream Valve, MV6 Reactor Valve, MV3 Mixer Reactor Ozone Destructor Sample Valve, MV4 Exhaust Valve, MV1 Fan Oxygen (O2) Tank Termination Board Molecular Sieve Bed 20 Oxygen Pressure Regulator 21 Hepa Filter 22 Cooler Fan 23 Sample Pump Motor 24 Oxygen (O2) Controller Board 25 Mass Flow Controller (MFC) 26 Filter Board 27 Rotary Valve, OV2 28 Air Isolation Valve, OV1 29 Pressure Relief Valve 30 Reactor Motor, P2 31 Exhaust Filter 32 Mixer Reactor Liquid Leak Detector 33 Inner and Outer Enclosure Liquid Leak Detector Page 39 4.1.2 Motherboard Enclosure Figure 3 and table 3 below shows the BioTector motherboard enclosure components. Figure 3 BioTector motherboard enclosure components 1 2 3 4 Page 40 Table 3 BioTector motherboard components 1 2 3 4 Motherboard Battery (CR2430, Lithium, 3V, 285mAh) Processor Board MMC/SD Flash Memory Card Slot and Memory Card Page 41 4.2 BioTector Operation Detailed information on the system operation is available, in presentation and video formats, in the MMC/SD card shipped with the BioTector. It is recommended to review these files to understand the system 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 100 µm 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. 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 sample tubes are purged 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. BioTector self-cleaning technology using hydroxyl radical oxidation ensures that the cleaning of the reactor is not necessary. Page 42 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. Sample is initially drawn from the source by a peristaltic Sample Pump. In standard TIC & TOC systems, Acid Pump activates and the first TIC acid is injected into the Mixer Reactor. Sample Valve and Reactor Valve activates, Sample Pump rotates forward and injects the sample directly into the Mixer Reactor with the relevant number of pulses appropriate to the range. In TC systems, the sample injection is carried out similar to the one described for TIC & TOC systems above but unlike TIC acid, first the base reagent (e.g. Sodium Hydroxide) is injected into Mixer Reactor. Sample Valve and Reactor Valve activates, Sample Pump rotates forward and injects the sample directly into the Mixer Reactor with the relevant number of pulses appropriate to the range. 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. Figure 4 shows the typical analysis layout of TIC & TOC system below. Detailed information on sample injection is available, in presentation and video formats, in the MMC/SD card shipped with the BioTector. It is recommended to review these files to understand BioTector sample injection. Page 43 Figure 4 BioTector analysis layout (typical TIC & TOC system) Page 44 4.2.3 BioTector Oxygen Concentrator The operation of BioTector oxygen concentrator is based on the crystalline zeolite molecular sieves, which permits the separation of oxygen gas from the mixture of gases that comprise air. As air flows through a column or bed of molecular sieve, the component gases it contains are adsorbed and stratified in the order of their relative affinity to the molecular sieve material. The process may continue until the next to last gas component stratifies near the end of the bed. Once the full bed length is used, the bed must be regenerated by desorbing (or purging) the adsorbed gases. Purging is accomplished by reducing the pressure in the bed and back-flushing with some of the concentrated gas product. Adsorption and desorption are completely reversible processes and are carried out indefinitely. The theory behind the operation of the oxygen concentrator is Pressure Swing Adsorption (PSA). This is based on flowing air through the column (the sieve bed) packed with molecular sieve material. The components of the air (Water Vapor, Carbon Dioxide, Carbon Monoxide, Hydrocarbons, Nitrogen, Oxygen and Argon) are adsorbed in order of their relative affinity to the molecular sieve material. Figure 5 shows the adsorption of air components inside the molecular sieves. Figure 5 Adsorption of air components in oxygen concentrator molecular sieves. Once the sieve bed is used, then it is re-generated by purging the adsorbed gasses from the molecular sieve. This is achieved by removing the air supply from the inlet to the sieve bed, and back-flushing the sieve bed with some of the concentrated gas product. The typical oxygen purity obtained from a PSA oxygen concentrator is 93% (±3%) with balance gas Argon. Figure 6 below shows the layout of BioTector oxygen concentrator and the operation of the Rotary Valve used for the PSA process. Page 45 Figure 6 BioTector oxygen concentrator layout Page 46 4.2.4 BioTector Analysis Types BioTector TOC analyzer has four factory calibrated analysis types: 1. TIC & TOC (NPOC) Analysis: Total Inorganic Carbon & Total Organic Carbon (Non-Purgeable Organic Carbon) Analysis 2. TC Analysis: Total Carbon Analysis 3. VOC (POC) Analysis: Volatile (Purgeable) Organic Carbon Analysis 4.2.4.1 TIC & TOC Analysis 1. An acid reagent (e.g. Sulfuric Acid) is added and the oxygen carrier gas flow is activated to remove the inorganic carbon. 2. An unfiltered sample is injected into the BioTector reaction chamber (Mixer Reactor). 3. 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. 4. Ozone generator is activated. A base reagent (e.g. Sodium Hydroxide) 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. 5. 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). 6. At the end of the reaction, the oxidized sample liquid is discharged from the reactor with increased oxygen flow. 4.2.4.2 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. An unfiltered sample is injected into the reactor of the BioTector with a low flow of oxygen carrier gas. 3. The volatile organic content if the sample is oxidized with hydroxyl radicals. This reaction phase is called VOC Oxidation, as the oxidation of the volatile organic 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. BioTector analysis types are optional features. If the BioTector is built as a TIC & TOC system only, modifications in the system configuration will be required for TC analysis to be possible. Page 47 4.2.4.3 VOC (POC) Analysis BioTector Volatile Organic Carbon (VOC) analysis type is a combination of TC analysis followed by a TIC & TOC (NPOC) 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 result obtained from the 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 carbon (POC) present in the sample. In other words the TOC result, obtained in VOC analysis type, is the sum of NPOC and POC: TOCv = NPOC + POC VOC (POC) result, which is calculated from the difference between the measured TC (from the TC analysis), and the sum of measured TIC and measured NPOC (from the TIC & TOC analysis): VOC (POC) = TC – (TIC + NPOC) The NPOC result, 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 signals to an external device. BioTector analysis types are optional features. If the BioTector is built as a TIC & TOC system only, modifications in the system configuration will be required for VOC analysis to be possible. BioTectors built with the VOC analysis option can be programmed on site to operate with the TIC & TOC only or TC only analysis types. Page 48 Section 5 5.1 Installation Basic System Requirements Power and Signal Requirements   Mains Connection: Mains Wire Specification:  Signal Wire Specification:  Power Consumption: 115V AC, 60Hz or 230V AC, 50Hz (10%) Number of Cores = 3 Current Rating minimum = 10 Amps 2 CSA (Cross Sectional Area minimum) = 1.50mm Number of Cores = 6 (+2 cores per additional signal) Current Rating minimum = 1 Amp 2 CSA (Cross Sectional Area minimum) = 0.22mm Maximum 100 W (VA) Air Supply and Reagent Requirements Instrument Air Requirements  Air Quality: - 20°C dew point (free of water, oil and dust) To meet or exceed the air quality specification, filter pack may be required.  Air Supply Pressure: 1.5 bar  Air Supply Flow Rate: Minimum 8.4 m /hour at 1.5 bar  Air Consumption: Average consumption is less than 5.4 m /hour, typically 3.6 m /hour 3 3 3 Typical Reagent Requirements   Acid Reagent: 6.0 N Sulfuric Acid (H2SO4), containing 350 mg/l Manganese Sulphate Monohydrate. Base Reagent: 4.0 N Sodium Hydroxide (NaOH). Sample, Drain and Exhaust Requirements      Sample Inlet & Outlet Pressure: Sample Inlet Temperature: Sample Flow Rate: Sample Particle Size: Drain & Exhaust: Ambient 2°C – 60°C (36°F - 140°F) Minimum 100ml per sample Up to 100 microns Ambient Page 49 5.2 Unpacking and Installation The BioTector analyzer weighs typically 46kg (101 lb). Therefore, appropriate means should be used for transporting, un-packing, lifting and installing the BioTector. Caution 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. Unless it is specified, the BioTector has an Ingress Protection rating of IP54. 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 45°C. If the ambient temperature exceeds 45°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 left hand side of the BioTector for the tube and electrical connections. There should be enough clearance at both sides 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 50 5.2.1 Analyzer Dimensions and Mounting The BioTector TOC analyzer enclosure is a 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 4 below gives the dimensions of BioTector enclosure. Figure 7 BioTector Dimensions Table 4 BioTector Dimensions BioTector TOC Analyzer Height 750mm Width 500mm Depth 320mm Page 51 Figure 8 below illustrates the BioTector door clearance dimensions. Figure 8 BioTector Door Clearance Dimensions     It is recommended that a clear space of at least 300mm is allowed around the analyzer from the right and the left sides and from the top and the bottom. The recommended clear space in the front of the analyzer is 1500mm for easy access to the system. 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 (~180 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 52 5.2.2 Wiring Power and Signal Terminals BioTector contains electrical components operating under high voltages. Contact may result in electric shock and severe or fatal injury. DANGER The equipment is for permanent connection to the mains only. (Plug and socket should not be used.) Caution Figure 9 below show the typical mains (for both 230 and 115 Volts systems) 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 2 cores, 10 Amps minimum current rating and 1.50mm 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 6 cores (+2 cores per additional signal), 1 Amp minimum current rating, 2 0.22mm minimum CSA (Cross Sectional Area). Page 53 Figure 9 Mains and 4-20mA terminal diagram for 115 / 230 V systems 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. 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. Page 54 5.2.3 Wiring External Power Disconnection Switches The mains power must be connected through one or more external 2-pole disconnection switches, so that the power to the BioTector and/or to the optional air compressor can be isolated without opening the electronics enclosure.  The external power disconnection switches must be located in easily accessible locations, with a maximum distance of 2 meters from the BioTector and/or the air compressor.  The switches must be clearly marked for their purpose.  The switch must comply with local electrical regulations, and have a breaking capacity of 10 Amps or greater.  The MCB or fuse (circuit breaker) located on the customers fuse board should be rated at 10 Amps or greater. Figure 10 below illustrates the positioning and the installation of the disconnection switch. Figure 10 External Power Disconnection Switch Page 55 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 switches are powered off, power on the internal Main Power Switch in the BioTector. ii) Close the BioTector electronics enclosure. iii) If installed, close the air compressor enclosure. iv) Switch on the external disconnection switches. The power off of the BioTector should be carried out by switching off with the external disconnection switch followed by the internal Main Power Switch. If installed, the power off of the air compressor should be carried out by switching off with the external disconnection switch followed by compressor power switch. Page 56 5.2.4 System Fuse Specifications Table 5 below summarizes the location and specification of the fuses used in BioTector. The locations of the fuses are also displayed in figure 9 above. 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. DANGER When any fuse replacement is required in the system, please refer to table 5 below and system specific drawings. Table 5 System Fuse Specifications Location Board Number Interru pt Rating Type Power and Input/Output Board 81204350-01 H-250V Miniature 5x20mm Motherboard 81204340_02 L-250V Miniature 5x20mm BioTector Compressor Start Signal Cable N/A L-250V Miniature 5x20mm Material Ceramic Glass Glass Fuse Number 230 V Systems Current Rating 115 V Systems Current Rating F1 *1 F1 F2 F3, F4 *2 F3, F4 F2 F3 F4 F5 F6 T 2.00A T 3.15A T 1.00A T 500mA T 1.00A F 2.00A F 2.00A F 2.50A F 3.15A F 2.50A T 3.15A T 5.00A T 1.00A T 500mA T 1.00A F 2.00A F 2.00A F 2.50A F 3.15A F 2.50A N/A T 200mA T 200mA KEY A: DIN: F1-6: F: H: ID: L: mA: N/A: PCB: T: V: *1: *2: Amperes German Institute for Standardization (Deutsches Institut für Normung e.V.) Fuse Number Fast Acting (Fast Blow) High Interrupt Identification Low Interrupt Milli-amperes Not Applicable Printed Circuit Board Time Lag (Time Delay) Volts (Optional) used with TDK power supply, type SWS300-24 only. (Optional) if higher powered device are connected, for example Multi-channel Modbus / Profibus, External Valve, External Relay. Page 57 5.3 Air Supply 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 11 shows the fitting side and the nut side of SS-316 (stainless steel), PFA and PVDF fittings and their corresponding correct ferrule orientation. Figure 11 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. When tightening Swagelok PFA TEE fittings with blue nuts, first fully insert the tube into the fitting, tighten the nut initially finger tight, then tighten further using an appropriate size spanner or an adjustable wrench until the nut stops or until it is not possible to tighten the nut any further. These TEE fittings with blue nuts, used on the 1/8” PFA tubing, contain only one ferrule with no back cutting ring or no back ferrule. Acid and Base pump fittings, which also contain one CTFE ferrule, should be tightened fully finger tight, assuring a strong connection. Page 58 5.3.1 Air Supply Connection The recommended air quality for BioTector is -20°C dew point, free of water, oil and dust. A filter pack may be required to meet or exceed the air quality specification. BioTector Air Compressor can be supplied by BioTector distributors as an option. The air can be supplied to BioTector from: A) An existing instrument air supply line B) BioTector Air Compressor 3 The required instrument air supply pressure is 1.5 bars. The minimum air supply flow rate is 8.4 m /hour at 3 3 1.5 bar. The average air consumption is less than 5.4 m /hour, and typically 3.6 m /hour during online operation. Figure 12 below illustrates the two options for air supply: A) from an existing instrument air supply line, B) from BioTector Air Compressor. Figure 12 BioTector air supply options Page 59 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. DANGER Use of 20 or 25 liter containers is recommended for each BioTector reagents. Figure 13 below shows the correct setup and connection of BioTector reagents: Acid (6.0 N Sulfuric Acid containing 350 mg/l Manganese Sulphate Monohydrate) and Base (1.2 N Sodium Hydroxide). See Section 6 Reagents and Calibration Standards for further details. Figure 13 BioTector reagent setup and connections Page 60 As can be seen in the figure 13 above, base (Sodium Hydroxide) reagent container does not contain any vent (breathing) hole. The breathing air into the base container is supplied through the CO 2 filter, which must be fitted on the base container lid. Figure 14 below shows the detailed connections on BioTector base reagent. The purpose of the CO 2 filter is to prevent the base reagent coming in contact with atmospheric CO 2 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 14 BioTector Sodium Hydroxide reagent dip tube setup The vent port on the acid reagent dip tube should not be isolated or blocked. 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. If HCl acid is used, stainless steel (SS-316) weights/filters should not be used in the reagent. The recommended weights/filters for such reagents are PFA. Page 61 5.4 Sample, Drain and Exhaust Connections 5.4.1 Sample Inlet Tube Position 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 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 100µm in diameter, however hard particulates (e.g. sand) will damage the analyzer and should be removed from the sample. The sample tubing length between the sample intake point and the BioTector sample port should be 2.5 meters exactly. The height of the sample chamber should be between 100mm and 500mm below the BioTector. BioTector in fact can draw samples from distances greater than 2.5 meters however, such distances may have an impact on the Sample Pump tubing life and may require changes in system configuration settings for the correct operation of the system. 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 required minimum sample volume is 100ml per sample. The drain tube should be placed to a well ventilated area at ambient pressure and it should not be subjected to any back pressure. Figure 15 and 16 illustrate the correct positioning and setup of the BioTector sample tube in various sampling systems. Figure 15 BioTector sample tube position in various sampling systems Page 62 Page 63 5.4.2 Drain 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. WARNING 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 16 illustrates BioTector connections including the Sample, Manual grab sample, Sample Out (drain) and the Exhaust connections. Figure 16 BioTector drain and exhaust connections Page 64 Section 6 6.1 Reagents and Calibration Standards Reagents BioTector TOC analyzer uses the following reagents: I. Acid: 6.0 N Sulfuric Acid (H2SO4) Reagent containing 350 mg/l Manganese Sulfate Monohydrate II. Base: 4.0 N Sodium Hydroxide (NaOH) Reagent Reagents should not contain high levels of organics, nitrates and phosphates. Ideally, the level of organics, nitrates and phosphates should be less than 100 g/l (ppb) in the deionized water used to prepare TOC analyzer reagents. Acid and Base reagents are stable up to 1 year. The reagents must be stored in a safe and secure location, where the temperature does not drop below 2°C, in compliance with the local regulations. Table 6 below summarizes the total days each BioTector TOC Analyzer reagent lasts at various system configurations: Table 6 BioTector TOC Analyzer Reagent Consumption REAGENTS Acid Base Container Size (Liters) TOTAL DAYS REAGENT LASTS 19 19 182 182 Above table is derived from several online operation parameters such as 100% online time. Recommended bunds (reagent spill trays) to contain above quantity reagents are 1x 50 Liters. Page 65 6.1.1 Sulfuric Acid Reagent There are a number of factors which affect the purity of the sulfuric acid solution used by the BioTector. These can take the form of inorganic or organic contamination. Inorganic contamination does not generally occur in concentrated acids, but there could be some dissolved CO 2 present in the deionized water, which is used to make up the acid solution. To remove any CO2 dissolved in the deionized water used to make up the acid solution, sparge the water with a CO2 free gas such as Nitrogen. Organic contamination has two main sources: Organics, which are present in the concentrated sulfuric acid, or dissolved organics in the water used to make up the solution. The manufacturer will specify the level of organics in the concentrated sulfuric acid. For the BioTector, this should be as low as possible. If the deionized water generator is functioning correctly, then there should not be any organics in the deionized water. Ideally, the level of organics should be less than 100 g/l (ppb). The procedure for making up sulfuric acid solutions for the BioTector from concentrated acid is as follows: Mixing Procedure for the Preparation of 6.0 N Sulfuric Acid Solution containing 350 mg/l Manganese Sulfate Monohydrate: Concentrated sulfuric acid is dangerous. The preparation of sulfuric acid solutions should only be carried out by persons properly trained in the handling of chemicals. WARNING NEVER POUR WATER INTO ACID, ALWAYS POUR ACID INTO WATER! Use eye protection and gloves. Typically, concentrated sulfuric acid has purities of 96-98%. The procedures for both 1 liter and 25 liters of acid reagents are described below. The instructions below assume that the sulfuric acid used has a purity of 98%, which is the standard commercial purity of sulfuric acid. When sulphuric acid at different purities are used, please refer to table 7 below. 1. To prepare an acid solution, always use deionized water, free from organic and inorganic carbon. The conductivity of the deionized water used should be less than 0.5 µS/cm. 2. Blow through the deionized water with a CO2 free gas such as Nitrogen or Oxygen, to purge the water of any dissolved CO2. 3. Fill 75% of the container with deionized water. 4. a) In order to prepare 1 liter of 6.0 Normal acid solution, add 300.2 grams of 98% purity sulfuric acid. Mix gently and add enough deionized water to make it exactly 1 liter. b) To prepare a 25 liters acid solution, add 7505 grams of 98% purity sulfuric acid in stages. Adding the sulfuric acid in stages will prevent the solution from heating up. Gently mix and then add enough deionized water to make it exactly 25 liters. 5. Seal the container. 6. Gently shake the container to mix the acid with the water. 7. Add enough Manganese Sulphate Monohydrate catalyst (MnSO 4.H2O), so that the acid reagent will contain 350 mg/l (mg per liter) of MnSO4.H2O. For instance, for a 25 litres acid solution, add 8.75 grams of MnSO4.H2O and mix well. 8. Allow the container to stand for one hour, and gently shake again to ensure a good mix. Page 66 Control of Normality: In order to check the Normality of the acid solution prepared, take a 12 ml sample from the prepared 6.0 N sulfuric acid solution. Add 2-3 drops phenolphthalein and just enough 1.2 N sodium hydroxide until the color of the mix becomes red. If the normality is correct, 60 ml of 1.2 N sodium hydroxide will neutralize 12 ml of 6.0 N sulfuric acid. Calculations for Different Purities of Sulfuric Acid: Table 7 below tabulates the required amounts of sulfuric acid at different purities. Table 7 Amounts of concentrated sulfuric acid required to prepare 25 liters of 6.0 N acid solutions at various purities. Sulphuric Acid % Purity of Sulfuric Acid quantity per 25 Liter container (grams) 100 7356 99 7430 98 7505 97 7583 96 7662 Page 67 6.1.2 Sodium Hydroxide Reagent There are a number of factors which affect the purity of the sodium hydroxide solution used by the BioTector. These can take the form of inorganic or organic contamination. Inorganic contamination has two main sources: Sodium Carbonate (Na2CO3), which is present in the concentrated sodium hydroxide, or dissolved CO2, which can be in the water used to make up the solution. The level of Na 2CO3 in the concentrated sodium hydroxide will be specified by the manufacturer. For the BioTector, this should be 0.1% (or lower if possible). Carbonates appears to be the main cause of contamination found in sodium hydroxide solutions, and generally the level of Na2CO3 is found to be lower in concentrated liquid sodium hydroxide than in sodium hydroxide pellets. To remove any CO2 dissolved in the deionized water used to make up the sodium hydroxide solution, sparge the water with a CO2 free gas, for example nitrogen. Ideally, the level of organics should be less than 100 g/l (ppb). Mixing Procedure for the preparation of 4.0N Sodium Hydroxide solution, from 50% concentrated Sodium Hydroxide solution: Concentrated sodium hydroxide is dangerous. The preparation of sodium hydroxide solutions should only be carried out by persons properly trained in the handling of chemicals. WARNING Use eye protection and gloves. The instructions below are for 25 liters of solution. Caution 1. 2. 3. 4. 5. 6. 7. It is important to purge the deionized water (used to make sodium hydroxide base reagent) with a CO2 free gas prior to the mixing procedure. As it is not possible to purge the carbonates (CO3 ) from the base reagent by means of any CO2 free gas, prepared base reagent should never be purged further with any gas after preparation. When mixing the sodium hydroxide solution, care should be taken to minimize the amount of atmospheric CO2 gas being absorbed in the solution. The base container should be fitted with a CO2 filter to prevent the reagent coming in contact with air. Failure to do so will result in increased background CO 2 readings. Use deionized water, free from organic and inorganic carbon. The conductivity of the deionized water used should be less than 0.5 µS/cm. Fill 60% of the container with deionized water. Blow through the deionized water with a CO2 free gas such as Nitrogen or Oxygen, to purge the water of any dissolved CO2. a) In order to prepare 1 liter of 4.0 Normal base solution, add 320 grams of 50% purity sodium hydroxide. Mix gently and add enough deionized water to make it exactly 1 liter. b) To prepare a 25 liters base solution, add 8000 grams of 50% purity sodium hydroxide in stages. Adding the sodium hydroxide in stages will prevent the solution from heating up. Gently mix and then add enough deionized water to make it exactly 25 liters. Seal the container. Gently shake the container to mix the base with the water. Allow the container to stand for one hour, and gently shake again to ensure a good mix. Page 68 If the base reagent is not mixed fully, then a highly concentrated layer will form in the bottom of the container. As the BioTector takes the base from the bottom of the container, this may create problems during operation, as the base will be too strong relative to the acid. Always mix the base solution for a second time, about 1 hour after it has been manufactured to ensure that it is completely mixed. Control of Normality Take a 10 ml of sample from the 4.0 N sodium hydroxide container. Add 2-3 drops phenolphthalein and just enough 1.0 N hydrochloric acid until it turns clear. If the normality is correct, 40 ml of 1.0 N hydrochloric acid will neutralize 10 ml of 4.0 N sodium hydroxide. Mixing Procedure for the preparation of 4.0 N Sodium Hydroxide solution, from 100% Sodium Hydroxide pellets: 1. Use deionized water, free from organic and inorganic carbon. The conductivity of the deionized water used should be less than 0.5 µS/cm. 2. Fill 80% of the container with deionized water. 3. Blow through the deionized water with a CO2 free gas such as Nitrogen or Oxygen, to purge the water of any dissolved CO2. 4. a) In order to prepare 1 liter of 4.0 Normal base solution, add 160 grams of 100% purity sodium hydroxide pellets. Mix gently and add more deionized water to make it exactly 1 liter. b) To prepare a 25 liters base solution, add 4000 grams of 100% purity sodium hydroxide pellets in stages. Adding the sodium hydroxide pellets in stages will prevent the solution from heating up. Gently mix to dissolve the sodium hydroxide pellets and then add more deionized water to make it exactly 25 liters. 5. Seal the container. 6. Gently shake the container to mix the base with the water. 7. Allow the container to stand for one hour, and gently shake again to ensure a good mix. Page 69 6.2 Calibration Standards 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. Caution 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 deionized water. Water solubility: 80 g/L at 20°C.  Acetic acid, C2H4O2, 2.51g (99.8% purity) in one liter of deionized water. Water solubility: Miscible in all proportions.  Glucose, C6H12O6, 2.53g (99% purity) in one liter of deionized 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 deionized water.  Sodium Hydrogen Carbonate, CHNaO3, 7.04g (99.5% purity) in one liter of deionized water.  Potassium Carbonate, CK2O3, 11.62g (99.0% purity) in one liter of deionized water. 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. Caution 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. Page 70 The calculation of the quantities required to prepare Potassium Hydrogen Phthalate (KHP) standard solutions with various purities are given as an example below: Name: Formula: Potassium Hydrogen Phthalate C8H5KO4 Carbon, 12 Oxygen, 16 Potassium, 39 Hydrogen, 1 Total weight x8 x4 x1 x5 = = = = = 96 64 39 5____________ 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 deionized water to make it exactly 1 liter solution. Note that the quantities required change with the % purity of the chemical used. Table 8 below gives the KHP quantities required at various % purity for the preparation of 1000mgC/l calibration standard. Table 8 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 deionized water. Table 9 below gives the required quantity of KHP for various concentration standard solutions to be mixed with deionized water and added enough deionized water to make the solution exactly 1 liter. Table 9 Quantity of KHP required to prepare various concentration TOC standard solutions. TOC Standard Solution Quantity of 99.9% KHP (grams) Concentration (mgC/l) to be added into 1 Liter DIW 1000 2.129 1250 2.661 1500 3.194 2000 4.258 5000 10.645 10000 21.290 Page 71 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 deionized 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 deionized 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 deionized 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 deionized 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 deionized 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 with Acetic Acid and TIC standards are recommended to be used within 48 hours of manufacture. Page 72 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, completing the 5 sections below. Detailed commissioning and startup procedures are available in a presentation format in the MMC/SD card shipped with the BioTector. It is recommended to review this document before starting the commissioning and startup procedures. For system and personal safety, refer to Section 1 Safety Precautions. Necessary safety precautions, such as wearing eye protection and gloves, should be taken throughout the commissioning and startup procedures. _____ 1. INSPECTION and SYSTEM CONNECTIONS: Several tubing are disconnected and labeled in BioTector for shipping. Before connecting any tubing, inspect the analyzer. Remove the three nuts and open the analysis door. Check all the electrical and tubing connections and confirm that there are no loose connections within the BioTector. Close the analysis door. _____  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 fitting linking the Ozone Destructor to the Exhaust Valve (MV1), at the bottom of the Ozone Destructor. The tubing of Sample Pump is disconnected and labeled in BioTector for shipping. Reconnect the Sample Pump tubing. _____  Check the Swagelok / PFA tube connections and confirm there are no loose connections within the BioTector. _____ Confirm the mains supply voltage and the frequency on site match the analyzer requirements. Remove the cover of the Power and Input/Output Board by sliding the cover from left to right slightly. Connect the power cable. Install the supplied ferrite by winding the power cable once around the ferrite, forming a single loop (see figure 1 and table 2 in Section 4.1.1 Analysis Enclosure). _____ Connect the 4-20mA cables. Install the supplied ferrite on the 4-20mA cables by winding the 420mA cables once around the ferrite, forming a single loop. _____ Connect low voltage wiring (e.g. Fault Relay). _____ Connect the air supply to the BioTector’s AIR port. See figure 12 in Section 5.3.1 Air Supply 3 Connection for details. The minimum air supply flow rate is 8.4 m /hour at 1.5 bar. The average 3 3 air consumption is less than 5.4 m /hour, and typically 3.6 m /hour during online operation. When the oxygen concentrator is running, the pressure typically cycles from 1.5 bar to 0.9 bar. Option A: Instrument air. The set point pressure of the air, supplied from an existing instrument air supply line, should be 1.5 bar. The recommended air quality is -20°C dew point, free of water, oil and dust. Option B: BioTector Compressor. The set point air pressure supplied from BioTector compressor should be 1.5 bar. In BioTectors built with a vortex cooler, air should be supplied to the vortex cooler using a regulator, which is dedicated for the vortex cooler only. _____ 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 and should be located in an environment so that any condensation or liquid at the outlet of the tubing cannot freeze during cold weather. See figure 16 in Section 5.4.2 Drain and Exhaust Connections for details. _____ Page 73 Remove the tapes, which are used to seal the ends of the supplied CO 2 filter. Fit the CO2 filter to the Base container and seal the Base container tightly. See figure 13 and figure 14 in Section 5.3.2 Reagent Connections for details. _____ Connect the Acid (6.0 N Sulfuric Acid, H2SO4, containing 350 mg/l Manganese catalyst) and Base (4.0 N Sodium Hydroxide, NaOH) containers to the BioTector’s ACID and BASE ports with 1/8” PFA tube. (~20 liter reagents last typically 6 months). Confirm that weight fittings (which contain 70 micron filters) supplied are installed at the end of the acid and base reagent dip tubes. _____ Confirm the sample or samples are supplied to the analyzer from a sample chamber and are at ambient pressure. See examples in figures 15 and 16 in Section 5.4 Sample, Drain and Exhaust Connections for the correct positioning and setup of the BioTector sample tube in various sampling systems. Locate the sample chamber within 2.5 meters of the BioTector. The sample tubing length between the sample intake point and the BioTector SAMPLE port should be 2.5 meters exactly. The height of the sample chamber should be between 100mm and 500mm below the BioTector. _____ Referring to typical examples in figures 15 and 16 in Section 5.4 Sample, Drain and Exhaust Connections, connect the sample or samples to the BioTector with ¼” PFA tube. These ports are marked SAMPLE 1 and if installed SAMPLE 2. _____ If a BioTector SAMPLER has been supplied with the system, connect the sampler in accordance with the drawings and instructions in the sampler manual. _____ Connect the SAMPLE OUT port with ¼” PFA tube to well ventilated pressure free drain. The tubing length between the drain and the BioTector SAMPLE OUT port should be maximum 2 meters. The tube should be fitted so that it cannot freeze in cold weather. See figure 16 in Section 5.4.2 Drain and Exhaust Connections for details. _____ If fitted, connect ¼” PFA tube to the MANUAL or CALIBRATION ports. Remove all tapes placed around the fittings for shipment. The tubing length between the manual grab sample intake point or calibration standard solution and the BioTector MANUAL/CALIBRATION ports should be between 2 and 2.5 meters. The height of the manual grab sample or calibration solution should be between 100mm and 500mm below the BioTector. _____ 2. POWER UP: Power up the analyzer. Go to Operation, Time & Date menu and adjust the time and the date. Using the Simulate menu (see Section 8.1.2 _____ Simulate ), check the following: Confirm that the Exhaust and Reactor Valves are working. _____ Confirm that the Sample Valve is working. _____ If installed, confirm that all other valves (e.g. multi-stream valve) are working. _____ Check the air supply pressure. The set point pressure should be 1.5 bar. When the oxygen concentrator is running, the pressure typically cycles from 1.5 bar to 0.9 bar. Check the O2 PRESSURE SENSOR in O2-Controller Status menu. The pressure should be between 390 mbar and 400 mbar at the idle 1 l/h “Mass Flow Controller” MFC FLOW. At 60 l/h MFC SETPOINT flow, the pressure should not be less than 320 mbar. See Section 8.1.6 Oxygen Controller Status for details. _____ Page 74 Oxygen Purity Test: Power up the system for at least 10 minutes before the oxygen purity test is carried out. Using the Simulate menu (see Section 8.1.2 Simulate) set the MFC (see figure 2 and table 2 in Section 4.1.1 Analysis Enclosure) flow to 10 l/h and flow oxygen gas through the CO2 analyzer for 5 minutes. At the end of this period, the CO2 analyzer zero reading (ppm CO2) should be within ±0.5% of full scale of the CO 2 analyzer range. For instance, if the CO2 analyzer range is 10000ppm, then the CO2 analyzer zero reading should be typically within ±50ppm. _____ (If the CO2 analyzer zero reading is outside the specifications, confirm that there is no CO 2 in the oxygen gas by connecting the CO2 filter “used with the sodium hydroxide reagent container” between the Cooler and CO2 analyzer inlet port and set the MFC to 10 l/h. 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 zero readings at the end of the 5 minute period. If the CO2 zero readings do not drop significantly with the CO2 filter in place, this will indicate that there is no CO2 contamination in the oxygen supply.) 3. PUMP TESTS: Caution! Below procedures involves handling strong acid and base reagents. Necessary safety precautions, such as wearing eye protection and gloves, should be taken throughout these tests. Go to Zero Calibration menu and select RUN REAGENTS PURGE function to prime the pumps. The factory Reagents Purge settings to prime reagents typically cover ~3 meters distance between the reagent containers and the BioTector. If it is necessary to increase the reagent purge times, see section 8.3.4.4Reagents Purge for details. __ (If the reagent lines do not fill during the Reagents Purge cycle, stop the BioTector to prime the pumps _____ __ manually. Remove the dip tubes from the reagent containers, and seal the containers. Place the dip tubes _ into a small container containing DIW. If DIW is not available use tap water. Raise the container above the height of the BioTector. Go to Zero Calibration menu and select RUN REAGENTS PURGE function to prime the pumps. Once the pumps have been primed, reinstall the dip tubes into the reagent containers and repeat the Reagents Purge cycle.) Confirm the Acid Pump is pumping correctly using a 10ml graduated cylinder. Run the Acid Pump in Simulate menu. Acid Pump rate for FMM20 Pump at 400 pulses should be between 4.20 ml and 3.80 ml. (Depending on the quantity of the liquid injected into the reactor and due to an internal system _____ interlock, the system may request the activation of Reactor Purge cycle to purge any excess liquid from the reactor. If necessary run “REACTOR PURGE” function in the same menu.) Confirm the Base Pump is pumping correctly. Base Pump rate for FMM20 Pump at 400 pulses should be between 4.20 ml and 3.80 ml. _____ Important Note: For the correct operation of the system, the measured Acid and Base Pump rates must be identical or similar. The maximum allowable difference in the measured volumes for acid and base injections above should not be more than 0.2ml. 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. (Any variation between these pumped volumes is corrected _____ when the zero and span calibration is carried out.) Page 75 4. COMMISSIONING MENU SETTINGS: Using the Commissioning menus (see Section 8.2 COMMISSIONING procedures to set up the BioTector for specific site requirements: MENU), follow In Reaction Time menu, program the INTERVAL time depending on the required sample analysis frequency. below _____ In Sample Pump menu, set the correct Sample Pump FORWARD and REVERSE times. These times are unique for each site depending on the distance between the sample and the BioTector. Sample Pump times can be set individually for each stream in the 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. In order to establish the required Sample Pump forward and reverse times, go to Simulate menu and run SAMPLE PUMP reverse (REV) and confirm that the sample tube is completely empty. Run SAMPLE PUMP forward (FWD) and measure the time (in seconds) required for a fresh sample to fill and flow out through the bypass port. Add 10 seconds to the measured time and enter this value as the FORWARD time in the Sample Pump menu. The sample pump REVERSE time will be automatically set as 10 seconds greater than the FORWARD time. _____ Go to Process Test, Sample Pump Test menu and select the PUMP FORWARD TEST and PUMP REVERSE TEST functions to confirm that the programmed sample pump times are correct to properly fill and empty the sample tube of each stream. _____ If the BioTector 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 BioTector 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 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”, which is available in the MMC/SD card shipped with the BioTector. _____ In New Reagents Program menu, confirm the factory settings are suitable for site requirements. _____ 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. Set the full scale concentration level for each 4-20mA channel. Full scale should be compatible with the external process control device (e.g. DCS) and BioTector calibrated ranges. In order to see BioTector calibrated ranges, see System Range Data screen (2.2.3 System Range Data Screen) and Stream Program menu (8.2.3 Stream Program). _____ In Alarm Program menu, set the available relays to the required ALARM levels for each stream. If necessary, to modify the relay parameters and conditions, go to Output Devices menu. See section 8.3.5 Output Devices for details. _____ Go to Signal Simulate menu and test 4-20mA signals. Simulate 1mA, 4mA, 12mA and 20mA signals and confirm that the signals are received by the external process control device (e.g. DCS). Simulate all digital input and output signals and confirm correct operation. _____ Page 76 5. ZERO and SPAN CALIBRATION: Go to Operation, Reagents Setup, Install New Reagents menu, confirm the menu items and select the “START NEW REAGENT CYCLE” function for the BioTector to prime the reagents and set the Zero Adjust (zero offset) values automatically. See Section 2.2.2.1 Install New Reagents and 8.2.5 New Reagents Program for details. _____ Observe that the automatic pressure/flow test passes when analyzer is started up. See Section 2.1.3 Analysis Data Screen and 8.3.4.5 Pressure/Flow Test Program for details. _____ It is recommended to check the zero response. When the Zero Calibration cycle is completed, go to Operation, Start Stop menu (see Section 2.2.1 Start Stop for details) and stop the analyzer. Go to Zero Calibration menu and select RUN ZERO CHECK function. Alternatively, to confirm that the zero response is correct, connect DIW to the manual sample port and run 5 analysis cycles on DIW using the Manual Program menu. (If manual port is not available, use the input _____ point for SAMPLE 1. If the BioTector has been in storage for a long period, and if the zero readings are not satisfactory, 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. _____ 1 Confirm that the pH in the reactor is correct, using the test sequence in the pH Test menu. See Section 8.1.1.5 pH Test for details. _____ 2 Check for a pH of <2 during the TIC phase. _____ 3 Check for a pH of >12 during the Base Oxidation phase. _____ 4 Check for a pH of <2 during the TOC phase. _____ 5 Run a further 2 reactions on DIW. _____ 6 Run an “Install New Reagents” cycle on the system to adjust the zero offset. _____ Program the concentration of the available standard solution in the Span Calibration menu. (To prepare a standard solution, see procedures described in Section 6.2 Calibration Standards or information sheet “R009. Standard Solutions for BioTector Multi-component Analyzer”, which is available inside the MMC/SD card shipped with the BioTector.) _____ Connect the standard solution to the MANUAL/CALIBRATION port. If these ports are not available, use the SAMPLE 1 port. It is recommended that the standard solution should be located at the same height as the sample chamber. 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. _____ Download BioTector “All Data” in text format into the MMC/SD card using the SEND ALL DATA function in Data Output menu to record all changes made in the system configuration. See Section 8.1.4 Data Output for details. _____ 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 CO 2 peaks are correct. _____ Page 77 Section 8 Maintenance Menu Maintenance Menu Diagram Page 78 8.1 DIAGNOSTICS MENU This group of menu allows the user to access the Process Test, Simulate, Data Output, Input/Output Status and Service menus for diagnostic purposes. Diagnostics Menu Diagram Page 79 8.1.1 Process Test This group of menus allows the user to simulate the Pressure Test, Flow Test, Ozone Test, Sample Pump Test and pH Test routines. In BioTector, when the user enters the Process Test menus, where the oxygen gas flow will be required, the oxygen generator starts to operate automatically. Detailed Process Test procedures are available in the MMC/SD card shipped with the BioTector. It is recommended to review these documents for troubleshooting purposes when necessary. 8.1.1.1 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 2 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 T M M S I F F T M E C S E T P O I N T C F L O W A T U S P R E S S E S C T O 6 4 0 T 0 0 3 E s . 0 l / h . 3 l / h S T I N G 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: MFC Setpoint: MFC Flow: Status: The time for the pressure test is 60 seconds. This time shows the time left to the end of the test. This is the BioTector mass flow controller flow setting (40 l/h by default) for the pressure test. 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. 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 (4 l/h by default). 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 (6 l/h by default). FAIL: The Pressure Test finished its cycle with a flow above the Fail (Pressure Test Fault) level (6 l/h by default). See Section 8.3.4.5 Pressure/Flow Test Program for details. 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. Page 80 8.1.1.2 Flow Test F L O W T E S T 1 < * E X H 2 E X H 3 S A M 4 S A M T M M S I F F T A A P P U U L L 0 9 : 1 7 : 2 8 S T T S T F E O U E O U E S T L O W T T E S T T F L O W M E C S E T P O I N T C F L O W A T U S P R E S S E S C 1 2 - 0 9 - 0 2 T O 3 6 5 T 0 0 8 E s . 0 l / h . 3 l / h S T I N G 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. 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: MFC Setpoint: MFC Flow: Status: The time for the flow test is 30 seconds. This time shows the time left to the end of the test. This is the BioTector mass flow controller flow setting (60 l/h by default) for the flow test. 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. 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, which is 54 l/h by default. See Section 8.3.4.5 Pressure/Flow Test Program for details. WARNING: The Exhaust Test finished its cycle with a flow below the Pass level (less than 54 l/h), but above the Fail level (greater than 40 l/h). FAIL: The Exhaust Test finished its cycle with a flow below the Fail level, which is 40 l/h by default. 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. This function allows the user to test the flow through the Sample Out port (through the Reactor Valve, MV3). 4. Sample Out Flow. This is similar to the Exhaust Flow. This function allows the user to test the flow through the Sample Out port (through the Reactor Valve, MV3). Page 81 8.1.1.3 Ozone Test The ozone test uses the procedure described in information sheet “T020. Procedure to check the ozone level in BioTector System-C (B3500C)”, which is available in the MMC/SD card shipped with the BioTector. The user must read and understand the processes described in this sheet, and have all the correct parts listed before carrying out the test. WARNING Ozone will be generated when the ozone generator is turned on. General overview of the operation of the ozone test: Phase 1: Install the tester according to information sheet T020, 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 2 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 M M S I F F T T E S T 0 9 : 1 7 : 2 8 M E C S E T P O I N T C F L O W A T U S P R E S S E S C T O 3 4 2 T 5 0 2 E A B O R T 1 2 - 0 9 - 0 2 s . 0 l / h . 0 l / H S T I N G 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. Page 82 Ozone Test, Phase 3: O Z O N E T E S T 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 1 * S T A R T T E S T 2 < S T O P T E S T T I M E S T A T U S 5 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 2 1 S T A R T T E S T 2 < * S T O P T E S T T I M E S T A T U S 1 2 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 o-ring breaks, 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 2 1 S T A R T T E S T 2 < * S T O P T E S T T I M E S T A T U S 1 2 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. Page 83 8.1.1.4 Sample Pump Test S A M P L E P U M P 1 V A 2 < * P U 3 P U 4 5 - - T E S T L V E M P F O R W A R D M P R E V E R S E > S A M P L E T I M E S T A T U S P R E S S 0 9 : 1 7 : 2 8 S T R E A M 1 2 - 0 9 - 0 2 1 T E S T T E S T P U M P 6 s T E S T I N G 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, 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 (see Section 8.2.2 Sample Pump for details). 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 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 (see Section 8.2.2 Sample Pump for details). Page 84 8.1.1.5 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. WARNING 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 TIC acid and sample are added into 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 1 < 2 3 4 5 6 T E S T R M S T C S A O T A O T N D A K N O 0 9 : 1 7 : 2 8 G E , V A E R T T E E S A M T I N U E P T E S L V E S T P L E T O T 1 2 - 0 9 - 0 2 1 , S T R E A M T I C + T O C N E X T 1 P H A S E 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. Page 85 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 1 < 2 3 4 5 6 R M S T C S A O T A O T N D A K N O 0 9 : 1 7 : 2 8 G E , V A E R T T E E S A M T I N U E P T E S L V E S T P L E T O T 1 2 - 0 9 - 0 2 1 , S T R E A M T I C + T O C N E X T C O N F I R M P R E V I O U S C O R R E C T L Y . P R E S S E S C T O E X I T 1 P H A S E R E A C T I O N E N T E R T O F I N I S H E D C O N F I R M , 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 1 < 2 3 4 5 6 T E S T R M S T C S A O T A O T N D A K N O 0 9 : 1 7 : 2 8 G E , V A E R T T E E S A M T I N U E P T E S L V E S T P L E T O T 1 , S T R E A M T I C + T O C N E X T 1 5 s O Z O N E C O 2 = W A I T T O P H A S E 1 P H A S E T I M E P H A S E M F C = 3 9 . 3 l / h T E S T 1 2 - 0 9 - 0 2 P U R G E 1 5 0 . 8 p p M 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. Page 86 pH Test, Phase 3: P H 1 < 2 3 4 5 6 T E S T R M S T C S A O T A O T N D A K N O 0 9 : 1 7 : 2 8 G E , V A E R T T E E S A M T I N U E P T E S T I M E P H A S E M F C = T E S T W H E N F R O M L V E S T P L E T O T 1 2 - 0 9 - 0 2 1 , S T R E A M T I C + T O C N E X T 1 P H A S E 0 s P A U S E D C O 2 = 1 5 0 . 8 p p M 0 . 0 l / h T I C p H . E X P E C T E D F I N I S H E D , S E L E C T M E N U . p H < 2 . N E X T A C T I O N At this phase, the TIC acid and sample are added into 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 a representative sample as the base reagent is injected prior to this test. When the tubing at the changeover port of the Reactor Valve is removed, it is recommended that a few drops of liquid is discharged manually from the reactor by tipping this tubing gently down and then measure the pH of the mixture with a pH paper. 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 1 < 2 3 4 5 6 T E S T R M S T C S A O T A O T N D A K N O 0 9 : 1 7 : 2 8 G E , V A E R T T E E S A M T I N U E P T E S T I M E P H A S E M F C = T E S T W H E N F R O M L V E S T P L E T O T 0 . 0 l / h 1 2 - 0 9 - 0 2 1 , S T R E A M T I C + T O C N E X T 1 P H A S E 0 s P A U S E D C O 2 = 1 5 0 . 8 p p M B A S E p H . E X P E C T E D p H > 1 2 . F I N I S H E D , S E L E C T N E X T A C T I O N 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. Page 87 pH Test, Phase 5: P H 1 < 2 3 4 5 6 T E S T R M S T C S A O T A O T N D A K N O 0 9 : 1 7 : 2 8 G E , V A E R T T E E S A M T I N U E P T E S T I M E P H A S E M F C = T E S T W H E N F R O M L V E S T P L E T O T 1 2 - 0 9 - 0 2 1 , S T R E A M T I C + T O C N E X T 1 P H A S E 0 s P A U S E D C O 2 = 1 5 0 . 8 p p M 0 . 0 l / h T O C p H . E X P E C T E D F I N I S H E D , S E L E C T M E N U . p H < 2 . N E X T A C T I O N 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 1 < 2 3 4 5 6 T E S T R M S T C S A O T A O T N D A K N O 0 9 : 1 7 : 2 8 G E , V A E R T T E E S A M T I N U E P T E S L V E S T P L E T O T 1 2 - 0 9 - 0 2 1 , S T R E A M T I C + T O C N E X T 1 P H A S E 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 1 < 2 3 4 5 6 T E S T R M S T C S A O T A O T N D A K N O 0 9 : 1 7 : 2 8 G E , V A E R T T E E S A M T I N U E P T E S T I M E P H A S E M F C = L V E S T P L E T O T 0 . 0 l / h 1 2 - 0 9 - 0 2 1 , S T R E A M T I C + T O C N E X T 1 P H A S E 0 s C O M P L E T E C O 2 = 1 5 0 . 8 p p M The pH test is complete. The BioTector will purge the reactor and the CO 2 analyzer. The user can either exit the menu or start the pH test again. Page 88 8.1.2 Simulate S I M U L A T E M F C = 0 9 : 1 7 : 2 8 1 0 . 0 l / h 1 < * M F C 2 O Z O N E G E 3 O Z O N E G E 4 A C I D P U M 5 B A S E P U M 6 S A M P L E P 7 R E A C T O R 8 S A M P L E V 9 R E A C T O R 1 0 E X H A U S T 1 1 C L E A N I N G ▼ N N P P U M A V V C O 2 = E R A T O R E R A T O R M O L A A V P T V L L A O E V V L F A N R E E V E S I M U L A T E 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 C * S M * C * C * S S S S T S L R R A T A O O Y A A A E A E E U L R N O O S M M M M M A A N - - > I E U L L T P P P P P K C . F F F F F F F F F F 3 5 . 0 p p m 0 l / h F F F F F F F F F F 0 9 : 1 7 : 2 8 M F C = 1 0 . 0 l / h  2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 1 0 O O O O O O O O O O B A A E E E L L L . L R M L R R M E E E C O 2 = A T I O N V A L V E V A L V E V A L V E R R R S E D E T O R R E A F A N F A N F I E M E R W I T S E N T E C P U G E N L P R C S T R T L T O H O O G Y R R R E P U R G E I N P U T / O U T P U T O 1 O A O O O O O A O O 1 2 - 0 9 - 0 2 , , , , , 1 . 0 0 A 5 . 0 0 V 1 1 1 1 2 - 0 9 - 0 2 3 5 . 0 p p m F F F U F F F F F U F F F T O F F F F F T O F F , , 1 . 0 0 A 5 . 0 0 V , 2 4 . 0 C S T A T U S This menu enables the user to test system devices such as Pumps, Valves, MFC (Mass Flow Controller) etc. installed and used in BioTector. In BioTector, when the user enters the Simulate menu, as the oxygen gas flow will be required, the oxygen generator starts to operate automatically. The menu also shows the current status of all devices when the BioTector is running. Note that the 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 CO 2 analyzer reading in ppm. 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. When ESCAPE key is used to return to the Diagnostics menu, BioTector carries out an automatic pump synchronization process. Page 89 1. MFC. Use this function to set the MFC (Mass Flow Controller) setpoint. Press the ENTER key, set the required setpoint (e.g. 60 l/h), 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 “*”. As a safety feature, when the Ozone Generator is switched on, a Pressure Test procedure is executed automatically to detect any gas leakage in the system. If this test fails then the Ozone Generator will not be switched on. See Section 8.1.1.1 Pressure Test and Section 8.3.4.5 Pressure/Flow Test Program for details on Pressure Test. When Ozone Generator activated, the current drawn, which is ~1.00 Amp, is displayed. If the current drops below 0.5 Amp, BioTector generates a “102_OZONE GEN FAULT” warning. Ozone will be generated when the Ozone Generator is turned on. WARNING 3. Ozone Generator Fan. This function displays the Ozone Generator Fan operation and voltage. When it is ON, the voltage displayed is typically 2.5 Volts. If the voltage drops below 1.5 Volts, or exceeds 3.5 Volts for longer than 5 seconds, BioTector generates a “103_OZONE FAN FAULT” warning. 4. Acid Pump. Use this function to test the Acid Pump. To turn the pump on, press the ENTER key, and select ON. Press the ENTER key again, input the number of pulses, press the ENTER key and the pump will run. When the pump is running the actual pulse time is displayed outside the brackets. The programmed pulse time is displayed inside the brackets. 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. 5. Base Pump. Use this function to test the Base Pump. To turn the pump on, press the ENTER key, and select ON. Press the ENTER key again, input the number of pulses, press the ENTER key and the pump will run. When the pump is running the actual pulse time is displayed outside the brackets. The programmed pulse time is displayed inside the brackets. The pump will stop when the required number of pulses is complete, or to manually stop the pump, press the ENTER key, select OFF, and press the ENTER key again. 6. Sample Pump. Use this function to test the Sample Pump. The pump has four operating states: FWR (forward), REV (Reverse), P-FWR (run under pulse control forward), P-REV (run under pulse control in reverse). To run the pump in the required mode, press the ENTER key, and select that mode. If P-FWR or P-REV is selected, enter the number of pulses (½ revolutions), press the ENTER key and the pump will run. When the pump is running, the actual pulse time is displayed outside the brackets. The programmed pulse time is displayed inside the brackets. The pump will stop when the required number of pulses is complete, or to manually stop the pump, press the ENTER key, select OFF, and press the ENTER key again. When Acid, Base and/or Sample Pumps are activated, depending on the quantity of the liquid injected into the reactor and due to an internal system interlock, the system may request the activation of Reactor Purge cycle to purge any excess liquid from the reactor. 7. Reactor Motor. Use this function to test the Reactor Motor. 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 “*”. Page 90 8. Sample Valve. Use this function to test the 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 “*”. 9. Reactor Valve. Use this function to test the Reactor 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. 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 “*”. 11. 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 “*”. 12. Calibration Valve (if configured in the system). Use this function to test the Calibration 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. Stream Valve. STREAM VALVE 1 is always programmed as default within the system software. Use this function to test the other optional Stream Valves if installed and configured in the system. 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. 14. Manual Valve (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. 15. Cooler. The Cooler is normally automatically controlled by the system. To test the Cooler, press the ENTER key and select device state option: ON, OFF, AUTO. When the device is on, it will be marked with an “*”. The actual Cooler current, which is typically between 1.00 and 1.5 Amp, is displayed. If the current drawn by the Cooler drops below 0.1 Amp, BioTector generates a “107_COOLER FAULT” warning. 16. Cooler Fan. This function displays the Cooler Fan operation and voltage. When it is ON, the voltage displayed is typically 2.5 Volts. If the voltage drops below 1.5 Volts, or exceeds 3.5 Volts for longer than 5 seconds, BioTector generates a “108_COOLER FAN FAULT” warning. 17. System Fan. System Fan is normally automatically controlled by the BioTector. To test the System Fan, press the ENTER key and select device state option: ON, OFF, AUTO. When the device is on, it will be marked with an “*”.The actual BioTector temperature in degrees Celsius (°C) is also displayed 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. 18. Sampler Fill (if configured in the system). Signal to fill the BioTector sampler. To test the Sampler Fill signal, 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 “*”. This signal remains on until turned off. 19. Sampler Empty (if configured in the system). Signal to empty the BioTector sampler. This signal is a 5 second pulse. To test the Sampler Empty signal, press the ENTER key to set the device ON. 20. Sampler Error (if configured in the system). Signal sent from the BioTector sampler indicating that there is an error in the sampler. To test the Sampler Error signal, 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 “*”. Page 91 21. Temp. Switch The Temperature Switch output is automatically controlled by the system depending on the system temperature control setting (System Fan Control), which is programmed as 20°C by default. To test the Temperature Switch, press the ENTER key and select device state option: ON, OFF, AUTO. When the device is on, it will be marked with an “*”. The current system temperature is also displayed. 22. Sample Sensor (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 Sample Sensor. 23. 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. 24. Reactor Purge. This function purges the mixer reactor. When activated, system automatically displays the Reactor Purge menu, which contains the relevant reactor purge parameters. 25. Run Reagent Purge. This function primes all reagents in the BioTector. 27.  Input/Output Status. Input/Output Status is a link to Maintenance, Diagnostics, Input/Output Status menu (see Section 8.1.5 Input/Output Status). Page 92 8.1.3 Signal Simulate S I G N A L 1 1 1 1 1 2 2 S I M U L A T E 1 < * C H A N N E L 5 A L A R M 1 8 C O 2 A L A R 1 S Y N C R E L 2 S A M P L E S 5 S A M P L E F 8 C A L S I G N 9 M A I N T S I 0 R E M O T E S 1 S T O P ▼ S I G N A L S I M U  2 2 N O T E 2 3 W A R N I N G 2 4 F A U L T 2 5 M A N M O D 2 6 4 - 2 0 m A 2 7 4 - 2 0 m A 3 0 4 - 2 0 m A 3 1 3 2 - - > I / O 1 3 M A T A A G T 0 9 : 1 7 : 2 8 - 4 1 - 3 Y A U L N A T U S 1 - 3 L T 1 - 3 A L N D B Y L A T E E T R I G C H N G C H N G 1 - 3 R E A D O O O O O O O O O 4 F F F F F F F F F . 0 m A F F F F F F F F F 0 9 : 1 7 : 2 8 O O O O O O O F F F F F F F 1 2 - 0 9 - 0 2 1 2 - 0 9 - 0 2 F F F F F F F S T A T U S This menu enables the user to test the 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. - 4. Channel 1-4. This allows the user to test the function of each 4-20mA channel. 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. 5. - 7. Alarm 1-3 (if configured in the system). This allows the user to test the function of the stream specific alarms if they are programmed in Output Devices menu. See Section 8.3.5 Output Devices for details. 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 “*”. 8. - 10. CO2 Alarm 1-3 (if configured in the system). This allows the user to test the function of the stream specific CO2 Alarms if they are programmed in Output Devices menu. See Section 8.3.5 Output Devices for details. 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. 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 Section 8.3.5 Output Devices for details. 12. - 14. Sample Status 1-3 (if configured in the system). Use this function to test the Sample Status output signal for each specific stream. 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 Section 8.3.5 Output Devices for details. 15. - 17. Sample Fault 1-3 (if configured in the system). Use this function to test the Sample Fault output signal for each specific stream. 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 Section 8.3.5 Output Devices for details. Page 93 18. Cal Signal (if configured in the system). Use this function to test the Calibration Signal 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 Section 8.3.5 Output Devices for details. 19. Maint Signal (if configured in the system). Use this function to test the Maintenance Signal 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 Section 8.3.5 Output Devices for details. 20. Remote Standby (if configured in the system). Use this function to test the Remote Standby 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 Section 8.3.5 Output Devices for details. 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 Section 8.3.5 Output Devices for details. 22. 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 Section 8.3.5 Output Devices for details. 23. Warning (if configured in the system). Use these functions to test the Warning 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 Section 8.3.5 Output Devices for details. 24. Fault (if configured in the system). Use this function to test the Fault 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 Section 8.3.5 Output Devices for details. 25. 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 Section 8.3.5 Output Devices for details. 26. 4-20mA Chng (if configured in the system). Use this function to test system generic 4-20mA Change 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 Section 8.3.5 Output Devices for details. 27-29. 4-20mA Chng 1-3 (if configured in the system). Use this function to test system 4-20mA Change output signal for stream specific channels from Channel 1 to Channel 3. 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 Section 8.3.5 Output Devices for details. 30. 4-20mA Read (if configured in the system). Use this function to test system 4-20mA Read 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 Section 8.3.5 Output Devices for details. 32.  Input/Output Status. Input/Output Status is a link to Maintenance, Diagnostics, Input/Output Status menu (see Section 8.1.5 Input/Output Status for details). Page 94 8.1.4 Data Output D A T A 1 < 2 3 4 5 6 7 O U T P U T O S S S S U E E E E T N N N N P U T D D R E A D F A U D C O N D A L L - - > D A T A 0 9 : 1 7 : 2 8 E C L F V T T I D I C E I O N A R C H I V E A R C H I V E G U R A T I O N A T A 1 2 - 0 9 - 0 2 M M C / S D C A R D 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 option is MMC/SD CARD. See Section 8.2.10 Data Program for specific output device settings. 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 (see Section 8.2.10 Data Program for details. 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. Page 95 8.1.4.1 Send Reaction Archive S E N D 1 < 2 3 4 5 * R E A C T I O N S N S P S T U T A T A M A U O R B R S P T D A E R O T S E E S E S E N O U T P U T T F N N D A R C H I V E E E D I D I I N # 1 2 3 V E N T S N G N G G 0 9 : 1 7 : 2 8 1 2 - 0 9 - 0 2 0 1 - 0 9 - 0 2 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. Page 96 The meaning of the abbreviations used in the downloaded analysis data in both standard and engineering modes (see Print Mode in Section 8.2.10 Data Program for details) 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). COD/BODmgO/l The calculated COD and/or BOD value in mgO/l (if activated in COD/BOD Program menu). TC Analysis: TIME DATE S1:2 TCmgC/l The time the reaction started. The date the reaction started. Reaction type and range. The calibrated TC value in mgC/l (TC represents TIC + NPOC + POC). VOC Analysis: TIME DATE S1:2 TCmgC/l TICmgC/l TOCmgC/l VOCmgC/l The time the reaction started. The date the reaction started. Reaction type and range. The calibrated TC value in mgC/l (TC represents TIC + NPOC + POC). The calibrated TIC value in mgC/l. The calculated TOC value in mgC/l (TOC is calculated as TC – TIC). The calculated VOC value in mgC/l (VOC is calculated as TC – TIC – NPOC). Engineering mode (TIC & TOC Analysis): TIME DATE S1:2 CO2z TICmgu TICmgc CO2p TOCmgu TOCmgc CO2p COD/BODmgc BT_DegC MB_DegC Atm SAMPLE SMPL PUMP ACID PUMP BASE PUMP COOLER O3 HEATER The time the reaction started. The date the reaction started. Reaction type and range. CO2 analyzer zero adjust for the current reaction. The un-calibrated TIC value in mgC/l. The calibrated TIC value in mgC/l. The height of the TIC CO2 peak. The un-calibrated TOC value in mgC/l. The calibrated TOC value in mgC/l (TOC represents NPOC). The height of the TOC CO2 peak. The calculated COD and/or BOD value in mgO/l (if activated in COD/BOD Program menu). BioTector temperature in Degrees Celsius (°C). Motherboard temperature in Degrees Celsius (°C). Atmospheric pressure in kPa. Sample quality (%) from Sample Sensor signal, which is used to activate SAMPLE STATUS output. 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. Similar information on Acid Pump operation (see items 2, 3 and 4 only, listed for SMPL PUMP above). Similar information on Base Pump operation (see items 2, 3 and 4 only, listed for SMPL PUMP above). The status of the Cooler. When the Cooler is off, “OFF” is printed in the reaction archive data. The status of the Ozone Destructor Heater. When the heater is off, “OFF” is printed in the data. Note that 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. Page 97 Engineering mode (VOC Analysis): TIME DATE S1:2 CO2z The time the reaction started. The date the reaction started. Reaction type and range. CO2 analyzer zero adjust for the current reaction. TCmgu TCmgc CO2p The un-calibrated TC value in mgC/l (measured value from the TC analysis). The calibrated TC value in mgC/l (measured value from the TC analysis). The height of the TC CO2 peak. TICmgu TICmgc CO2p The un-calibrated TIC value in mgC/l (measured value from the TIC&TOC analysis). The calibrated TIC value in mgC/l (measured value from the TIC&TOC analysis). The height of the TIC CO2 peak. NPOCmgu NPOCmgc CO2p The un-calibrated NPOC value in mgC/l (measured value from the TIC&TOC analysis). The calibrated NPOC value in mgC/l (measured value from the TIC&TOC analysis). The height of the NPOC CO2 peak. TOCmgc VOCmgc The calculated TOC value in mgC/l (TOCmgc is calculated as TCmgc – TICmgc). The calculated VOC value in mgC/l (VOCmgc is calculated as TCmgc – TICmgc – NPOCmgc). COD/BODmgc BT_DegC MB_DegC Atm SAMPLE SMPL PUMP The calculated COD or BOD value in mgO/l (if activated in COD/BOD Program menu). BioTector temperature in Degrees Celsius (°C). Motherboard temperature in Degrees Celsius (°C). Atmospheric pressure in kPa. Sample quality (%) from Sample Sensor signal, which is used to activate SAMPLE STATUS output. 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. Similar information on Acid Pump operation (see items 2, 3 and 4 only, listed for SMPL PUMP above). Similar information on Base Pump operation (see items 2, 3 and 4 only, listed for SMPL PUMP above). The status of the Cooler. When the Cooler is off, “OFF” is printed in the reaction archive data. The status of the Ozone Destructor Heater. When the heater is off, “OFF” is printed in the data. ACID PUMP BASE PUMP COOLER O3 HEATER Note that the COD or BOD result is added into the reaction screens and reaction archives if the COD or BOD is activated in COD/BOD Program menu. Page 98 8.1.4.2 Send Fault Archive This menu is used to download the fault archive. The communication port parameters used are those set up in the Data Program menu. All items in the fault archive will be downloaded unless the user interrupts the downloading with the Pause Sending or Stop Sending functions. 1. Start Sending. Press the ENTER key to start downloading the data. 2. 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. 3. Stop Sending. Press the ENTER key to stop downloading the data. OUTPUT ITEMS is the number of events currently downloaded. The maximum number of events in the fault archive is 99. When external MMC/SD flash memory card is being used as the output device, the fault archive will be saved into the card in text format and named as “FARCH.TXT” by default. 8.1.4.3 Send Configuration This menu is used to download the configuration data in the BioTector. The communication port parameters used are those set up in the Data Program menu. All the configuration data will be downloaded unless the user interrupts the downloading with the Pause Sending or Stop Sending functions. 1. Start Sending. Press the ENTER key to start downloading the data. 2. Pause Sending. Press the ENTER key to interrupt the downloading of data. Press again to continue downloading. Note: If the downloading is interrupted for more than 60 seconds, then the downloading is automatically resumed. 3. Stop Sending. Press the ENTER key to stop downloading the data. OUTPUT ITEMS is the number of events currently downloaded. When external MMC/SD flash memory card is being used as the output device, the system configuration will be saved into the card in text format and named as “CNFG.TXT” by default. 8.1.4.4 Send All Data This menu is used to download all data (i.e. Reaction Archive, Fault Archive, Configuration and System Diagnostics) in one simple operation. The communication port parameters used are those set up in the Data Program menu. All the diagnostic data will be downloaded unless the user interrupts the downloading with the Pause Sending or Stop Sending functions. Unlike individual data download (e.g. reaction archive, fault archive and configuration), which are downloaded in the selected system language, all data is downloaded in English language only. 1. Start Sending. Press the ENTER key to start downloading the data. 2. 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. 3. Stop Sending. Press the ENTER key to stop downloading the data. OUTPUT ITEMS is the number of events currently downloaded. When external MMC/SD flash memory card is being used as the output device, the all data will be saved into the card in text format and named as “ALLDAT.TXT” by default. Page 99 8.1.5 Input/Output Status Input/Output Status menus are used for monitoring the analog and digital inputs and outputs for advanced diagnostics purposes. Digital Input The Digital Input menu allows the engineer to monitor the system digital inputs. This feature is useful for the system trouble-shooting or diagnostics. On the screen the digital inputs are organized in columns and rows with their code, logical states and function. Each input name is composed of the “DI” prefix and two-decimal index, which identifies the input. For example, the digital input named “DI06” is digital input 6, which is the ENTER key. Its logical state is shown as 0, therefore the ENTER key is not pressed or activated. When ENTER key is pressed, its logical state will be shown as 1. In the idle or open circuit state, all the system digital inputs are set to logical state 0. The active or closed circuit state is logical state 1. The programmable digital inputs are marked as [PROGRAMMABLE] in this menu. Digital Output The Digital Output menu allows the engineer to monitor the system digital outputs. This feature is useful for the system trouble-shooting or diagnostics. On the screen the digital outputs are organized in columns and rows with their code, logical states and function. Each output name is composed of the “DO” prefix and twodecimal index, which identifies the output. For instance, the digital output named “DO34” is digital output 34, which is used to control the heater of the Ozone Destructor. Its logical state is shown as 0 and 1, which stands for OFF and ON respectively. Upon system power up or reset, all system digital outputs are set to logical state 0. Analog Input The Analog Input menu allows the user to monitor the system analog inputs. This feature is useful for the system trouble-shooting or diagnostics. On the screen the analog inputs are organized in columns and rows. Each analog input has three parameters. The first is ADC converter digital value, the second is the input voltage measured in volts and the third is the function. The BioTector uses a 12-bit ADC, therefore the range of the digitized inputs are 0-4095. The voltage range is 0 to 5.00 Volts. Analog Output The Analog Output menu allows the user to monitor the system analog outputs. This feature is useful for the system trouble-shooting or diagnostics. On the screen, each analog output has three parameters. The first is DAC converter digital value, the second is output voltage measured in volts and the third is the function. The BioTector uses a 12-bit DAC, therefore the range of the digitized outputs are 0-4095. The voltage range is 0 to 10.00 Volts. Page 100 8.1.6 Oxygen Controller Status O 2 - C T R L 1 < 2 3 4 5 6 7 8 9 1 0 1 1 I V M T A O V R R M M D E O E I 2 A O O F F E R D M R L T T C C S T A T U S N T I F S I O N E P E R A P R E P R E S V E 1 A R Y A R Y S E T F L O 0 9 : 1 7 : 2 8 I C A T I O N T S S , V V P W U R E S S S E 2 , 3 A L V A L V O I N S E N S O R E N S O R N S O R E E T S E N S O R # c 3 0 0 1 . 0 M F C / 2 5 . 1 5 0 0 4 0 0 1 , F O R W 0 2 0 . 1 9 . 0 0 O 0 m m 0 A 1 2 - 0 9 - 0 2 0 0 1 9 2 C b a r b a r , R D , , , 0 0 l / h 9 l / h , 1 . 2 4 V 4 . 4 5 V 2 . 2 4 V 1 . 7 8 V The O2-CTRL STATUS (Oxygen Controller Status) menu displays the system the air supply, oxygen supply, gas flow, pressure and temperature related parameters. In BioTector, when the user enters the Oxygen Controller Status menu or any menu, where the oxygen gas flow will be required, the oxygen generator starts to operate automatically. 1. Identification. Identification is the specific identification number for the Oxygen Controller Board. 2. Version. This menu item specifies the software version of the Oxygen Controller Board. 3. Mode. This menu item allows the Oxygen Controller Board to operate the Mass Flow Controller (MFC) only, the Oxygen Concentrator only, or both. 4. Temperature Sensor. This is the BioTector temperature sensor, located on the Oxygen Controller Board, which displays the system temperature. The voltage (V) readings as obtained from the temperature sensor are displayed in real time. 5. Air Pressure Sensor. This menu item displays the air inlet pressure for the oxygen concentrator. The pressure (mbar) and the voltage (V) readings as obtained from the Air Pressure Sensor are displayed in real time. 6. O2 Pressure Sensor. This menu item displays the oxygen inlet pressure for the Mass Flow Controller. The pressure (mbar) and the voltage (V) readings as obtained from the Oxygen Pressure Sensor are displayed in real time. 7. Valve 1, 2, 3. This item displays the Oxygen Controller valve outputs for valves 1, 2 and 3. Valve 1 is the Air Isolation Valve. See figure 6 in Section 4.2.3 BioTector Oxygen Concentrator for details. Valve 2 and 3 are reserved. When Valve 1 is activated, the displayed value is “1”. When Valve 1 is deactivated, the displayed value is “0”. 8. Rotary Valve. This menu item displays the operation (Forward, Reverse and Stop) of the Rotary Valve. 9. Rotary Valve Sensor. This menu item shows the sensor position of the Rotary Valve. If the Rotary Valve is on the sensor, the displayed value is “1”. If the valve is not on the sensor, the displayed value is “0”. 10. MFC Setpoint. This menu item allows the user to test the Mass Flow Controller. Use this function to set the MFC setpoint. Press the ENTER key, set the required setpoint (e.g. 60 l/h), 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. 11. MFC Flow. When MFC Setpoint is programmed above, this menu item displays the actual flow and the corresponding voltage on the MFC. When BioTector is not running, that is, when it is powered up and stopped, or when it is in standby state, as the MFC Setpoint is 1 l/h, the MFC Flow displays the 1 l/h flow. Page 101 8.1.7 Service S E R V I C E 1 < 2 3 4 5 R S R S R E E E E E A R S T S 0 9 : 1 7 : 2 8 C T I O V I C E E T S S E R E T S N R E R V I E R C E V C V O Q I E I U N T E U I R E C E C Z E R C E Z R D I N O U N T E R O E R O 1 2 - 0 9 - 0 2 5 2 3 8 1 7 8 D A Y S 2 0 , 5 The Service menu displays the system service information. It is also used to reset the service counter and activate zero calibration cycles after the service is carried out. 1. Reaction Counter. This is the number of reactions performed by the BioTector. 2. Service Required In. This menu item specifies the number of days left before service is required. Note that the factory setting for this counter is typical for normal site conditions, and the service interval may have to be adjusted depending on site conditions. See Section 8.3.8 Fault Setup for details. When the BioTector is powered up, the number of days counter of the Service Required In function keeps operating regardless of the system is running or stopped. 3. Reset Service Counter. This menu item allows the user reset the service counter after the service has been completed. 4. Set Service Zero. During the service of some critical component parts in the BioTector (e.g. Sample Pump), there is a possibility for contamination of such components and this may create an unacceptable TOC offset (particularly in low range analyzers). Zero calibration may therefore be required after the BioTector removes contamination as it operates. If this occurs the zero calibration can be automatically initiated using the “Set Service Zero” function. When initiated, BioTector automatically runs a total of 5 zero calibration cycles during the following 100 online measurements (default values) and automatically adjusts the zero offset values to compensate for the removal of the contamination. It will therefore not be necessary to revisit the BioTector after the service or to repeat the zero calibration cycle. “Set Service Zero” function can be activated while the BioTector is running or stopped. An asterisk “*” mark is displayed to indicate that this function is activated. If the BioTector is stopped, the service zero calibration cycle begins when the system is started. BioTector returns online operation when the service zero calibration cycle is completed. In the example Service menu displayed above, the first number entry “20” displays the number of online reactions, which will be carried out before each service zero calibration cycle. The second number entry “5” displays the total number of zero calibration cycles. 5. Reset Service Zero. This menu item allows the user to deactivate or to stop the service zero calibration cycle (see Set Service Zero function above). When the Reset Service Zero function is selected, the asterisk “*” mark, which indicates the activation of Set Service Zero function, is removed. If Reset Service Zero function is selected during one of the zero calibration cycles, BioTector returns online operation after completing the current zero calibration cycle. Page 102 8.2 COMMISSIONING MENU The Commissioning menus are used during the commissioning and startup of the analyzer. The functions in the menus are used to program system site specific settings. Commissioning Menu Diagram 8.2.1 Reaction Time REACTION TIME 4m45s INTERVAL 0m TOTAL 4m45s  REACTION TIME displays the total reaction time (in minutes and seconds) for range 1, based on all programmed settings in System Program, System Program 1 menu.  INTERVAL is the time (0 minutes by default) added between each reaction. Interval can be programmed on site if frequent analysis is not necessary. The longest interval time, which can be programmed, is 1440 minutes (or 1 day). A programmed interval time would reduce the reagent usage significantly.  When BioTector automatically extends the reaction time due to high level of TIC and/or TOC in the sample, if any INTERVAL time is programmed, the extended reaction time is taken out from the interval time.  BioTector automatically generates an INTERVAL time when the user programs any SAMPLER, FORWARD and/or REVERSE times, which exceeds the maximum allowable time in the Sample Pump menu below. The system determines the maximum allowable time from the System Program 1 settings in System Program menu.  TOTAL displays the total reaction time including the interval time if programmed. Page 103 8.2.2 Sample Pump SAMPLER FORWARD REVERSE STREAM 1 100s 60s 75s STREAM 2 100s 60s 75s STREAM 3 45s 60s …………………… MANUAL 1 50s 0s MANUAL 2 MANUAL 3 …………………… CALIBRATION 50s  BioTector Sample Pump runs forward for the FORWARD time to bring a fresh sample from the STREAM, MANUAL and/or CALIBRATION points to the analyzer. This time should be long enough to guarantee a fresh sample is injected into the reactor and any old samples and bubbles are completely removed from the sample lines.  BioTector Sample Pump runs in reverse for the REVERSE time so as to wash and empty the sample lines prior to the next reaction. The recommended time for REVERSE is approximately FORWARD time plus 15 seconds. See Section 8.1.1.4 Sample Pump Test to test Sample Pump operation times.  The REVERSE time for a Manual Valve can only be activated if an optional Manual Bypass Valve is installed in the system. Manual Bypass Valve is used to return the previous sample into drain.  If a Sampler is programmed in Stream Program menu, system automatically shows the Sampler time in this menu. The sampler time should also be long enough to guarantee that the sampler chamber is filled with fresh sample.  When the user programs any SAMPLER, FORWARD and/or REVERSE times, which exceeds the maximum allowable time, BioTector generates the required INTERVAL time automatically in the Reaction Time menu above. The maximum allowable time is determined by the system from the System Program 1 settings in System Program menu. 8.2.3 Stream Program SAMPLER CONTROL NO BIOTECTOR START-UP RANGE 1 RANGE LOCKED NO PROGRAMMED STREAMS 3  If a sampler is used with the BioTector, SAMPLER is programmed (YES). When activated in this menu, the programmable Sampler time will be displayed automatically in the Sample Pump menu above.  In multi-stream systems, CONTROL determines the multi-stream valve sequence to be controlled by either BIOTECTOR or by an EXTERNAL device.  If the CONTROL is programmed as EXTERNAL, then both multistream valve sequence and operation ranges have to be controlled by an external device.  START-UP RANGE (1 by default) defines the range BioTector will use at the first reaction it starts up with. In multi-stream systems, if none of the RANGE setting for stream sequence below is programmed as AUTO, this function is automatically hidden by the system.  If RANGE LOCKED (NO by default) is programmed as YES, BioTector locks the operation range at the defined RANGE above. In other words, the automatic range change function is disabled with the YES setting.  In multi-stream systems, if none of the RANGE setting for stream sequence below is programmed as AUTO, this function is automatically hidden by the system.  PROGRAMMED STREAMS displays the number of streams installed and programmed in Output Devices menu. Page 104 STREAM STREAM STREAM ……………… 1 , 2 2 , 1 3 , 4 …………… RANGE RANGE RANGE …………… 3 3 3 …  If the CONTROL is programmed as BIOTECTOR, the multistream valve sequence operates according to the STREAM and RANGE settings defined in this menu.  In STREAM 1 , 2 setting, the first setting “1” represents the multistream valve number (e.g. Stream Valve 1), and the second setting “2” represents the number of reactions to be carried out at this stream before switching to the next stream.  RANGE defines the operation range for each stream. In a multistream system, the ranges are locked to Range 3 by default in the factory. It is recommended to lock each stream to a particular range (e.g. 1, 2 or 3), which is appropriate to the concentration levels of the sample, in multi-stream systems.  The AUTO (AUTOMATIC) range change function is disabled in multi-stream systems by default. If it is necessary to run any of the streams with AUTO range change function, please contact your local distributor or the manufacturer. When AUTO range change function is used, a minimum of five analysis reactions is recommended as BioTector needs to find the optimum operation range automatically. Therefore, depending on the system response, it may be necessary to discard the first two or three analysis results, when the AUTO range change function is selected for a specific stream. 8.2.4 COD/BOD Program DISPLAY ---- STREAM 1 TOC FACTOR STREAM 2 TOC FACTOR STREAM 3 TOC FACTOR …………………… STREAM 6 TOC FACTOR 1.0 1.0 1.0 1.0 1.0 1.0 ……… 1.0 1.0 0.0 0.0 0.0 …… 0.0  DISPLAY function (--- not programmed by default) allows the user to program (COD and/or BOD) the system to display and send the relevant 4-20mA signals for COD and/or BOD (mgO/l) if required. See Section 8.2.8 4-20mA Program for details.  In Stream 1 1.0 0.0 setting , the first setting “1.0” acts as the “OVERALL FACTOR” and the second setting acts as the “OFFSET FACTOR” in the following equation:  COD (and/or BOD) = [Overall Factor * (TOC Factor * TOC)] + Offset Factor  In TC analysis mode, instead of the TOC FACTOR, the TC FACTOR is displayed in this menu and used in above equation.  If the DISPLAY is programmed as COD and/or BOD above, the system multiplies the TOC result of the corresponding stream (STREAM 1-3) with the TOC FACTOR and with the OVERALL FACTOR and adds the OFFSET FACTOR to calculate the COD and/or BOD value.  The STREAM FACTOR for each stream is obtained following the procedures described in information sheet “I030. TOC to COD or BOD Correlation Method”, which is available in the MMC/SD card shipped with the BioTector.  Stream 1 factor is used for manual samples and calibration standards. Page 105 8.2.5 New Reagents Program SPAN CALIBRATION NO SPAN CHECK NO AUTOMATIC RE-START YES  SPAN CALIBRATION (NO by default) defines if the Span Calibration reactions are part of the Install New Reagents procedure in Reagents Setup menu.  If SPAN CALIBRATION is activated (YES), the standard solution needs to be connected to the Calibration/Manual port of the BioTector as part of the Install New Reagents procedure. See concentrations of the TOC STANDARD defined in Span Calibration menu (see Section 2.3.2 Span Calibration for details).  SPAN CHECK (NO by default) defines if the Span Check reactions are part of the Install New Reagents procedure in Reagents Setup menu.  Note that both SPAN CALIBRATION and SPAN CHECK functions cannot be selected as YES simultaneously and cannot occur together in the Install New Reagents procedure.  AUTOMATIC RE-START (Yes by default) defines BioTector to return automatically online operation having completed the Install New Reagents cycle. 8.2.6 Reagents Monitor REAGENTS MONITOR YES LOW REAGENTS NOTE LOW REAGENTS AT 20 DAYS NO REAGENTS WARNING  When REAGENTS MONITOR is activated (YES), the system creates a new Reagent Status screen which displays the amount of reagents and the estimated number of days left for each reagent to last. The Reagent Status screen is displayed for a period of 15 minutes and the system automatically reverts back to the default Reaction Result screen.  BioTector calculates the reagent usage and the days remaining based on the average reagent usage from the reaction archive. If there are no reactions available in the archive, BioTector calculates the reagent usage using the operation range information in the system program menus and updates the reagent status figures accordingly.  Note that when one or more reagent volumes are updated in this menu, system automatically resets the new reagents volumes in Install New Reagents menu and also updates the figures displayed in the main Reagents Status screen.  LOW REAGENTS, which is programmed as NOTE (notification) by default, will activate a relay specifically programmed for notification events.  When LOW REAGENTS is programmed as WARNING, and if reagents run low, system generates an “85_LOW REAGENTS” warning and activates a relay specifically programmed for warning events.  LOW REAGENTS AT specifies the number of days (20 days by default), before the system generates an “85_LOW REAGENTS” warning or notification, depending on the LOW REAGENT setting above.  This function can be used by the user as an early warning or notification of system low reagents so that the required reagents can be prepared or ordered in time.  NO REAGENTS programmed as a WARNING event by default, can also be set as a FAULT event. When system calculates no reagents, the fault relay is activated and system generates a “20_NO REAGENTS” fault or warning.  NO REAGENTS can also be programmed as NOTE (notification) where only a relay programmed as notification operates in the event of no reagents. Page 106 ACID VOLUME 19.0l ~210 DAYS BASE VOLUME 19.0l ~210 DAYS  ACID VOLUME allows the user to enter the volume of the acid reagent. When the volume is programmed, system automatically calculates the number of days acid reagent will last.  BASE VOLUME allows the user to enter the volume of the base reagent. When the volume is programmed, system automatically calculates the number of days base reagent will last.  It is strongly recommended that each time acid and/or base reagents are replaced or topped up, a Zero Calibration cycle is activated using the Start New Reagent Cycle function in Install New Reagents menu or using the Run Zero Calibration function in Zero Calibration menu. 8.2.7 Autocal Program TIME MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY 00:00 S Z ZS ----- CHECK CAL CAL -----  TIME (00:00 by default) schedules the Zero & Span Calibration or Check reactions time (in HR:MIN) for the weekdays if any is programmed below.  In this menu, Zero and/or Span Calibration reactions and/or Check reactions are scheduled if programmed on a particular day of the week. Note that by default, there will be no scheduled zero and span cycles in the system. See Section 2.3 Calibration Menu for details.  If CAL (CALIBRATION) is programmed, system generates the zero and span adjust figures which are applied to the reaction results. If CHECK is programmed, system does not generate any zero or span adjust figures.  The meaning of the abbreviations used in this menu are as follows: -No function is programmed. S Span reactions only. Z Zero reactions only. ZS Zero reactions followed by Span reactions. CAL Calibration reactions CHECK Check reactions. 8.2.8 4-20mA Program OUTPUT MODE DIRECT  OUTPUT MODE specifies the 4-20mA outputs operation. This parameter is programmed as: DIRECT (direct mode by default), BASIC (basic mode), STREAM MUX (stream multiplex mode) or FULL MUX (full multiplex mode).  In DIRECT mode, each 4-20mA output channel is dedicated to a specific stream and result type.  In BASIC mode, 4-20mA signals of zero and span calibration/check reactions are also sent to the 4-20mA channels programmed as STREAM 1.  In STREAM MUX and FULL MUX modes, specific channels are dedicated to periodically change their value in steps to indicate the stream number and result type. This periodic operation reduces the number of required 4-20mA channels significantly. If STREAM MUX and FULL MUX modes are required, please contact manufacturer or distributor for the complete protocols and the details of required system configuration modifications. Page 107 CHANNEL 1 CHANNEL 1 CHANNEL 2 CHANNEL 2 ……………………… CHANNEL 4 CHANNEL 4 STREAM 1 25mgC/l STREAM 1 100mgC/l …………………… --100mgC/l SIGNAL FAULT YES FAULT LEVEL 1.0mA OUTPUT < 4mA 0% EXCLUDE RESULTS 3 TOC INST TIC INST …… TIC AVRG  In CHANNEL 1 STREAM 1 TOC setting, the first parameter defines the type of 4-20mA output which can be programmed as: STREAM and MANUAL reaction results, CAL (zero & span calibration results), CAL Z (zero results) and CAL S (span results). The second parameter is the data type which can be programmed as TOC, TIC, TC, VOC, BOD and COD. In TIC & TOC analysis mode, TC is the sum of TIC and TOC.  In CHANNEL 1 25mgC/l INST setting, the first parameter (e.g. 25mgC/l) is the full scale of the channel. The second parameter could be programmed as INST (Instantaneous) or AVRG (Average).  If INST is selected, the result for the selected stream is updated at the end of each reaction. If AVRG is selected, the average result of the 24 hour reactions is updated for the specific stream at the AVERAGE UPDATE time programmed in Sequence Program, Average Program menu.  When ANALYSIS TYPE is changed in Analysis Mode menu, modifications on the 4-20mA result type and the channel full scale may be required.  When SIGNAL FAULT is activated (YES) by default, if a fault occurs, system sends the FAULT LEVEL signal below for all 420mA channels. When it is set to (NO), 4-20mA outputs do not signal FAULT LEVEL if a fault occurs and system keeps sending live data on the outputs.  FAULT (1.0mA by default) specifies the fault output level for all system 4-20mA channels.  OUTPUT < 4mA function defines the factor (0% by default) to be applied on the stream value if the output value becomes smaller than 4mA (negative result). This function allows the user to clamp or reduce the effect of negative result on the 4-20mA output value.  For instance, if the OUTPUT value is set as 100%, 100% of the negative result is sent as 4-20mA signal. If the setting is 50%, 50% of the negative results is sent as 4-20mA signal. When the setting is 0%, no negative result is send and any negative result is clamped to 4mA (0mgC/l) level.  When OUTPUT MODE is programmed as BASIC above, EXCLUDE RESULTS defines the number of stream analysis reactions (3 by default) to be omitted after the zero and/or span calibration/check reactions. This is achieved by keeping the calibration output relay activated until the programmed number of stream analysis is completed. In other words, the calibration contact remains active for a programmable number of online reactions after the completion of the calibration cycle. This function helps to ignore any possible calibration impact on the system response. Page 108 8.2.9 Alarm Program ALARM 1 TOC ALARM 2 TIC ALARM 3 COD CO2 ALARM 1 CO2 ALARM 2 CO2 ALARM 3 STREAM 1 20.0mgC/l STREAM 2 10.0mgC/l STREAM 1 70.0mgO/l 50.0ppm 100.0ppm 150.0ppm --> PROGRAMMABLE OUTPUTS  If ALARM 1-3 is not programmed in Output Devices menu, this option will not be available in this menu.  ALARM 1-3 operates on a specific stream and reaction result type. In “ALARM 1 TOC STREAM 1” setting, TOC is the desired reaction result, which can also be programmed as COD, BOD, TIC, TC or VOC. STREAM 1 is the selected stream.  In ALARM 1 20.0mgC/l setting, 20mgC/l defines the desired alarm activation level. The concentration level determines the alarm condition where the Alarm Relay is set or reset at the end of each reaction once the calibrated result is known.  If CO2 ALARM 1-3 is not programmed in Output Devices menu, this option will not be available in this menu.  CO2 ALARM 1-3 is a predictor function of a possible high TOC/TC (COD or BOD if programmed) level for a specific stream. By default, this function is disabled by 0.0ppm setting. If programmed, it provides an earlier warning of an unusually high TOC result from the rising slope of the CO2 peak generated during the reaction.  If programmed, the alarm level (ppm CO2 peak) need to be selected carefully considering the temperature effect, which could be significant on the CO2 peaks. In other words, enough margins needs to be given for the settings which will create an actual early warning for an unusually high reading. At the end of the reaction, the CO2 Alarm Relay status is maintained or reset depending on the reading. In addition, this function is only suitable for multi-stream systems operating on fixed ranges, or systems operating on a single range. The use of this function is not recommended for systems which uses automatic range change.  Note that in TIC & TOC and VOC analysis types, the CO2 peak used for the CO2 ALARM 1-3 is the TOC CO2 peak. In TC and TC – TIC analysis type, the CO2 peak used is the TC CO2 peak.  Programmable Outputs is a link to Output Devices, Programmable Outputs menu. Page 109 8.2.10 Data Program MMC/SD CARD PRINT MODE ENGINEERING REACTION ON-LINE YES FAULT ON-LINE YES CONTROL CHARS NO DECIMAL POINT 8.2.11  This menu allows the user to program the output device communication port configuration profiles for MMC/SD flash card.  PRINT MODE specifies the format in which the data will be sent over the communication port to all output devices. The available modes are STANDARD (includes time, date and calibrated analysis data etc.), and ENGINEERING (includes un-calibrated data, temperature and atmospheric pressure, pump diagnostic information, liquid phase measurement information etc. in addition to the STANDARD data).  REACTION ON-LINE enables (YES by default) or disables (NO) the automatic printout of the reaction result at the end of each reaction.  FAULT ON-LINE enables (YES by default) or disables (NO) the automatic printout of a fault or warning log as soon as it occurs.  CONTROL CHARS enables (YES) or disables (NO by default) the control characters sent with the RS232 data for the output device operation.  DECIMAL specifies whether a POINT (.) by default or a COMMA (,) character represents the decimal point in the downloaded analysis data files for all output devices. Information CONTACT INFORMATION SOFTWARE VERSION 02.01.00 DATE May 5 2011  Contact menu displays the contact details of the manufacturer and if programmed the distributor.  VERSION displays the system firmware (software) revision number.  DATE displays the firmware (software) revision date. IDENTIFICATION B5C 2.01 247  IDENTICIFATION displays the specific identification number (system serial number) for the BioTector. Page 110 8.3 SYSTEM CONFIGURATION MENU System Configuration menus are used to configure the system in the factory. The user should avoid any modifications in these menu settings unless it is absolutely necessary. System Configuration Menu Diagram Page 111 8.3.1 Analysis Mode ANALYSIS TYPE DEMO MODE DEMO MODE DEMO MODE CO2 DATA TIC CURVE PEAK TIC CURVE WIDTH TIC CURVE DELAY TOC CURVE WIDTH TOC CURVE PEAK TOC CURVE DELAY TC CURVE WIDTH TC CURVE PEAK TC CURVE DELAY  ANALYSIS TYPE defines BioTector’s analysis modes, which are TIC+TOC (TIC&TOC), TC and VOC. TIC&TOC and VOC systems can be programmed to run in TIC+TOC, TC and VOC analysis types. If it is necessary to run a TIC&TOC system in any other analysis modes, please contact the distributor or the manufacturer.  When the analysis type is changed, the system automatically modifies several system configuration parameters and resets them to their default values. Therefore, when this function is entered, before the analysis type is changed, system automatically displays a “CAUTION! CHANGING ANALYSIS TYPE ALTERS SYSTEM PARAMETERS AND REQUIRES USER TO CHANGE SYSTEM CONFIGURATION SETTINGS. PLEASE PRESS ESCAPE OR RIGHT ARROW TO PROCEED.” warning to the user to inform the user about the changes required in the system configuration settings.  Systems, which are built with two or more analysis type options, are shipped with the relevant system configurations, which are available in both electronic format and as printouts. When the user changes the analysis type of the system, the necessary system configuration modifications needs to be carried out following the procedures described in information sheet “M067. BioTector Arm Configuration Upgrade Procedure”, which is available in the MMC/SD card shipped with the BioTector. When the procedures are followed, the system configuration settings will be updated automatically. Alternatively, all system configuration modifications can be carried out manually by looking at the corresponding configuration printout. TIC+TOC  When DEMO MODE (OFF by default) is activated (ON), system can be started to operate in demonstration mode. In this mode, BioTector does not require any reagents or carrier gas to operate. When BioTector is started using the Operation menus, the relevant CO2 peaks are generated artificially to demonstrate the operation of the system. Because the system normal operation is inhibited, system automatically displays a warning to the user before the DEMO MODE is activated. OFF 1000ppm 25s 2s 3000ppm 55s 5s 4000ppm 65s 5s  The TIC/TOC/TC CURVE PEAK/WIDTH/DELAY functions in Demo Mode CO2 Data menu allows the user to program the size of the relevant CO2 peaks, the duration of the CO2 peaks and the time delays artificially generated during the DEMO MODE operation.  In TC and VOC systems, the relevant TIC/TOC/TC CURVE PEAK/WIDTH/DELAY parameters are displayed. Page 112 8.3.2 System Program SYSTEM PROGRAM 1 SYSTEM PROGRAM 1 TIC + TOC  Sample Pump ANALYZER ZERO 15s, 20 l/h TIC ACID 6p SAMPLE LINE FILL 4p SAMPLE IN 20p, DELAY 1s, 40 l/h SAMPLE PORT PURGE 1p P-V TIC SPARGE TIME 25s, 40 l/h BASE 34p BASE OXIDATION TOC ACID 130s, 10 l/h 28p  SYSTEM PROGRAM 1 TIC + TOC defines the system parameters for Oxidation Phase operation in TIC & TOC analysis mode. In TIC & TOC analysis mode, the TIC and TOC contents of a sample are measured consecutively by means of a single sample injection into a single reactor.  SAMPLE PUMP is a shortcut to Commissioning, Sample Pump menu. See Section 8.2.2 Sample Pump for details.  CO2 analyzer establishes a zero offset level for the ANALYZER ZERO time (15s by default) with the oxygen flow (20 l/h) settings.  A “12_HIGH CO2 IN O2” fault is generated during this phase and BioTector stops if the CO2 analyzer’s reading is higher than CO2 ZERO LINE plus the CO2 ZERO ALARM value (250ppm by default) for three consecutive reactions. See Section 8.3.8 Fault Setup for details.  TIC ACID specifies the amount of acid reagent (in pulses) to be injected into the reactor at range 1.  SAMPLE LINE FILL defines the number of pulses Sample Pump operates forward to fill the sample tube between the Sample Valve and the Reactor Valve.  SAMPLE IN defines the amount of sample (in pulses) to be injected into the reactor at operation range 1. P-V stands for “Pinch Valve”, which identifies the type of valve used during sample injection.  A single pulse pump operation corresponds to ½ revolution of the pump roller.  Note that any change carried out on the factory SAMPLE IN setting requires recalibration of the system.  DELAY is the time (1 second by default) the carrier gas is activated to inject the reagents into the Mixer Reactor with a flow of 40 l/h by default.  SAMPLE PORT PURGE defines the number of pulses Sample Pump operates reverse after the sample injection. With this operation, the sample liquid, located inside the tubing between the Reactor Valve (MV3) and the T fitting, is discharged.  BioTector sparges and measures the TIC content of the sample for the TIC SPARGE TIME (45s by default) with the oxygen flow (40 l/h) settings.  If the TIC level does not drop below the TIC CHECK level (10ppm CO2 by default in Reaction Check menu) by the end of TIC SPARGE TIME, BioTector automatically extends this time (extension time) until the TIC level drops below 10ppm level.  A “50_TIC OVERFLOW” warning is generated and BioTector keeps running if the TIC level does not drop below 10ppm by the end of the maximum extension time, which is 300 seconds. The maximum extension time is not a programmable function. It is a fixed figure within the system software.  BASE defines the amount of base (in pulses) to be injected into the reactor for the reaction at range 1.  BioTector oxidizes the sample for the BASE OXIDATION time (130s by default) with the oxygen flow (10 l/h) settings. If any CO2 is released during this phase, it is measured and added to the TOC result because the default setting of PEAK INTEGRATION is TOC+BASE OXID in Result Integration menu.  TOC ACID states the amount of acid (in pulses) to be injected into the reactor for the TOC SPARGE phase at range 1. Page 113 TOC SPARGE TIME 75s, 20 l/h TOC OXIDATION 25s REACTOR PURGE 59s PRESSURE CHECK 30s, 40 l/h PRESSURE RELEASE 10s, 20 l/h PRESSURE PURGE 7s, 60 l/h PRESSURE RELEASE 5s, 20 l/h CYCLES 2 ANALYZER PURGE 20s 40 l/h IDLE O2 FLOW 1 l/h REACTION TIME 5m25s  BioTector sparges and measures the TOC content of the sample for the TOC SPARGE TIME (50s by default) with the oxygen flow (20 l/h) settings.  If the TOC level does not drop below the TOC CHECK level (25ppm CO2 by default in Reaction Check menu) at the end of TOC OXIDATION TIME, BioTector automatically extends this time (extension time) until the TOC level drops below 25ppm level.  A “51_TOC OVERFLOW” warning is generated if the TOC level does not drop below 25ppm at the end of the maximum extension time, which is 300 seconds. The maximum extension time is not a programmable function. It is a fixed figure within the system software.  TOC OXIDATION determines the time (25s by default), the ozone generator will be running at the start of the TOC Sparge phase. Note that TOC OXIDATION time is part of the TOC Sparge phase and does not increase the TOC SPARGE TIME.  REACTOR PURGE displays the overall time, which is 59s by default, the BioTector purges the Mixer Reactor.  During the REACTOR PURGE phase, system continuously monitors the oxygen gas flow using the mass flow controller. If any gas leak or any flow problem is detected during this phase, BioTector generates a “06_PRESSURE CHCK FAIL” or a “02_LOW O2 FLOW - SO” fault and stops. These faults are logged into the fault archive.  PRESSURE CHECK defines the time and oxygen gas flow (20 second at 40 l/h by default) the Mixer Reactor is pressurized for the REACTOR PURGE phase above.  When the gas flow is equal to or less than the PRESSURE CHECK FAULT level, which is 6.0 l/h defined in Sequence Program, Pressure/Flow Test Program menu, for longer than 1 second during the PRESSURE CHECK phase above, BioTector opens the Reactor Valve (MV3) and releases the pressure of the reactor for 10 seconds at 20 l/h oxygen flow by default using the PRESSURE RELEASE function. With this process, the majority of the liquid present in the Mixer Reactor is discharged into drain through the Sample Out port.  When PRESSURE RELEASE phase above is completed, using the PRESSURE PURGE function, the Mixer Reactor is pressurized once again for 7 seconds at a higher oxygen flow of 60 l/h by default.  When the PRESSURE PURGE phase above is completed, BioTector opens the Reactor Valve (MV3) and releases the pressure of the reactor for 5 seconds at 20 l/h oxygen flow by default using the PRESSURE RELEASE function.  Unlike the first PRESSURE RELEASE phase described above, the motor of the Mixer Reactor is activated during this phase. With this process, any remaining liquid present in the Mixer Reactor is discharged into drain through the Sample Out port.  CYCLES (2 by default) defines the number of times the PRESSURE PURGE and the PRESSURE RELEASE phases take place during the REACTOR PURGE phase.  BioTector purges the CO2 analyzer for the ANALYZER PURGE time (20s by default) with the oxygen flow (40 l/h) settings.  When the BioTector is not running, that is when it is powered up and in stop state, or when it is in remote standby state, the carrier gas flow is set to 1 l/h by default.  REACTION TIME displays the total reaction time (in minutes and seconds) for range 1, based on all programmed settings above. Page 114 SYSTEM PROGRAM 1 TC PRE OXIDATION 25s , 10 VOC OXIDATION 25s , 0 TC SPARGE TIME 50s 20l/h TC ACID 28p TC OXIDATION 25s SYSTEM PROGRAM 1 VOC SAMPLE PUMP FORWARD 2 3s  SYSTEM PROGRAM 1 TC defines the system parameters for Oxidation Phase operation in TC analysis mode. In TC analysis mode, the TC content of a sample is measured by means of a single sample injection into a single reactor.  When the Analysis Type is changed to TC, the System Program 1 menu is automatically updated with the corresponding TC system parameters. The TC system parameters, which are not covered in SYSTEM PROGRAM 1 TIC + TOC above are as follows:  PRE OXIDATION defines the time (45s by default) and oxygen flow (10 l/h) settings for the initial oxidation stage, where hydroxyl radicals are generated for the VOC Oxidation phase.  VOC OXIDATION states the time (45s) and oxygen flow (0 l/h no flow by default) settings for the VOC Oxidation stage, where the volatile organic carbon element of the sample is oxidized.  The objective of no oxygen flow at this reaction phase is to prevent the loss of any volatiles before they are oxidized.  BioTector sparges and measures the TC content of the sample for the TC SPARGE TIME (150s by default) with the oxygen flow (20 l/h) settings.  If the TC level does not drop below the TC CHECK level (25ppm CO2 by default in Reaction Check menu) at the end of TC OXIDATION time, BioTector automatically extends this time (extension time) until the TC level drops below 25ppm level.  A “91_TC OVERFLOW” warning is generated if the TC level does not drop below 25ppm at the end of the maximum extension time, which is 300 seconds. The maximum extension time is not a programmable function. It is a fixed figure within the system software.  TC ACID states the amount of acid (in pulses) to be injected into the reactor for the TC SPARGE phase in TC mode at range 1.  TC OXIDATION determines the time (75s by default), the ozone generator will be running at the start of the TC Sparge phase. Note that TC OXIDATION time is part of the TC Sparge phase and does not increase the TC SPARGE TIME.  SYSTEM PROGRAM 1 VOC defines the system parameters for Oxidation Phase operation in VOC analysis mode. In VOC analysis mode, two reactions (first one in TC mode and the second one in TIC & TOC mode) are run consecutively by means of two sample injections into a single reactor.  When the Analysis Type is changed to VOC, the System Program 1 menu is automatically updated with the corresponding VOC system parameters. The VOC system parameters, which are not covered in SYSTEM PROGRAM 1 TIC + TOC and TC analysis modes above is as follows:  SAMPLE PUMP FORWARD 2 specifies the Sample Pump’s forward operation time (3s by default), where the Sample Pump runs forward to fill the sample line with sample liquid, prior to the second sample injection into the reactor for the second TIC & TOC analysis reaction in VOC systems. Page 115 SYSTEM PROGRAM 2 SYSTEM PROGRAM 2 TIC + TOC RANGE CHANGE 1-2 50.0mgC/l RANGE CHANGE 1-3 RANGE CHANGE 2-1 150.0mgC/l 40.0mgC/l SAMPLE IN 5p TIC ACID 12p BASE 70p BASE OXIDATION 130s TOC ACID 58p P-V  RANGE CHANGE 1-2 defines the concentration levels for the BioTector to change its range automatically from range 1 to range 2.  The RANGE CHANGE 1-2 is typically the top concentration point of TOC RANGE 1 in System Range Data menu by default.  RANGE CHANGE 1-3 specifies the concentration level for the BioTector to change its range automatically from range 1 to range 3.  The RANGE CHANGE 1-3 is typically 50-75% of the top concentration point of TOC RANGE 2 in System Range Data menu by default.  RANGE CHANGE 2-1 states the concentration level for the BioTector to change its range automatically from range 2 to range 1.  The RANGE CHANGE 2-1 is typically 20% less of the top concentration point of TOC RANGE 1 in System Range Data menu by default.  SAMPLE IN identifies the amount of sample (in pulses) to be injected into the reactor at range 2.  TIC ACID defines the amount of acid reagent (in pulses) to be injected into the reactor at range 2.  BASE specifies the amount of base (in pulses) to be injected into the reactor for the BASE OXIDATION phase at range 2.  BASE OXIDATION defines the oxidation time (150s by default), which can be programmed independently for range 2.  If the Base Oxidation time is different than the one programmed in System Program 1 menu, depending on the difference between the two settings, the reaction time at range 2 will be either longer or shorter than the reaction time displayed in System Program 1 menu.  TOC ACID states the amount of acid (in pulses) to be injected into the reactor for the TOC SPARGE phase at range 2. Page 116 SYSTEM PROGRAM 2 TC SAMPLE IN 5p , P-V  All system parameters for SYSTEM PROGRAM 2 VOC analysis mode are covered in System Program 2 TC and System Program 2 TIC + TOC above. SYSTEM PROGRAM 2 VOC SYSTEM PROGRAM 3 SYSTEM PROGRAM 3 TIC + TOC RANGE CHANGE 2-3 150.0 mgC/l RANGE CHANGE 3-2 120.0mgC/l RANGE CHANGE 3-1 40.0mgC/l SAMPLE IN  SAMPLE IN defines the amount of sample (in pulses) to be injected into the reactor in TC mode at range 2. 3p P-V TIC ACID 12p BASE 70p BASE OXIDATION 130s TOC ACID 58p  RANGE CHANGE 2-3 defines the concentration level for the BioTector to change its range automatically from range 2 to range 3.  The RANGE CHANGE 2-3 is typically the top concentration point of TOC RANGE 2 in System Range Data menu by default.  RANGE CHANGE 3-2 specifies the concentration level for the BioTector to change its range automatically from range 3 to range 2.  The RANGE CHANGE 3-2 is typically 20% less of the top concentration point of TOC RANGE 2 in System Range Data menu by default.  RANGE CHANGE 3-1 defines the concentration level for the BioTector to change its range automatically from range 3 to range 1.  The RANGE CHANGE 3-1 is typically 20% less of the top concentration point of TOC RANGE 1 in System Range Data menu by default.  SAMPLE IN states the amount of sample (in pulses) to be injected into the reactor at range 3.  TIC ACID defines the amount of acid reagent (in pulses) to be injected into the reactor at range 3.  BASE specifies the amount of base (in pulses) to be injected into the reactor for the BASE OXIDATION phase at range 3.  BASE OXIDATION defines the oxidation time (150s by default), which can be programmed independently for range 3.  If the Base Oxidation time is different than the one programmed in System Program 1 menu, depending on the difference between the two settings, the reaction time at range 3 will be either longer or shorter than the reaction time displayed in System Program 1 menu.  TOC ACID states the amount of acid (in pulses) to be injected into the reactor for the TOC SPARGE phase at range 3. Page 117 SYSTEM PROGRAM 3 TC SAMPLE IN TC ACID 5p , P-V 58p  SAMPLE IN defines the amount of sample (in pulses) to be injected into the reactor in TC mode at range 3.  TC ACID states the amount of acid (in pulses) to be injected into the reactor for the TC SPARGE phase in TC mode at range 3.  All system parameters for SYSTEM PROGRAM 3 VOC analysis mode are covered in System Program 3 TC and System Program 3 TIC + TOC above. SYSTEM PROGRAM 3 VOC 8.3.3 Calibration Data DECIMAL PLACES 3 TOC/TC CALIBRATION 1 TOC/TC CALIBRATION 2 TOC/TC CALIBRATION 3 TIC CALIBRATION 1 TIC CALIBRATION 2 TIC CALIBRATION 3  DECIMAL PLACES setting defines the number of decimal places (0, 1, 2 or 3) system displays in the reaction results and in the relevant system menus.  Calibration menus are used to install the calibration data and thus to calibrate the BioTector in factory. TOC CALIBRATION 1, 2 and 3 shows the calibration curves for range 1, 2 and 3 respectively. In TC and VOC systems, the TOC CALIBRATION 1/2/3 menus are named as TC CALIBRATION 1/2/3.  The first column shows the number of calibration points, the second point [%] shows the calibration factors automatically calculated from the calibration data, the third column STANDARD shows the standard solution concentrations and the fourth column shows the un-calibrated result (mgC/l) measured and calculated from the CO2 analyzer readings.  System calibration curves should not be modified by the user on site unless a recalibration of the system is required at a different analysis range. 8.3.4 Sequence Program 8.3.4.1 Average Program LOG AVERAGE NO AVERAGE UPDATE 00:00  LOG AVERAGE function enables (YES) or disables (NO by default) the 24-hour averaging of the reaction results in the reaction archive.  The reaction results obtained from manual samples are not included in the averaging calculations.  If the LOG AVERAGE above is enabled (YES), the system calculates a 24 hours average of the reaction results and displays it in the reaction archive for each stream at the time programmed for AVERAGE UPDATE (00:00, HR:MIN, by default). Page 118 8.3.4.2 Zero Program ZERO PROGRAM ZERO PROGRAM MAX 5 , 3 2 , 2 10 ZERO AVERAGE ZERO BAND 3 , 3 , 0.050mgC/l pH ADJUST BASE 14 , pH ADJUST TIME 60s 0 , 0  In ZERO PROGRAM 5, 3, 3 setting, the first, second and third inputs define the minimum number of reactions to be carried out at Range 1, Range 2 and Range 3 respectively during the Zero Calibration and Zero Check cycles. Zero cycles are activated by RUN ZERO CALIBRATION/CHECK functions in Zero Calibration menu or by START NEW REAGENT CYCLE function in Install New Reagents menu.  If two or any of the three ZERO PROGRAM settings is set to zero, system runs the zero calibration/check reactions only at the programmed range(s) and calculates the TOC Zero Adjust values for the corresponding range(s) using the measured zero adjust figure.  ZERO PROGRAM MAX defines the maximum number of zero reactions system will operate at a specific range if the corresponding AVERAGE ZERO reading is not within the programmed ZERO BAND below. The corresponding AVERAGE ZERO result is calculated from the programmed number of readings defined in ZERO AVERAGE below. This parameter is common to all ranges.  In ZERO AVERAGE 3, 2, 2 setting, the first, second and third inputs define the number of zero reactions to be averaged to get a representative Zero Adjust value for Range 1, Range 2 and Range 3 respectively.  ZERO BAND is the mgC/l concentration band for the TOC/TC readings obtained during the Zero Calibration or Zero Check reactions. System initially runs the minimum number of reactions and calculates the average value at a specific programmed range. If the variation between the average result and each of the reaction results used in the averaging is not higher than the programmed ZERO BAND, the system completes its zero cycle and generates the necessary Zero Adjust figures. However, if any of the reaction results used in averaging is outside the band, then the system runs an additional Zero Reaction, and evaluates the readings again using the new average value. This cycle is repeated until the system obtains stable zero readings, which must be within the ZERO BAND. If stable zero readings are obtained within a certain number of reactions, which is less than or equal to the maximum number of reactions defined in ZERO PROGRAM MAX above, the Zero Adjust values are generated without any system warning.  If zero stability is obtained on the executed range, system does not seek for further stability on the subsequent ranges.  If the system cannot reach stable zero readings, in other words, if one or more of the TOC/TC readings are outside the programmed ZERO BAND at the end of the maximum number of reactions, depending on the type of zero cycle, system creates a “42_ZERO CAL FAIL” or a “43_ZERO CHCK FAIL” warning and logs it into the fault archive. When a “42_ZERO CAL FAIL warning occurs, system does not generate any Zero Adjust figures and continues operation using the previous Zero Adjust values.  The three pH ADJUST BASE parameters defines the number of pulses the base reagent pump operates to inject base reagent into the reactor at each available system operation range, which are Range 1, Range 2 and Range 3.  This function is used to neutralize the pH of the Mixer Reactor.  pH ADJUST TIME determines the mixing time (60 seconds by default) the Mixer Reactor operates for the pH neutralization of the reactor. Page 119 SERVICE ZERO 20 , 5 ZERO ADJUST HISTORY 8.3.4.3  SERVICE ZERO specifies the number of zero calibration cycles to be repeated after a defined number of reactions between each zero calibration cycle. The first setting “20” is the number of reactions between each zero calibration cycle, and the second setting “5” is the total number of zero calibration cycles which will be carried out.  SERVICE ZERO cycle is activated by the SET SERVICE ZERO function in Service menu.  Anytime the Zero Adjust value is changed, either manually by the user or automatically by the system, the new Zero Adjust value is stored in the Zero Adjust History archive with the time, date, zero range and the zero type (calibration, check or manual) information.  The meaning of the codes used in the system for zero adjust are as follows: TOC/TC-ZC: Zero calibration result for TOC/TC. TOC/TC-ZK: Zero check result for TOC/TC. TOC/TC-ZM: Manually input Zero Adjust for TOC/TC. Span Program SPAN PROGRAM 5 SPAN AVERAGE 3 RANGE 1 TOC CAL STD 10.0mgC/l TOC CHECK STD 10.0mgC/l TIC CAL STD 5.0mgC/l TIC CHECK STD 5.0mgC/l  SPAN PROGRAM defines the number of reactions to be carried out for Span Calibration and Span Check cycles, which are activated by RUN SPAN CALIBRATION/CHECK functions in Span Calibration menu. If the Span Calibration or Span Check is programmed as YES in New Regents Program menu, START NEW REAGENT CYCLE function in Install New Reagents menu will also run the relevant span cycle.  The span calibration/check reactions are run at a single range programmed by the RANGE below. System calculates and uses the same Span Adjust values for other ranges as well.  SPAN AVERAGE is the number of span reactions the system averages to calculate the Span Adjust factor.  RANGE (1 by default) determines the range at which all Span Calibration and Span Check reactions are carried out.  TOC CALIBRATION STANDARD defines the TOC standard solution concentration level (mgC/l) to be used in Span Calibration reactions.  If TOC CALIBRATION STANDARD is programmed as 0.0mgC/l, system ignores the Span Calibration results and omits any related warnings defined in TOC BAND below.  TOC CHECK STANDARD defines the TOC standard solution concentration level (mgC/l) to be used in Span Check reactions.  If TOC CHECK STANDARD is programmed as 0.0mgC/l, system ignores the Span Check results and omits any related warnings defined in TOC BAND below.  TIC CALIBRATION STANDARD defines the TIC standard solution concentration level (mgC/l) to be used in Span Calibration reactions.  If TIC CALIBRATION STANDARD is programmed as 0.0mgC/l, system ignores the Span Calibration results and omits any related warnings defined in TIC BAND below.  In TC systems, TIC CALIBRATION STANDARD is not displayed.  TIC CHECK STANDARD defines the TIC standard solution concentration level (mgC/l) to be used in Span Check reactions.  If TIC CHECK STANDARD is programmed as 0.0mgC/l, system ignores the Span Check results and omits any related warnings defined in TIC BAND below.  In TC systems, TIC CHECK STANDARD is not displayed. Page 120 TC CAL STD 15.0mgC/l TC CHECK STD 15.0mgC/l TOC BAND 25% TIC BAND 25% TIC FACTOR = TOC YES SPAN ADJUST HISTORY  In VOC systems, the sum of the TIC and TOC Calibration Standard solution is displayed as TC Calibration Standard. When TOC Calibration Standard is programmed as 0.0mgC/l above, and when a concentration of TIC Calibration Standard is programmed above, BioTector displays the TC Calibration Standard as 0.0mgC/l on purpose. This allows the calibration of TIC without any effect on the TC calibration. In other words, as programmed, system ignores the TC span calibration results and omits any TC related warnings.  In VOC systems, the sum of the TIC and TOC Check Standard solution is displayed as TC Check Standard. When TOC Check Standard is programmed as 0.0mgC/l above, and when a concentration of TIC Check Standard is programmed above, BioTector displays the TC Check Standard as 0.0mgC/l on purpose. This allows the check of TIC without any effect on the TC check. In other words, as programmed, system ignores the TC span check results and omits any TC related warnings.  TOC BAND determines the tolerance limits (25% by default) for the Span Calibration or Span Check reaction results for TOC.  In TC and VOC systems, this function is named as TC BAND.  If the average span result is outside the tolerance limits, a “30_TOC/TC SPAN CAL FAIL” or “33_TOC/TC SPAN CHCK FAIL” warning is logged depending on system analysis mode.  TIC BAND determines the tolerance limits (25% by default) for the Span Calibration or Span Check reaction results for TIC.  If the average span result is outside the tolerance limits, a “31_TIC SPAN CAL FAIL” or “34_TIC SPAN CHCK FAIL” warning is logged.  If the TIC FACTOR = TOC is selected as “YES” (by default), the TOC span factor is used for TIC.  If the TIC FACTOR = TOC setting is “YES”, when the TOC Span Adjust value is changed, the TIC Span Adjust value will also change automatically.  In VOC systems, this function is named as TIC FACTOR = TC.  Anytime the Span Adjust value is changed, either manually by the user or automatically by the system, the new Span Adjust factor is stored in the Span Adjust History archive with the time, date, span RANGE, span type (calibration or check) and the standard solution used.  The meaning of the codes used in the system for span adjust are as follows: TOC/TC/TIC-SC: Span calibration result for TOC/TC/TIC. TOC/TC/TIC-SK: Span check result for TOC/TC/TIC. TOC/TC/TIC-SM: Manually input span adjust for TOC/TC/TIC. Page 121 8.3.4.4 Reagents Purge ACID & BASE PURGE 50s , 3 REACTOR ACID FILL REACTOR BASE FILL REACTOR WASH TIME 300p 450p 100s 8.3.4.5  ACID & BASE PURGE defines the operation time (50 seconds by default) of the acid and base pumps to prime the reagents during the Install New Reagent cycle. The reagent priming and the subsequent reactor purge operation is repeated three times by default.  The reagent purge is activated by START NEW REAGENT CYCLE function in Install New Reagents menu or alternatively by RUN REAGENTS PURGE function in Zero Calibration menu.  The REACTOR ACID/BASE FILL time defines the quantity of acid and base reagents injected into the reactor at the end of the ACID & BASE PURGE phase described above.  When the acid and base reagents are injected into the reactor, the reagents are mixed in the reactor for the duration of REACTOR WASH time (100 seconds by default) to balance and neutralize the reactor pH. Pressure/Flow Test Program TIME 08:15 PRESSURE TEST FAULT 6.0l/h PRESSURE TEST WARN 4.0l/h  BioTector performs an automatic pressure and flow test every day at the TIME programmed (at 08:15 hours by default).  Each time BioTector is started up and every day during online operation at the programmed TIME above, BioTector pressurizes the system with oxygen gas and uses its mass flow controller to detect any gas leak in the system. If the measured flow is less than or equal to the programmed PRESSURE TEST FAULT flow level (6.0 l/h by default), the pressure test passes.  If the flow is greater than programmed PRESSURE TEST FAULT setting, the pressure test fails, and BioTector generates a “05_PRESSURE TEST FAIL” fault and stops. This fault is logged in the fault archive. In TC – TIC systems, BioTector generates a “07_TIC PRESSURE FAIL” fault if TIC reactor pressure test fails.  The pressure test cycle can be disabled by setting PRESSURE TEST FAULT setting to 0.0 l/h. When disabled, BioTector automatically displays an “OFF” message on the screen and logs a “29_PRESSURE TEST OFF” warning in the fault archive.  If the pressure test is skipped during the startup sequence with the “Quick Startup” function (see Section 2.2.1 Start Stop for details) a “28_NO PRESSURE TEST” warning is logged in the fault archive. This warning cannot be acknowledged by the user, it can only be acknowledged automatically by the system the next time the pressure test is passed.  PRESSURE TEST WARNING, which is typically 30% less than the PRESSURE TEST FAULT setting (4.0 l/h by default), gives an advanced warning of a possible gas leak in BioTector.  The pressure warning can be disabled by setting PRESSURE TEST WARNING to 0.0 l/h. When disabled, BioTector automatically displays an “OFF” message on the screen.  If the flow measured during Pressure Test is less than or equal to 6.0 l/h but greater than 4.0 l/h, BioTector generates a “26_PRESSURE TEST WARN” and continues to run. The warning is logged in the fault archive. In TC – TIC systems, BioTector generates a “27_TIC PRESSURE WARN” if TIC reactor pressure test fails. Page 122 PRESSURE CHCK FAULT 6.0l/h FLOW WARNING 54.0l/h  At the end of each reaction during operation, BioTector automatically pressurizes the system with oxygen gas and uses its mass flow controller to detect any gas leak in the system. If the measured flow is less than or equal to the programmed PRESSURE CHECK FAULT flow level (locked to 6.0 l/h by default) during the test, the pressure check passes. The PRESSURE CHECK FAULT acts a safety function, to ensure that there is no gas leak in the system and it is safe to start the next analysis reaction.  The pressure check cycle cannot be disabled in the system.  If the flow measured during the pressure check is greater than the programmed PRESSURE CHECK FAULT level (greater than 6.0 l/h) the pressure check fails, and BioTector generates a “06_PRESSURE CHCK FAIL” fault and stops. This fault is logged in the fault archive.  Each time BioTector is started up and everyday during online operation at the programmed TIME above, oxygen gas flows through the system and mass flow controller is used to detect any blockage in the system. If the measured flow is greater than or equal to the programmed FLOW WARNING level (54.0 l/h by default), the flow test passes.  If the measured flow is less than the programmed FLOW WARNING setting, the flow test fails, and BioTector generates a “22_FLOW WARNING - EX” or “23_FLOW WARNING - SO” in the fault archive and continues to run. This warning is logged in the fault archive.  In TC – TIC systems, BioTector generates a “24_TIC FLOW WARN - EX” or “25_TIC FLOW WARN - SO” if TIC reactor flow test fails. 8.3.5 Output Devices 8.3.5.1 System Outputs POWERED ALL TIME VALVE ACTIVATION NO SPF/SAMPLER  POWERED ALL TIME parameter specifies if the relays are powered all the time even if the system is stopped or paused with the YES setting, or if the relay is powered only when required with the default NO setting.  VALVE ACTIVATION determines the two possible times for the multi-stream valve to change over for the next stream. If the default SPF (SAMPLE PUMP FORWARD) option is selected, the valve for the next stream is selected as the Sample Pump starts to run forward to bring the sample from the next stream. If SPR (SAMPLE PUMP REVERSE) option is selected, the valve for the next stream is selected when the Sample Pump reverse operation is completed for the current stream, or when the BioTector powers up.  If SAMPLER is activated in Stream Program menu, SPF option is displayed as SPF/SAMPLER. Page 123  OUTPUT 1-6 menus typically contain internal output settings related to system operation. These relay outputs, located on the Motherboard, are system optional features.  STREAM 1 is always functional as default within the system software. OUTPUT 4-6 menus are not displayed as they are reserved for future use.  OUTPUT 1-6 relays are programmed to a single output function or to multiple output functions if the relevant option has been installed in the BioTector. The programmed output function or functions are marked with an asterisk “*” sign in these menus as in the example for OUTPUT 1, which is programmed for MAINTANENCE SIGNAL and CALIBRATION SIGNAL below.  When multiple functions are programmed for an output relay, the relay output is activated when one or multiple conditions are initiated. In the example below, OUTPUT 1 is activated when MAINTANENCE SIGNAL or CALIBRATION SIGNAL is triggered.  In BioTector configuration data download (or in All Data download), the programmed output functions for each output is tabulated and marked with asterisk “*” signs for clarity. OUTPUT 1-6 OUTPUT 1 DEFAULT STATE N/D STOP FAULT WARNING NOTE SAMPLER FILL SAMPLER EMPTY SAMPLER ERROR SYNC REMOTE STANDBY MAN MODE TRIG MAINT SIGNAL TEMP. SWITCH CAL CAL SIGNAL STREAM 1-3 MANUAL 1-3 SAMPLE STATUS 1-3 ALARM 1-3 CO2 ALARM 1-3 4-20mA CHNG 4-20mA CHNG 1-3 4-20mA READ SAMPLE FAULT 1-3 * * DEFAULT STATE defines the idle state of the relay. N/D stands for “Normally Deenergized” relay by default and N/E stands for “Normally Energized” relay. Output set to operate when the BioTector is stopped condition. Note that remote standby is not considered as a stop condition. Output set to operate on fault condition. Output set to operate on warning condition. Output activated when a notification is logged in the fault archive. Fill signal, sent to the sampler, which remains on from start of sampler fill time to the completion of the sample injection. Empty signal, sent to the sampler, which is a pulse of 5 seconds duration and is triggered after the Sample Pump reverse operation is complete. Output when SAMPLER ERROR input signal is activated due to a sample error in the BioTector Sampler. Synchronization relay, use to synchronize the system with external control units. Output when Remote Standby input is activated. Indicates that manual reactions are activated and going to be executed regardless of the activation is carried out manually on the keyboard or remotely from a system input. Output when MAINTENANCE SWITCH input is activated. Temperature Switch output activated when the temperature of the system increases above the predefined system temperature control level (System Fan Control), which is programmed as 20°C by default. Calibration Valve used during calibration reactions. Output set to operate on Zero/Span Check and Zero/Span Calibration reactions. Output set for Stream Valves 1-3. Output set for Manual Valves 1-3. Digital output activated (energized) when BioTector Sample Sensor detects no sample or when the sample quality is less than the default 95% threshold value for a specific stream. Alarm relay, activated upon programmed alarm conditions for a specific stream. CO2 Alarm relay, activated upon programmed CO2 alarm conditions for a specific stream. 4-20mA output change flag relay, which is always activated for a period of 10s, when a new result causes update of any of the 4-20mA output channels. 4-20mA output change flag relay, which is always activated for a period of 10s, when a new result causes update of a given 4-20mA output channels for a specific stream. This signal is used to indicate valid/stable values on 4-20mA output channels in 420mA Stream & Full Multiplex operation modes. Output when the external stream specific SAMPLE FAULT 1-3 input signal is activated. Page 124 8.3.5.2 Programmable Outputs  POWER BOARD OUTPUT1-6 menus typically contain output settings related to external devices. These relay outputs, located on the Power and Input/Output Board, are system optional features.  POWER BOARD OUTPUT1-6 relays can be programmed to a single output function or to multiple output functions as described for OUTPUT 1-6 above. The programmed output function or functions are marked with an asterisk “*” sign in these menus as in the example for POWER BOARD OUTPUT 2, which is programmed for STOP, FAULT, WARNING and NOTE signals below.  In the example below, POWER BOARD OUTPUT 2 is activated when STOP or FAULT or WARNING or NOTE signal is triggered.  POWER BOARD OUTPUT 1 is a standard system relay programmed to STOP and FAULT output functions by default.  In BioTector configuration data download (or in All Data download), the programmed output functions for each output is tabulated and marked with asterisk “*” signs for clarity. PWR BRD OUT 1-6 PWR BRD OUT 2 DEFAULT STATE STOP FAULT WARNING NOTE SAMPLER FILL ……………………… ……………………… …………………….. N/E * * * * .. .. .. Page 125 8.3.6 Reaction Check CO2 LEVEL FAULT TYPE 100ppm, AUTO WARNING REACTION COUNT 3 TIC CHECK 10ppm TOC CHECK 25ppm TC CHECK 25ppm  Due to the organic and inorganic contamination in the BioTector reagents, every TOC/TC reaction will generate a small level of CO2 from the reagents alone even if there is no sample present. The first setting (100ppm by default) of CO2 LEVEL specifies the reaction check CO2 level, which is the minimum expected CO2 reading in ppm measured by the CO2 Analyzer in a reaction.  The second setting (AUTO by default) of CO2 LEVEL defines the reaction check CO2 level mode. When programmed as AUTO, BioTector automatically sets the CO2 LEVEL to 60% of the average CO2 peak reading recorded during the Zero Calibration or Zero Check reactions. If it is set as MAN (Manual), system uses the fixed programmed CO2 LEVEL value.  BioTector looks for first an increase and then a decrease in the CO2 peak data during the TOC phase (or TC phase depending on ANALYSIS TYPE). If the CO2 peak occur at the wrong phase of the reaction and/or if the CO2 peak is smaller than the expected CO2 LEVEL (100ppm by default) for the number of consecutive reactions defined by REACTION COUNT below (3 reactions by default), system generates a “04_NO REACTION” warning or a “04_NO REACTION” fault (depending on the FAULT TYPE setting below) and logs into the fault archive.  When CO2 LEVEL is programmed as 0ppm, the reaction check function will be disabled. Reaction check function is omitted during the zero calibration or zero check reactions.  FAULT TYPE determines the type (WARNING or FAULT) of the “04_NO REACTION” fault.  When “04_NO REACTION” fault occurs, if FAULT TYPE is programmed as WARNING (by default), BioTector keeps running. If it is programmed as FAULT, BioTector stops.  REACTION COUNT defines the number of consecutive reactions (3 by default) before a “04_NO REACTION” fault is triggered.  TIC CHECK (10ppm CO2 by default) represents the CO2 check point in the TIC phase. If the CO2 level is above the programmed check point at the end of the TIC phase, then the system automatically extends the TIC SPARGE TIME by 1 second and checks the CO2 level again. If the TIC level does not drop below the check point at the end of the maximum 300 seconds, a “50_TIC OVERFLOW” warning is generated.  TOC CHECK (25ppm CO2 by default) represents the CO2 check point in the TOC phase. If the CO2 level is above the programmed check point at the end of the TOC Oxidation section of the TOC phase, then the system automatically extends the TOC SPARGE TIME and TOC OXIDATION time by 1 second and checks the CO2 level again. If the TOC level does not drop below the check point at the end of the maximum 300 seconds, a “51_TOC OVERFLOW” warning is generated.  In TC and VOC systems, TC CHECK (25ppm CO2 by default) represents the CO2 check point in the TC phase. If the CO2 level is above the programmed check point at the end of the TC Oxidation section of the TC phase, then the system automatically extends the TC SPARGE TIME and TC OXIDATION time by 1 second and checks the CO2 level again. If the TC level does not drop below the check point at the end of the maximum 300 seconds, a “91_TC OVERFLOW” warning is generated. Page 126 8.3.7 Result Integration TOC INTEGRATION 3 TOC INT. LIMITS 10% , 0.100  TOC INTEGRATION (3 by default) defines the number of reaction results to be averaged to get the actual TOC result.  TOC INTEGRATION LIMITS controls the averaging function defined in TOC INTEGRATION above. The first parameter “10%” defines the % band variation and the second parameter “0.100” defines the absolute variation in mgC/l. If the reaction result is outside the specified bands (TOC INTEGRATION LIMITS), then the reaction result averaging is omitted. In other words, the result, which is outside the TOC INTEGRATION LIMITS, is displayed at the end of the reaction without averaging. If the result is within the TOC INTEGRATION LIMITS, the averaging function is continued and the programmed number of reaction results (defined in TOC INTEGRATION above) is averaged. Page 127 8.3.8 Fault Setup LOW O2 FLOW TIME 12s HIGH O2 FLOW TIME 20s BASE CO2 ALARM 250ppm CO2 ZERO LINE 0ppm , AUTO CO2 ZERO ALARM 250ppm SERVICE COUNTER 200 DAYS  If the O2 flow drops more than 50% of the MFC set value for longer than the LOW O2 FLOW TIME (12s by default), a “01_LOW O2 FLOW - EX” or “02_LOW O2 FLOW - SO” fault is logged.  If the O2 flow increases more than 50% of the MFC set value during any reaction phase for longer than the HIGH O2 FLOW TIME (20s by default), a “03_HIGH O2 FLOW” fault is logged.  During the zero calibration & zero check reactions, system monitors the CO2 peak level with the CO2 Analyzer. If the monitored value is higher than the programmed BASE CO2 ALARM level (250ppm by default), a “52_HIGH CO2 IN BASE” warning is logged into the fault archive.  In the event of a “52_HIGH CO2 IN BASE” warning, BioTector generates the relevant Zero Adjust factors automatically, at the end of a successfully completed Zero Calibration cycle.  When it is set as AUTO (Automatic by default), the CO2 ZERO LINE value is updated automatically by the system during Analyzer Zero phase. If it is set as M (Manual), the set value in ppm is used as the fixed CO2 zero line.  For instance, if there is a CO2 leak into the CO2 analyzer’s source or detector sections, a typical of 400ppm CO2 level in the environment will increase the CO2 ZERO LINE level to ≈250ppm within 24 days of online operation or approximately after 5000 analysis cycles.  If the concentration of CO2 measured during the Analyzer Zero phase for the oxygen gas input is higher than CO2 ZERO LINE plus CO2 ZERO ALARM (250ppm by default) value for 3 consecutive reactions, a “12_HIGH CO2 IN O2” fault is logged in the fault archive and the system stops.  The purpose of this function is to monitor the operation of the oxygen concentrator. If the oxygen concentrator fails, then the oxygen purity will be reduced and CO2 at atmospheric levels (~400ppm) will enter the BioTector, and will be detected by the CO2 analyzer. It is important not to run the BioTector with a faulty oxygen concentrator as eventually water could enter the BioTector with the contaminated oxygen gas, which may cause damage on the Mass Flow Controller.  SERVICE COUNTER (200 days by default) specifies the number of days the system operates before triggering an “83_SERVICE TIME” warning.  Note that the service counter keeps operating and decreases the count by a day if system is powered up during the same day even though system was not running. Because the default factory setting is a typical value for normal site conditions, the service interval may need to be adjusted according to specific site conditions. Page 128 OZONE TEST TIME 18s OZONE GEN ALARM 0.50A , 5s OZONE GEN FAN ALARM 1.00V , 5s SAMPLE STATUS 5s , ARCHIVE NO AUTO RESET NO SAMPLE FAULT 1 SAMPLE FAULT 2 SAMPLE FAULT 3 AUTO RESET 95% 1000s 1000s 1000s NO  OZONE TEST TIME defines the programmed time (18 seconds by default), which passes the Ozone Test in Process Test, Ozone Test menu. The maximum time the ozone generator remains on during the Ozone Test is 60 seconds.  OZONE GENERATOR ALARM defines the current (0.5A by default) and the time (5 seconds by default) setting for the “102_OZONE GEN FAULT” event. If the current drawn through the Ozone Generator has dropped below 0.5 Amp for longer than 5 seconds, BioTector generates a “102_OZONE GEN FAULT” warning.  OZONE GENERATOR FAN ALARM defines the Voltage Band (1.0V by default) and the time (5 seconds by default) settings for the “103_OZONE FAN FAULT” event. If the voltage on the Ozone Generator Fan drops below 2.5V minus the Voltage Band (i.e. 1.5V by default), or if the voltage increases more than 2.5V plus the Voltage Band (i.e. 3.5V by default), for longer than 5 seconds, BioTector generates a “103_OZONE FAN FAULT” warning.  When OZONE GENERATOR FAN ALARM voltage is set to 0.0 Volt, then the Ozone Fan Fault generation is switched off.  The first parameter in SAMPLE STATUS setting is the sample detection time (5 seconds by default) BioTector processes the output of the Sample Sensor. When the parameter is set to 0s (zero seconds), the sample detection is switched off. The second parameter (95% by default) is the % sample quality threshold, which is used to activate SAMPLE STATUS output.  Sample Status output is activated (energized) when BioTector Sample Sensor detects no sample or when the sample quality is less than the default 95% threshold value.  Sample Status output is set/reset as soon as the Sample Sensor signal is processed. Sample Status holds its state between reactions and when system is stopped or put into standby mode.  In systems built with Sample Sensor, if SAMPLE STATUS ARCHIVE function is programmed as “YES”, the “116/117/118 LOW/NO SAMPLE 1/2/3” notification events are generated and logged into the Fault Archive when there is no or low sample liquid in the corresponding streams from stream 1 to stream 3.  If SAMPLE STATUS AUTO RESET function is programmed as “YES”, the corresponding “116/117/118 LOW/NO SAMPLE 1/2/3” notification events are automatically acknowledged in the Fault Archive depending on the sample status of the relevant streams from stream 1 to stream 3.  In multi-stream systems, the Sample Status relay output signal is a common signal, which is activated/deactivated when the sample quality is determined by the BioTector Sample Sensor for any of the streams during analysis.  SAMPLE FAULT 1-3 defines the stream specific programmable output time delay (1000 seconds by default), which delays the activation of the SAMPLE FAULT 1-3 output signals and logging of the “122/123/124 SAMPLE FAULT 1/2/3” notification events into the fault archive. The purpose of the time delay is to prevent unnecessary generation of the sample fault signals if the sample fault only occurs for a very short time.  SAMPLE FAULT AUTORESET determines whether the “122/123/124 SAMPLE FAULT 1/2/3” notification events are automatically acknowledged by the system (with the “YES” setting) or to be acknowledged manually from the BioTector keyboard (with the “NO” setting by default). Page 129 COOLER ALARM 0.10A , 5s COOLER FAN ALARM 1.00V , 5s  COOLER ALARM defines the current (0.1A by default) and the time (5 seconds by default) setting for the “107_COOLER FAULT” event. If the current drawn through the Cooler has dropped below 0.1 Amp for longer than 5 seconds, BioTector generates a “107_COOLER FAULT” warning.  When COOLER ALARM current is set to 0.0 Amp, then the Cooler Fault generation is switched off.  COOLER FAN ALARM defines the Voltage Band (1.0V by default) and the time (5 seconds by default) settings for the “108_COOLER FAN FAULT” event. If the voltage on the Cooler Fan drops below 2.5V minus the Voltage Band (i.e. 1.5V by default), or if the voltage increases more than 2.5V plus the Voltage Band (i.e. 3.5V by default), for longer than 5 seconds, BioTector generates a “108_COOLER FAN FAULT” warning.  When COOLER FAN ALARM voltage is set to 0.0 Volt, then the Cooler Fan Fault generation is switched off. Page 130 8.3.9 Fault Status This menu gives a short status history of several system devices before a fault is registered. The default 0.0 values indicate that there are no faults detected for the specific device. O2 FLOW BIOTECTOR TEMPERATURE CO2 ANALYZER FAULT OZONE GEN FAULT COOLER FAULT  The O2 FLOW menu consists of 120 entries for the MFC setpoint value (first column) and MFC flow value (second column). The entries are sampled at every 1 second intervals. If a fault is detected, the events are stored in the O2 FLOW fault archive and are retained even if the fault is acknowledged in Fault Archive menu. The archive is only over-written if a new fault is detected.  The BIOTECTOR TEMPERATURE menu consists of 120 readings of the BioTector temperature. The entries are sampled at every 2 seconds intervals, covering 240 seconds. If a fault is detected, the events are stored in the BIOTECTOR TEMPERATURE fault archive and are retained even if the fault is accepted in Fault Archive menu. The archive is only overwritten if a new fault is detected.  The CO2 ANALYZER FAULT menu consists of 120 readings of the CO2 Analyzer. The entries are sampled at every 2 second intervals, covering 240 seconds. If a fault is detected, the events are stored in the CO2 ANALYZER FAULT archive and are retained even if the fault is accepted in Fault Archive menu. The archive is only over-written if a new fault is detected.  The OZONE GENERATOR FAULT menu consists of 120 readings of the current drawn through the OZONE GENERATOR. If a fault is detected, the events are stored in the OZONE GENERATOR FAULT archive and are retained even if the fault is accepted in Fault Archive menu. The archive is only over-written if a new fault is detected. By careful analysis of the fault data, it is possible to determine between an abrupt fault, and an intermittent fault.  The COOLER FAULT menu consists of 120 readings of the Cooler. The entries are sampled at every 1 second intervals. The data in first column displays the current drawn by the Cooler in Amperes. The data in the second column displays the % output activation time of the Cooler. For instance, 90% means that the Cooler is activated for 90% of the Pulse Width Modulation period. If a fault is detected, the events are stored in the COOLER FAULT archive and are retained even if the fault is accepted in the Fault Archive menu. The archive is only overwritten if a new fault is detected. Page 131 8.3.10 CO2 Analyzer ANALYSIS GRAPH SCALE 10000ppm BAUDRATE CO2 ANALYZER RANGE CO2 ANALYZER CAL 9600 10000ppm  ANALYSIS GRAPH SCALE determines the scale of the y-axis “CO2 analyzer’s ppm-CO2 readings” on the Analysis Graph Screen (see section 2.1.4 Analysis Graph Screen for details). This function allows the system to display CO2 data peaks in optimal resolution on the LCD screen.  The ANALYSIS GRAPH SCALE is independent of the CO2 ANALYZER RANGE described below. Note that, in certain circumstances, when the displayed CO2 peaks on screen exceeds the scale of the graph, the CO2 analyzer keeps measuring and integrating the CO2 readings to obtain the TOC result, without losing any CO2 data.  BAUDRATE (9600bps by default) specifies the data communication signaling speed of CO2 Analyzer with the RS232 communication interface.  CO2 ANALYZER RANGE defines the full scale range of the CO2 analyzer installed in the BioTector.  The CO2 ANALYZER CALIBRATION menu allows the user to change CO2 Analyzer range and the CO2 analyzer zero and span parameters when necessary. If required, please contact manufacturer or distributor for details of the procedures. Page 132 8.3.11 Cooler Program MODE T CONTROL BACKUP PWM DUTY 10% 50% PWM OFFSET 14.0C 50% PWM SLOPE 5.00%/C T DIFFERENCE 16.0C  MODE defines the operation mode of the Cooler. Cooler operates automatically with the default TEMPERATURE CONTROL setting, to achieve the programmed TEMPERATURE DIFFERENCE below.  When MODE is programmed as PWM “PULSE WIDTH MODULATION”, the Cooler operates using the BACKUP PWM DUTY setting below.  BACKUP PULSE WIDTH MODULATION DUTY defines the operation of the cooler in back-up mode, i.e. when there is a fault with the Cooler or with the BioTector temperature sensor (i.e. when system generates 107_COOLER FAULT and/or 108_COOLER FAN FAULT or 113_TEMP SENSOR FAULT warning events). The default 10% setting means that the Cooler is activated for 10% of the time and deactivated for 90% of the time.  The BACKUP PWM DUTY mode is automatically cancelled when the relevant faults are acknowledged in the Fault Archive menu.  The 50% PWM OFFSET setting (14°C by default) is the midpoint offset of the cooler temperature calibration curve, which is linear. When Cooler operates with PULSE WIDTH MODULATION at 50%, the Cooler temperature is typically ~14°C below ambient temperature, which is ~25°.  The 50% PWM slope setting (5% per 1°C by default) is the slope of the cooler temperature calibration curve at midpoint. When Cooler operates with PULSE WIDTH MODULATION at 50%, the Cooler temperature changes by ~1°C with every 5% change in PULSE WIDTH MODULATION.  TEMPERATURE DIFFERENCE (16% by default) defines the temperature difference to be achieved between the BioTector temperature and the Cooler temperature. BioTector temperature sensor is located on the O2-Controller Board. Cooler temperature is achieved with the settings described above.  Cooler Temperature = BioTector Temperature – TEMPERATURE DIFFERENCE.  When BioTector detects that the Cooler temperature will drop below 5°C applying above settings, system automatically decreases the PULSE WIDTH MODULATION so that the temperature of the Cooler does not drop below 5°C. This is carried out to avoid possible freezing of the condensate water, which could be present inside the Cooler. Page 133 8.3.12 Ozone Destructor Program PWM DUTY PURGE CYCLE MODE MAN PURGE CYCLE 50% AUTO 2000, 15, 15 PURGE CYCLE FLOW 58 l/h AUTO PURGE CYCLE 15 , 40  PULSE WIDTH MODULATION defines the standard operation of the Ozone Destructor Heater. The default 50% settings mean that the Ozone Destructor Heater is on for 50% of the time, which is typically 5 seconds on and 5 seconds off during normal operation.  When the temperature of the BioTector exceeds 40°C for more than 2 minutes, system automatically applies a PWM DUTY setting of 10%, which means that the Ozone Destructor Heater is on for 10% of the time, which is typically 1 second on and 9 seconds off.  When the temperature of the BioTector is below 15°C for more than 2 minutes, system automatically applies a PWM DUTY setting of 100%, which means that the Ozone Destructor Heater is on all the time. When system automatically changes the operation of the Ozone Destructor Heater, no system warnings are generated.  PURGE CYCLE MODE, which is automatically controlled (AUTO by default), specifies how the purging of the Ozone Destructor is carried out. In AUTO (Automatic) mode, the Ozone Destructor heater and the BioTector Cooler are controlled by the PURGE CYCLE FLOW and AUTO PURGE CYCLE parameters defined below.  When PURGE CYCLE MODE is OFF, the Ozone Destructor heater and the Cooler operate normally.  When PURGE CYCLE MODE is programmed as MAN (Manual), the Ozone Destructor heater and the Cooler operates as described in MAN PURGE CYCLE below.  When the PURGE CYCLE MODE above is programmed as MAN above, in MANUAL PURGE CYCLE setting, the first parameter (2000 by default) defines the number of analysis cycles the Ozone Destructor and the BioTector Cooler operates as normal. The second parameter (15 by default) defines the number of analysis cycles the Ozone Destructor heater is switched off. The third parameter (15 by default) defines the number of analysis cycles both the Ozone Destructor heater and the Cooler are switched off.  When MANUAL PURGE CYCLE is selected, above operation routine is repeated with the relevant number of programmed analysis cycles.  This menu item is only displayed, when the PURGE CYCLE MODE operation mode is selected as MAN above.  When the PURGE CYCLE MODE above is programmed as AUTO, and if the flow measured during the Flow Test (see Section 8.3.4.5 Pressure/Flow Test Program for details) is below the default PURGE CYCLE FLOW setting of 58 l/h, the Ozone Destructor heater and the Cooler operates as described in AUTO PURGE CYCLE below.  This menu item is only displayed, when the PURGE CYCLE MODE operation mode is selected as AUTO above.  When the PURGE CYCLE MODE above is programmed as AUTO above, in AUTOMATIC PURGE CYCLE setting, the first parameter (15 by default) defines the number of analysis cycles the Ozone Destructor heater is switched off. The second parameter (40 by default) defines the number of analysis cycles both the Ozone Destructor heater and the Cooler are switched off. The AUTO PURGE CYCLE operation routine is carried out only once after the Flow Test routine.  This menu item is only displayed, when the PURGE CYCLE MODE operation mode is selected as AUTO above. Page 134 8.3.13 Software Update LOAD FACTORY CONFIG. SAVE FACTORY CONFIG. LOAD CONFIG. FROM MMC/SD CARD SAVE CONFIG. TO MMC/SD CARD UPDATE SYSTEM SOFTWARE  Each BioTector system contains a configuration which is installed and protected by system flash memory. When any modification is carried out in system configuration, LOAD FACTORY CONFIGURATION function allows the user to revert back to the original system settings programmed in the factory.  Before any change is carried out in the system configuration, it is recommended to use the SAVE FACTORY CONFIGURATION function below.  When SAVE FACTORY CONFIGURATION function is activated, the system saves the most up to date configuration into system flash memory. When this function is used successfully, it allows the user to make necessary modifications in system configuration and then revert back to the original settings with the use of LOAD FACTORY CONFIGURATION function above.  Each system contains an external flash memory card (MMC/SD card), which contains the factory configuration, with the name “syscnfg.bin” in binary format. When any modification is carried out in system configuration, LOAD CONFIG. FROM MMC/SD CARD function can be used and the user can revert back to the original system settings programmed in factory or on site.  This function is very useful during system software update (see UPDATE SYSTEM FIRMWARE below), as the new system configuration can be installed automatically with this function once the new configuration is available inside the MMC/SD card (in binary format and with the correct name).  When SAVE CONFIG. TO MMC/SD CARD function is activated, the system saves the most up to date configuration into the MMC/SD card. When this function is used successfully, it allows the user to make necessary modifications in system configuration and then revert back to the original settings with the use of LOAD CONFIG. FROM MMC/SD CARD function above.  UPDATE SYSTEM SOFTWARE function can be used to update system software on site. If a software update is required, please contact manufacturer or distributor for details of the system software update procedures. Page 135 8.3.14 Password OPERATION CALIBRATION DIAGNOSTICS COMMISSIONING SYSTEM CONFIGURATION 8.3.15 ENGLISH DEUTSCH FRANCAIS 8.3.16 0000 0000 0000 0000 0000  Password menu allows any number from 1 to 9999 to be set as passwords for the Operation, Calibration, Diagnostics, Commissioning and System Configuration menus (levels). When the setting is 0000 (by default), the password is disabled.  The higher level passwords can be used to access password protected lower levels. For instance the DIAGNOSTICS password can be used for access the OPERATION level. The SYSTEM CONFIGURATION password can be used to access the password protected OPERATION, CALIBRATION, DIAGNOSTICS and COMMISSIONING levels. Language  LANGUAGE menu allows the user to change the language of the system if it is available in the software. Hardware Configuration  Hardware Configuration menus are for factory use only. Page 136 Section 9 Troubleshooting of System Fault, Warning and Notification Events 9.1 BioTector Fault Event Explanation and Remedial Action The following fault conditions activate the BioTector stop sequence, set all 4-20mA signals to the FAULT LEVEL (1mA by default) programmed in the 4-20mA Program menu, and activate the FAULT relay. When the system fault is rectified, acknowledge the fault by pressing the ENTER key in the Fault Archive menu. Detailed information on system operation, commissioning & startup, service and Process Tests are available in the MMC/SD card shipped with the BioTector. It is recommended to review these documents for troubleshooting purposes. If the BioTector LCD Screen is not operating, check the main power switch and confirm the red light on the switch is ON. Check/replace Fuse 2 on the motherboard. FAULT CONDITION CAUSE/REMEDY 01_LOW O2 FLOW - EX MFC oxygen flow through the Exhaust “EX” Valve (MV1) has been below 50% of its setpoint for the time longer than the “LOW O2 FLOW TIME” defined in Fault Setup menu. This fault may be initiated after the occurrence of warnings 92/94/96/98 HI/LO AIR/O2 PRESSURE. Various, for example, air and oxygen supply problem. Check oxygen pressure looking at the Oxygen Controller Status (O2-CTRL STATUS) menu. It should be 400mbar (±10mbar) at 20 l/h MFC flow. Blocked ozone destructor. Blocked tube after MFC. Faulty/blocked Exhaust Valve. Faulty MFC. Run Flow Test (see Section 8.1.1.2 Flow Test for details). 02_LOW O2 FLOW - SO MFC oxygen flow through the Sample Out “SO” port (through Reactor Valve, MV3) has been below 50% of its setpoint for the time longer than the “LOW O2 FLOW TIME” defined in Fault Setup menu. This fault may be initiated after the occurrence of warnings 92/94/96/98 HI/LO AIR/O2 PRESSURE. Various, for example, air and oxygen supply problem. Check oxygen pressure looking at the Oxygen Controller Status (O2-CTRL STATUS) menu. It should be 400mbar (±10mbar) at 20 l/h MFC flow. Faulty/blocked Reactor Valve and/or Sample Valve. Blocked tube after MFC. Faulty MFC. Run Flow Test (see Section 8.1.1.2 Flow Test for details). 03_HIGH O2 FLOW MFC oxygen flow through the Exhaust Valve (MV1) has been above 50% of its setpoint for the time longer than the “HIGH O2 FLOW TIME” defined in the Fault Setup menu. Faulty MFC. Check oxygen pressure looking at the Oxygen Controller Status (O2-CTRL STATUS) menu. It should be 400mbar (±10mbar) at 20 l/h MFC flow. Page 137 04_REACTION ERROR No TOC (or TC) CO2 peak detected or the CO2 peak is below the “CO2 LEVEL” for 3 consecutive reactions. See Section 8.3.6 Reaction Check for details. Acid/Base containers are empty. Acid/Base tube rail installed incorrectly. Acid/Base Pumps are faulty. Delivery problem or air bubbles in Acid/Base lines. Mixer Reactor is not mixing. Acid/Base reagents are at incorrect strength. Run pH Test (see Section 8.1.1.5 pH Test for details). 05_PRESSURE TEST FAIL MFC flow did not drop below the “PRESSURE TEST FAULT” level during the pressure test cycle. See Section 8.3.4.5 Pressure/Flow Test Program for details. Gas/liquid leak in the BioTector. Valve leaking or not sealing. Open Reactor Valve, inspect for dirt/damage. Check system fittings. Check Mixer Reactor. Run Pressure Test (see Section 8.1.1.1 Pressure Test for details). 06_PRESSURE CHCK FAIL MFC flow did not drop below the “PRESSURE CHCK FAULT” level during the pressure check cycle for 3 consecutive reactions. See Section 8.3.4.5 Pressure/Flow Test Program for details. Gas/liquid leak in the BioTector. Valve leaking or not sealing. Open Reactor Valve, inspect for dirt/damage. Check system fittings. Check Mixer Reactor. Run Pressure Test (see Section 8.1.1.1 Pressure Test for details). 11_CO2 ANALYZER FAULT Fault in CO2 Analyzer. Very dirty optics in CO2 Analyzer. (can also be programmed as a warning condition) Check CO2 analyzer’s ppm CO2 response in Simulate menu (see Section 8.1.2 Simulate for details). Open CO2 analyzer and clean the optics. Power down and power up the BioTector. If problem persists, check outgoing 24V DC power to CO2 analyzer on Motherboard at wires N11 and N12. For further tests, see information sheet “T019. BioTector CO2 Analyzer Troubleshooting”, which is available in the MMC/SD card shipped with the BioTector. Page 138 12_HIGH CO2 IN O2 High level of CO2 has been detected in the input oxygen gas. Go to Simulate menu and read the CO2 analyzer’s CO2 ppm value. If this value is greater than 250-300ppm, check the oxygen purity. Check the quality of oxygen following the Oxygen Purity Test procedures in Section 7 Analyzer Commissioning and Startup. If the oxygen purity test is satisfactory, open CO2 analyzer and clean the optics. If problem persists, replace the CO2 Analyzer filters. If the oxygen purity test is unsatisfactory, replace the oxygen concentrator. 18_LIQUID LEAK DET BioTector’s liquid leak detector is activated by the three liquid leak detector points fitted in the BioTector. First point is in the main analysis enclosure cabinet, the second point is in the oxygen concentrator cabinet and the third point is in the Mixer Reactor. See figure 2 in Section 4.1.1 Analysis Enclosure for details. Check for a liquid leak in the BioTector main cabinet and in the oxygen concentrator cabinet. Check for a liquid leak in Mixer Reactor by unplugging the leak detector connector on the bottom of the reactor. Rectify the leak. 20_NO REAGENTS BioTector has calculated that the reagent containers should be empty. Change reagents, and reset reagent monitor in Install New Reagents menu. Confirm that the reagent volume/container size input values are correct in the Reagents Monitor menu. If necessary, to readjust the number of days reagents last, see Section 8.2.6 Reagents Monitor for details. 104_MOTHERBOARD FUSE4 Fuse 4 (for Cooler and Ozone Generator) is blown on the motherboard. See Section 5.2.4 System Fuse Specifications for details. Check/replace fuse 4 (F4). Check fuse holder and confirm that the fuse is snapped in tightly into the fuse holder. 105_MOTHERBOARD FUSE5 Fuse 5 (for sample/acid/base pumps, mixer Check/replace fuse 5 (F5). Check fuse holder and confirm that the fuse is snapped in tightly into the fuse holder. Go to Simulate menu and activate each device connected. (can also be programmed as a warning or notification condition) reactor, sample/stream/manual valves, reactor/exhaust valves, cooler fan, ozone destructor, ozone generator fan) is blown on the motherboard. See Section 5.2.4 System Fuse Specifications for details. 106_MOTHERBOARD FUSE6 Fuse 6 (which is reserved for future) is blown on the motherboard. See Section 5.2.4 System Fuse Specifications for details. Check/replace fuse 5 (F5). Check fuse holder and confirm that the fuse is snapped in tightly into the fuse holder. Page 139 109_HI MPU TEMP Temperature on the Micro Processor Unit (MPU) has been exceptionally high and has exceeded 70°C. Check the filters in the fan and vent. Check the operation of the fan. (Note that at temperatures below 25°C, BioTector automatically switches the fan off to stabilize system temperature using its own internal heat.) Check ambient temperature, which should be less than 45°C. Confirm that the Analyzer is not exposed to direct sun light. If the problem is not related to above, contact the distributor or the manufacturer. Page 140 9.2 BioTector Warning Event Explanation and Remedial Action The following warning conditions do not activate the BioTector stop sequence and leave the 4-20mA signals un-changed and do not activate the fault relay. When the system warning is rectified, acknowledge the warning by pressing the ENTER key in the Fault Archive menu. WARNING CONDITION CAUSE/REMEDY 21_CO2 ANL LENS DIRTY CO2 Analyzer has detected dirt on its optical system. Clean the CO2 Analyzer. Clean the lenses on the CO2 Analyzer. 22_FLOW WARNING – EX MFC oxygen flow through the Exhaust “EX” Valve (MV1) has dropped below the “FLOW WARNING” level defined in Pressure/Flow Test Program menu 8.3.4.5 Pressure/Flow Test Program during the Pressure/Flow Test cycle. Various, for example, air and oxygen supply problem. Check oxygen pressure looking at the Oxygen Controller Status (O2CTRL STATUS) menu. It should be 400mbar (±10mbar) at 20 l/h MFC flow. Partially blocked ozone destructor. Partially blocked tube after MFC. Faulty/blocked Exhaust Valve. Faulty MFC. Run Flow Test (see Section 8.1.1.2 Flow Test for details). 23_FLOW WARNING – SO MFC oxygen flow through the Sample Out “SO” port (through Reactor Valve, MV3) has dropped below the “FLOW WARNING” level defined in Pressure/Flow Test Program menu 8.3.4.5 Pressure/Flow Test Program during the Pressure/Flow Test cycle. Various, for example, air and oxygen supply problem. Check oxygen pressure looking at the Oxygen Controller Status (O2CTRL STATUS) menu. It should be 400mbar (±10mbar) at 20 l/h MFC flow. Faulty/blocked Reactor Valve and/or Sample Valve. Partially blocked tube after MFC. Faulty MFC. Run Flow Test (see Section 8.1.1.2 Flow Test for details). 26_PRESSURE TEST WARN MFC flow did not drop below the “PRESSURE TEST WARNING” level defined in Pressure/Flow Test Program menu 8.3.4.5 Pressure/Flow Test Program during the Pressure/Flow Test cycle. Small gas/liquid leak in the BioTector. Valve leaking or not sealing. Open Reactor Valve, inspect for dirt/damage. Check system fittings. Check Mixer Reactor. Run Pressure Test (see Section 8.1.1.1 Pressure Test for details). 28_NO PRESSURE TEST This warning is logged when the pressure test procedure is skipped during the system startup sequence. The warning cannot be acknowledged by the user. It can only be acknowledged automatically by the system next time the pressure test is passed. This warning occurs when the Pressure/Flow Test is deactivated, and when the “QUICK STARTUP” function is used. See Section 2.2.1 Start Stop for details. Page 141 29_PRESSURE TEST OFF There are two pressure tests carried out in BioTector. One is a daily pressure test and the other, called pressure check, is carried out every analysis cycle. This function relates to the daily pressure test. Pressure/Flow Test cycle has been switched off. See Section 8.3.4.5 Pressure/Flow Test Program for details. Activate the Pressure/Flow Test cycle by programming the factory flow settings in Pressure/Flow Test Program menu. 30_TOC/TC SPAN CAL FAIL 31_TIC SPAN CAL FAIL TOC/TC/TIC Span Calibration result is outside the specified TOC/TC/TIC BAND defined in Span Program menu. See Section 8.3.4.3 Span Program for details. Check the concentration of the standard solution used. Check the settings in Span Calibration menu. Check the operation of the BioTector. 33_TOC/TC SPAN CHCK FAIL 34_TIC SPAN CHCK FAIL TOC/TC/TIC Span Check result is outside the specified TOC/TC/TIC BAND defined in Span Program menu. See Section 8.3.4.3 Span Program for details. Check the concentration of the standard solution used. Check the settings in Span Calibration menu. Check the operation of the BioTector. 42_ZERO CAL FAIL Zero Calibration result is outside the specified ZERO BAND defined in Zero Program menu. See Section 8.3.4.2 Zero Program for details. Check the stability of the zero reactions and the quality of the reagents used. Check the settings in Zero Program menu. Repeat the zero calibration cycle. 43_ZERO CHCK FAIL Zero Check result is outside the specified ZERO BAND defined in Zero Program menu. See Section 8.3.4.2 Zero Program for details. Check the stability of the zero reactions and the quality of the reagents used. Check the settings in Zero Program menu. Repeat the zero calibration cycle. 50_TIC OVERFLOW High TIC reading at the end of the TIC phase, even though the TIC sparge time has been automatically extended to its maximum time of 300s. See Section 8.3.6 Reaction Check for details. Exceptionally high TIC. Check system operation ranges in System Range Data menu. Increase operation range to reduce injected sample volume. Increase the TIC SPARGE TIME in System Program, System Program 1 menu. 51_TOC OVERFLOW High TOC readings at the end of TOC phase, even though the TOC time has been automatically extended to its maximum time of 300s. See Section 8.3.6 Reaction Check for details. Exceptionally high TOC. Check system operation ranges in System Range Data menu. Increase operation range to reduce injected sample volume. Increase the TOC SPARGE TIME in System Program, System Program 1 menu. System factory configuration settings are available in the MMC/SD card shipped with the BioTector. Page 142 52_HIGH CO2 IN BASE CO2 level in the base reagent, which is checked during the Zero Calibration or Zero Check cycles, is higher than the “BASE CO2 ALARM” level programmed in Fault Setup menu. Confirm the base reagent CO2 filter is serviced and in good condition, and the container is sealed. Check reagent quality. Replace the base reagent. 62_SMPL PUMP STOP ON Sample Pump stopped with its rotation sensor ON or the sensor is faulty and it is always showing ON. Run the Sample Pump and check the rotation. Check pump sensor signal looking at DI15 in Digital Input menu. Replace the pump. 63_SMPL PUMP STOP OFF Sample Pump stopped with its rotation sensor OFF or the sensor is faulty and it is not sensing the rotation of the pump. Run the Sample Pump and check the rotation. Check pump sensor signal looking at DI15 in Digital Input menu. Replace the pump. 81_ATM PRESSURE HIGH System atmospheric pressure sensor reading is above 115kPa. Therefore, the sensor reading is defaulted to 101.3kPa fault operation mode. Check ADC[05] in Analog Input menu, which should be ~4 Volts. Faulty pressure sensor. Replace the motherboard. 82_ATM PRESSURE LOW System atmospheric pressure sensor reading is below 75kPa. Therefore, the sensor reading is defaulted to 101.3kPa fault operation mode. Check ADC[05] in Analog Input menu, which should be ~4 Volts. Faulty pressure sensor. Replace the motherboard. 83_SERVICE TIME The service counter has counted down the days between service intervals and indicates that service is required. Service the BioTector. After service, acknowledge the warning by resetting the counter using the “RESET SERVICE COUNTER” function in Diagnostics, Service menu. 84_SAMPLER ERROR Warning generated on the BioTector venturi/vacuum sampler due to no/low sample or low air pressure/vacuum in the sampler. Check the LCD screen of the venturi/vacuum sampler for details. See BioTector venturi/vacuum sampler user manual. 88_O2 CONTROLLER WARN A problem has been found during communication with the O2-Controller Board. The communication between the O2Controller Board and the Motherboard is lost. Check LED 2 (L2) on the O2Controller Board, it should be on. Check the 24V DC power on the O2-Controller Board at terminals N01 and N02. Check the data cable (ribbon cable) connections on the board. Power down and power up the BioTector to reset the system. Replace the board. Page 143 89_TC SPAN CAL FAIL 90_TC SPAN CHCK FAIL TC Span Calibration/Check result is outside the specified TC BAND defined in Span Program menu. See Section 8.3.4.3 Span Program for details. Check the concentration of the standard solution used. Check the settings in Span Calibration menu. Check the operation of the BioTector. 91_TC OVERFLOW High TC readings at the end of TC phase, even though the TC time has been automatically extended to its maximum time of 300s. See Section 8.3.6 Reaction Check for details. Exceptionally high TC. Check system operation ranges in System Range Data menu. Increase operation range to reduce injected sample volume. Increase the TC SPARGE TIME in System Program, System Program 1 menu. 92_HI AIR PRESSURE 2 Air pressure supply has been more than 2.0 bar for longer than 5 seconds. When the oxygen concentrator is running, the pressure typically cycles from 1.5 bar to 0.9 bar. If system does not detect the air pressure drop to normal levels, the air supply is isolated from the system and oxygen is not generated. Extreme fluctuations in air supply pressure or faulty external air regulator. Reduce the external air supply pressure to 1.5 bar when the oxygen concentrator is not running. When the problem is rectified, acknowledge the warning by pressing the ENTER key in the Fault Archive menu, to reset the O2-Controller Board. 93_HI AIR PRESSURE 1 Air pressure supply has been more than 1.8 bar for longer than 60 seconds. When the oxygen concentrator is running, the pressure typically cycles from 1.5 bar to 0.9 bar. Extreme fluctuations in air supply pressure or faulty external air regulator. Stop the BioTector and reduce the external air supply pressure to 1.5 bar when the oxygen concentrator is not running. When the problem is rectified, acknowledge the warning by pressing the ENTER key in the Fault Archive menu, to reset the O2-Controller Board. 94_LO AIR PRESURE 2 Air pressure supply has been less than 0.6 bar for longer than 5 seconds. When the oxygen concentrator is running, the pressure typically cycles from 1.5 bar to 0.9 bar. If system does not detect the air pressure increase to normal levels, the air supply is isolated from the system and oxygen is not generated. Extreme fluctuations in air supply pressure or faulty external air regulator. Increase air supply pressure to 1.5 bar when the oxygen concentrator is not running. When the problem is rectified, acknowledge the warning by pressing the ENTER key in the Fault Archive menu, to reset the O2-Controller Board. Page 144 95_LO AIR PRESURE 1 Air pressure supply has been less than 0.8 bar for longer than 60 seconds. When the oxygen concentrator is running, the pressure typically cycles from 1.5 bar to 0.9 bar. Extreme fluctuations in air supply pressure or faulty external air regulator. Increase air supply pressure to 1.5 bar when the oxygen concentrator is not running. When the problem is rectified, acknowledge the warning by pressing the ENTER key in the Fault Archive menu, to reset the O2-Controller Board. 96_HI O2 PRESSURE 2 Oxygen pressure supply has been more than 500 mbar for longer than 5 seconds. If system does not detect the oxygen pressure drop to normal levels, the air supply is isolated from the system and oxygen is not generated. Reduce oxygen pressure to 400 mbar (±10mbar) at 20 l/h MFC flow, looking at the Oxygen Controller Status (O2-CTRL STATUS) menu and using the oxygen pressure regulator. When the problem is rectified, acknowledge the warning by pressing the ENTER key in the Fault Archive menu, to reset the O2-Controller Board. 97_HI O2 PRESSURE 1 Oxygen pressure supply has been more than 450 mbar for longer than 60 seconds. Reduce oxygen pressure to 400 mbar (±10mbar) at 20 l/h MFC flow, looking at the Oxygen Controller Status (O2-CTRL STATUS) menu and using the oxygen pressure regulator. 98_LO O2 PRESSURE 2 Oxygen pressure supply has been less than 150 mbar for longer than 5 seconds. If system does not detect the oxygen pressure increase to normal levels, the air supply is isolated from the system and oxygen is not generated. Increase oxygen pressure to 400 mbar (±10mbar) at 20 l/h MFC flow, looking at the Oxygen Controller Status (O2-CTRL STATUS) menu and using the oxygen pressure regulator. When the problem is rectified, acknowledge the warning by pressing the ENTER key in the Fault Archive menu, to reset the O2-Controller Board. 99_LO O2 PRESSURE 1 Oxygen pressure supply has been less than 200 mbar for longer than 60 seconds. Increase oxygen pressure to 400 mbar (±10mbar) at 20 l/h MFC flow, looking at the Oxygen Controller Status (O2-CTRL STATUS) menu and using the oxygen pressure regulator. Page 145 100_ROTARY V STOP:ON Rotary Valve stopped with its rotation sensor on (sensor signal 1). The sensor is faulty and it is always showing on (sensor signal 1). See Rotary Valve and Rotary Valve Sensor in Section 8.1.6 Oxygen Controller Status for details. Go to Simulate menu, set MFC flow to 20 l/h and check the rotation of the Rotary Valve. Check ROTARY VALVE SENSOR signals (1 “on” and 0 “off”) in the Oxygen Controller Status menu as the valve rotates. Replace the valve. When the warning is cleared, the green LED, labeled as “Stepper” on the Oxygen Controller Board, should be on. 101_ROTARY V STOP:OFF Rotary Valve stopped with its rotation sensor off (sensor signal 0). The sensor is faulty and it is not sensing the rotation of the pump. Sensor in Section 8.1.6 Oxygen Controller Status for details. Go to Simulate menu, set MFC flow to 20 l/h and check the rotation of the Rotary Valve. Check ROTARY VALVE SENSOR signals (1 “on” and 0 “off”) in the Oxygen Controller Status menu as the valve rotates. Replace the valve. When the warning is cleared, the green LED, labeled as “Stepper” on the Oxygen Controller Board, should be on. 102_OZONE GEN FAULT The current drawn through the Ozone Generator has dropped below 0.5 Amp for longer than 5 seconds. Fuse 4 (for Cooler and Ozone Generator) is blown on the motherboard. See Section 5.2.4 System Fuse Specifications for details. Check/replace the fuse 4 (F4) on the motherboard. Check fuse holder and confirm that the fuse is snapped in tightly into the fuse holder. Press the “RESET” button on the motherboard. Power off the BioTector, wait 30 seconds and power up. Go to Simulate menu, turn the OZONE GENERATOR on and adjust Ozone Current to 1 Amp (±0.05 Amp) using the potentiometer on the Ozone Generator box. 103_OZONE FAN FAULT If this optional device is fitted, the voltage on the Ozone Generator Fan has dropped below 1.5 Volts or has exceeded 3.5 Volts for longer than 5 seconds. Check the operation of the fan inside the Ozone Generator. Check wiring on terminals N01 and N03 on the Ozone Generator Board. Page 146 107_COOLER FAULT The current drawn through the Cooler has dropped below 0.1 Amp for longer than 5 seconds. This indicates cooler peltier element failure. Fuse 3 (for Cooler) is blown on the motherboard. See Section 5.2.4 System Fuse Specifications for details. Check fuse 3 (F3) on the motherboard. Check fuse holder and confirm that the fuse is snapped in tightly into the fuse holder. Inspect the Cooler wiring on the green terminal block. Check the wiring between the Cooler and the Termination Board 81204370_01. Go to Simulate menu and set COOLER to 100%, the voltage on the peltier element of the Cooler should be 10 Volts. Replace the Peltier Element and the Cooler Fan. 108_COOLER FAN FAULT The monitoring voltage on the Cooler Fan has dropped below 1.5 Volts or has exceeded 3.5 Volts for longer than 5 seconds. Check the wiring between the Cooler Fan and the Termination Board 81204370_01. Measure the voltage on the Cooler Fan on the green terminal block, it should be 24 Volts. Replace the Cooler Fan. 110_HI TEMP DUTYCYCLE BioTector temperature has exceeded 50°C for longer than 2 minutes. An analysis delay time of 300 seconds has been introduced between each analysis cycle. When system temperature drops below 48°C for longer than 2 minutes, BioTector continues normal operation. Check the filters in the fan and vent. Check the operation of the fan. BioTector temperature has exceeded 55°C for longer than 2 minutes. BioTector has been automatically put into standby mode and has stopped analyzing. When the temperature drops below 50°C for longer than 2 minutes, BioTector continues operation as described for “110_HI TEMP DUTYCYCLE” above. When system temperature drops below 48°C for longer than 2 minutes, BioTector continues normal operation. Check the filters in the fan and vent. Check the operation of the fan. 111_HI TEMP STANDBY (Note that at temperatures below 25°C, BioTector automatically switches the fan off to stabilize system temperature using its own internal heat.) Check ambient temperature, which should be less than 45°C. Confirm that the Analyzer is not exposed to direct sun light. If the problem is not related to above, contact the distributor or the manufacturer. (Note that at temperatures below 25°C, BioTector automatically switches the fan off to stabilize system temperature using its own internal heat.) Check ambient temperature, which should be less than 45°C. Confirm that the Analyzer is not exposed to direct sun light. If the problem is not related to above, contact the distributor or the manufacturer. Page 147 112_LO TEMP STANDBY BioTector temperature has dropped below 2°C for longer than 2 minutes. BioTector has been automatically put into standby mode and has stopped analyzing. When BioTector temperature increases above 5°C for longer than 2 minutes, BioTector continues normal operation. Check ambient and BioTector temperature. Confirm BioTector is operating within its specification temperatures (5°C – 45°C). 113_TEMP SENSOR FAULT The temperature readings recorded by Micro Processor Unit (MPU) temperature sensor (located on the Motherboard) has been less than the BioTector temperature sensor (located on the O2-Controller Board). The difference between the temperature readings recorded by the MPU temperature sensor and the BioTector temperature sensor has been greater than 15°C. Confirm that motherboard cover is installed and the door of the analyzer is closed. Check ambient temperature, which should be less than 45°C. Confirm that the Analyzer is not exposed to direct sun light. If the problem is not related to above, contact the distributor or the manufacturer. 114_I/O WARNING System has detected changes in the Input/Output bus extender chips, which have read/write control registers, during the periodic checks carried out automatically. When system detects a discrepancy between the requested and the read configuration registers values, then all devices on SPI “Serial Peripheral Interface” bus are reset and re-initialized automatically. Acknowledge the warning and inform the distributor or the manufacturer. Page 148 9.3 BioTector Notification Event Explanation and Remedial Action The following Notification conditions do not activate the BioTector stop sequence, leave the 4-20mA signal un-changed and do not activate the fault relay. Relevant notifications below can be acknowledged in the Fault Archive menu. NOTIFICATION CONDITION CAUSE/REMEDY 85_REAGENTS LOW BioTector has calculated that the reagent containers are running low. Change reagents, and reset reagent monitor in Install New Reagents menu. Confirm that the reagent volume/container size input values are correct in the Reagents Monitor menu. If necessary, to readjust the number of days reagents last, see Section 8.2.6 Reagents Monitor for details. 86_POWER UP Power applied to the BioTector or system reboot after the processor watchdog timeout. Automatically acknowledged notification. No action is required. 87_SERVICE TIME RESET This message is logged into the fault archives when “RESET SERVICE COUNTER” function is selected in Diagnostics, Service menu. Automatically acknowledged notification. No action is required. 116/117/118_ LOW/NO SAMPLE 1/2/3 This message is logged into the fault archives when BioTector Sample Sensor detects no sample liquid or when the sample quality is less than the default 95% threshold value for the corresponding streams from stream 1 to stream 3. See Section 8.3.8 Fault Setup for details. Check sample liquid level and sampling system for each sample channel. Go to Sample Pump Test menu and run PUMP FORWARD TEST and check sample delivery and sample bypass. Confirm that no air bubbles are getting introduced into the sample lines. 122/123/124_ SAMPLE FAULT 1/2/3 This message is logged into the fault archives when external device sends a stream specific sample fault input signal to the BioTector. See Section 8.3.8 Fault Setup for details. Check the external sample liquid level and sampling system for each sample channel. Check the external sample monitoring device and the external input signal wiring. (can also be programmed as a warning condition) Page 149 Section 10 Service and Maintenance 10.1 Weekly Maintenance  Check the air supply pressure: A) An existing instrument air supply line B) BioTector Compressor   Check and confirm that the air pressure is 1.5 bar on the filter pack pressure regulator. Check the Sulfuric Acid level in the acid reagent container. Check the Acid Pump and confirm that there are no leaks. Check the Sodium Hydroxide (base) level in the base reagent container. If installed check the sampling system: Option 1: Confirm that the BioTector Vacuum Sampler or BioTector Venturi Sampler is operating Option 2: Confirm that the Sample Catch-Pot has sufficient sample flow, which guarantees a fresh sample for each analysis cycle. Option 3: Confirm that the Sample Pipe has sufficient sample flow, which guarantees a fresh sample for each analysis cycle. Check the Sample Pump and confirm that there are no leaks. Observe Sample Pump operation and sample delivery from the sample point and confirm that there are no blockages inside sample lines. Check all valves inside the BioTector and confirm that there are no leaks. Check the filter mats in the Fan and Vent housings and confirm that they are not blocked. Check the Sample Out and Exhaust lines outside the BioTector and confirm that there are no damages and blockages.       Page 150 10.2 Six Month Service th Below procedure is a recommended check list for the 6 month service on the BioTector using the 6 Month Service Kit. Please note that any special models and applications may require additional service items. Detailed service procedures are available in a presentation format in the MMC/SD card shipped with the BioTector. It is recommended to review this document before starting the service procedures. Service should only be carried out when “SYSTEM STOPPED” message is displayed on the top left corner of the main Analysis 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. For system and personal safety, all reagent lines should be washed with water and then purged with air before the service procedures are carried out. In order to wash the reagent lines, connect all reagent dip tubes to a DIW (or tap water) container. Go to Zero Calibration menu and activate “RUN REAGENT PURGE” function to wash the reagent lines with water (see Section 2.3.1 Zero Calibration for details). When the reagent purge with water is completed, remove the tubes from the water container and place them open to air. Using the same menu, select the “RUN REAGENT PURGE” function one more time to purge the reagent lines with air. As the system may still contain small traces of reagents after the reagent purge cycles, it is strongly recommended to take the necessary safety precautions, such as wearing eye protection and gloves throughout the service. (If the reagents lines do not fill with DIW during the Reagents Purge cycle, raise the DIW container above the height of the BioTector, go to Zero Calibration menu and select the RUN REAGENTS PURGE function again.) Disconnect power to ozone destructor heater. The ozone destructor should never be opened when it is hot as the threads may seize. _____ Replace the 6.4mm OD, 3.2mm ID EMPP 562 tubing used in the Sample Valve (see item C1 in the service kit). _____ Replace the tubing (6.4mm OD, 3.2mm ID EMPP 562 tubes) of the WMM60 Sample Pump. The WMM60 replacement tubes are supplied in the service kits (see item C2 in the service kit). The overall length of the tube is 156.5mm. If process conditions require this tube to be changed every 3 months, an additional tube is supplied in the service kit. _____ Replace the 6.4mm OD, 3.2mm ID EMPP 562 tubing used in the pinch valves (see item C1 in the service kit) and any PP (Poly-Propylene) Y fittings (see item C3 in the service kit) in the analyzer. If additional Y fittings are required they should be ordered separately. _____ Disconnect the PFA fitting above the cooler. Remove the three nuts and open the analysis door. Using the Simulate menu (see Section 8.1.2 Simulate for details) and referring to figure 1, figure 2 and table 2 in Section 4.1.1 Analysis Enclosure, check and confirm that the valves are operating and there are no leaks: Check Sample Valve, MV4. _____ Check Reactor Valve, MV3 operation. When the valve is activated, the LED on the valve should be on. _____ Check Exhaust Valve, MV1. When the valve is activated, the LED on the valve should be on. _____ Check all the other valves (e.g. multi-stream valves) if installed in the BioTector. _____ Check and confirm that MANUAL/CALIBRATION ports are not blocked or isolated. _____ Page 151 Check for possible build-up of salts or any material at any of the PFA T fittings located between the Ozone Generator and the Mixer Reactor. Clean the fittings and/or the tubing if necessary. _____ Remove Ozone Line Filter and wash it with DIW (or tap water). Dry the filter well and reinstall in place. See figure 4 in Section 4.2.2BioTector Sample Injection for details. _____ Using the Simulate menu (see Section 8.1.2 Simulate for details) and a 10ml graduated cylinder, check and confirm that the pumps are pumping correctly. Acid Pump rate for FMM20 Pump at 400 pulses should be between 3.80 ml and 4.20 ml. (Depending on the quantity of the liquid injected into the reactor and due to an internal system interlock, the system may request the activation of Reactor Purge cycle to purge any excess liquid from the reactor. If necessary run “REACTOR PURGE” function in the Simulate menu.) _____ Base Pump rate for FMM20 Pump at 400 pulses should be between 3.80 ml and 4.20 ml. _____ Important Note: For the correct operation of the system, the measured Acid and Base Pump rates must be identical or similar. The maximum allowable difference in the measured volumes for acid and base injections above should not be more than 0.2ml. Sample Pump rate for WMM60 Pump at 16 pulses should be between 5.5ml and 7.5ml in ~8 seconds. (Any variation between these pumped volumes is corrected when the zero and span _____ calibration is carried out.) Replace the 100mm filter mats in fan and vent housing (see item C4 in the service kit.) Check the operation of the fan. (Note that at temperatures below 25°C, BioTector automatically switches the fan off to stabilize system temperature using its own internal heat.) Clean CO2 analyzer optics by removing the 4x M4x60 Allen bolts on the detector section. If necessary, clean both lenses, which are located on the detector and the source section of the CO2 Analyzer using the Lens Tissue (see item C5 in the service kits). Replace O-ring with the 72-0325-30 O-ring provided (see item C6 in the service kit). Oxygen Purity Test: Power up the system for at least 10 minutes before the oxygen purity test is carried out. Using the Simulate menu (see Section 8.1.2 Simulate) set the MFC (see figure 2 and table 2 in Section 4.1.1 Analysis Enclosure) flow to 10 l/h and flow oxygen gas through the CO2 analyzer for 5 minutes. At the end of this period, the CO 2 analyzer zero reading (ppm CO2) should be within ±0.5% of full scale of the CO2 analyzer range. For instance, if the CO2 analyzer range is 10000ppm, then the CO2 analyzer zero reading should be typically within ±50ppm. _____ _____ _____ _____ (If the CO2 analyzer zero reading is outside the specifications, confirm that there is no CO 2 in the oxygen gas by connecting the CO2 filter “used with the base container” between the Cooler and CO2 analyzer inlet port and set the MFC to 10 l/h. As the size of the CO 2 filter is small, keep the 10 l/h gas flow running for at least for 5 minutes and record the CO2 zero readings at the end of the 5 minute period. If the CO2 zero readings do not drop significantly with the CO2 filter in place, this will indicate that there is no CO2 contamination in the oxygen supply.) Page 152 Warning! A torque screwdriver calibrated to 1.2 Nm (120 Ncm) is required for the correct service of the Mixer Reactor. It is strongly recommended not to proceed with the Mixer Reactor service procedures without a torque screwdriver. Tools Required – Torque Screwdriver with Torx 20 bit. An adjustable torque screwdriver can be obtained from a local supplier. Example specifications and suppliers of the torque screwdriver are as follows: Lindstrom adjustable torque driver, 40-200Ncm Stanley Supply & Services, Inc. http://www.stanleysupplyservices.com/product-detail.aspx?pn=419-704 RS Components Ltd. http://uk.rs-online.com/web/p/torque-drivers/3851794/ Remove the screws on the front of the Mixer Reactor and remove the reactor motor at the back. Hold the reactor diaphragm carefully using both hands and turn the diaphragm anticlockwise to unscrew. It is recommended to count the number of turns by putting a small mark on the diaphragm during this process. Using both hands screw in the new diaphragm (see item C7 in the service kit) and tighten it firmly. The typical minimum number of turns to tighten the diaphragm is from 7 to 8.5 turns. If a minimum number of 7 turns, or the number of turns counted above when the old diaphragm was removed, is not achieved, the diaphragm must be removed and reinstalled. Push the edge of the diaphragm down firmly into place. When the installation of the diaphragm is complete, confirm that the diaphragm forms a “concave” shape at the center. In other words, when the diaphragm is installed correctly, the diaphragm should curve in forming a dent at the center. If such dent has not formed, unscrew the diaphragm, confirm that the diaphragm is installed correctly and if necessary tighten the diaphragm more with additional turns. Install the reactor motor back onto the Mixer Reactor and tighten the screws. The torque of the screws should not exceed 1.2 Nm (120 Ncm). _____ Confirm that the temperature of the ozone destructor has dropped to ambient temperature level. Open the ozone destructor. The ozone destructor should never be opened when it is hot as the threads may seize. Confirm that the PTFE filters (discs) in the ozone destructor are clean. If there is any material build up (e.g. white powder), wash the filters using DIW (or tap water) and dry. Do not use compressed air or any gas to clean the filters. _____ Replace the catalyst and glass wool in the ozone destructor (see item C8 in the service kit). _____ Replace the o-ring in the Ozone Destructor (see item C6 in the service kit). _____ Reconnect power to ozone destructor heater. _____ Using the Simulate menu (see Section 8.1.2 Simulate for details) and referring to figure 1 and table 2 in Section 4.1.1 Analysis Enclosure, activate OZONE GENERATOR and confirm that the Ozone Generator is working and current displayed on screen is 1.00 Amp (±0.05 Amp). The normal warm running current should not exceed 1.1 Amp. If necessary adjust the current using the Ozone Generator Current Adjustment Potentiometer located on the Ozone Generator. _____ Remove the tapes, which are used to seal the ends of the supplied CO 2 filter (see item C9 in the service kit). Replace the CO2 filter on the Base reagent container. Seal the Base container tightly. _____ Isolate the air supply to the analyzer. Go to Simulate menu and set MFC to 60 l/h and run the oxygen supply until the flow drops to 0 l/h (until the oxygen tank is empty). Install the new Hepa Filter (see item C10 in the service kit) carefully without contaminating the open tubing. Turn the air supply on. _____ Page 153 Check the air supply pressure. The set point pressure should be 1.5 bar. When the oxygen concentrator is running, the pressure typically cycles from 1.5 bar to 0.9 bar. Check the O2 PRESSURE SENSOR reading looking at the O2-Controller Status menu. The pressure should be 400 mbar (±10 mbar) at 20 l/h MFC flow. See Section 8.1.6 Oxygen Controller Status for details. _____ Using the Simulate menu (see Section 8.1.2 Simulate for details), check the operation of the Mass Flow Controller (MFC) and confirm that the MFC is working at various flow set points. _____ Check the BioTector for any gas/liquid leaks by running the PRESSURE TEST cycle using the Process Test menu (see Section 8.1.1.1 Pressure Test for details). Check the gas flow in the system by running the EXHAUST TEST and SAMPLE OUT TEST in Process Test, Flow Test menu (see Section 8.1.1.2 Flow Test for details). _____ Confirm all signals (4-20mA and volt free contacts) are signaling correctly to the external control device. _____ If necessary, go to Operation, Time & Date menu and adjust the time and the date. When the system service is completed, go to Diagnostics, Service menu and select RESET SERVICE COUNTER function (see Section 8.1.7 Service for details). _____ Carry out an “Install New Reagents” cycle using the Install New Reagents menu (see Section 2.2.2.1 Install New Reagents for details). Confirm that the zero readings obtained during the Zero Calibration cycle are stable. (If the reagent lines do not fill during the Install New Reagents cycle, stop the BioTector to prime the pumps manually. Remove the dip tubes from the reagent containers, and seal the containers. Place the dip tubes into a small container containing DIW. If DIW is not available use tap water. Raise the container above the height of the BioTector. Go to Zero Calibration menu and select RUN REAGENTS PURGE function to prime the pumps. Once the pumps have been primed, reinstall the dip tubes into the reagent containers and repeat the Install New Reagents cycle.) When the Mixer Reactor is serviced, there is a possibility of contamination, which may create an unacceptable TOC offset. If the TOC readings obtained during the zero calibration cycle are higher than expected, a service zero calibration cycle can be initiated using the SET SERVICE ZERO function in Service menu, while the BioTector is running. When initiated, BioTector automatically runs a total of 5 zero calibration cycles during the following 100 online measurements and automatically adjusts the zero offset values to compensate for the removal of the contamination. It will therefore not be necessary to revisit the BioTector after the service or to repeat the zero calibration cycle. See Section 8.1.7 Service for further details. _____ _____ Program the concentration of the available standard solution in the Span Calibration menu. (See procedures described in Section 6.2 Calibration Standards to prepare a standard solution and see Section 2.3.2 Span Calibration for details.) Connect the standard solution to the MANUAL/CALIBRATION port. If these ports are not available, use the SAMPLE 1 port. It is recommended that the standard solution is located at the same height as the sample chamber. The tubing length between the standard solution and the BioTector MANUAL/CALIBRATION port should be between 2 and 2.5 meters. 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. In systems using multiple operation ranges, it is recommended to carry out a Span Check cycle at each operation range and if necessary to adjust the span factor manually using the Span Calibration menu. Span Calibration cycle should be carried out only when stable zero readings are obtained after a Zero Calibration cycle completed without any warnings. _____ _____ Page 154 Section 11 System Replacement and Spare Parts Page 155 BioTector Parts and Spare Parts Part Number and Description Part Number and Description 20-B5C-010 19-PCB-050 B5C Oxygen Concentrator Rebuild Module B5C Motherboard 20-B5C-013 20-PCB-036 B5C PSU Module B5C Oxygen Controller Board 20-PCB-038 19-MAX-008 B5C Termination Board B5C Sample Pump 20-B5C-019 20-B5C-020 B5C Acid Pump B5C Base Pump 10-KNF-008 19-B5C-024 NF300 PTFE Diaphragm B5C Mixer Reactor Motor, 24V DC 19-B5C-023 19-B5C-009 B5C Mixer Reactor complete with 24V DC Motor B5C Mixer Reactor Page 156 Part Number and Description Part Number and Description 19-B5C-014 19-B5C-015 B5C Type 6606 N/O Valve B5C Type 6606 N/C Valve 19-B5C-016 19-B5C-017 B5C Pinch Valve N/O B5C Pinch Valve C/O 20-B5C-011 20-CO2-008 B5C Oxygen Concentrator Rotary Valve B5C CO2 Analyzer 20-B5C-025 19-PCB-034 B5C Ozone Generator Module B5C Ozone Board 10-SMC-001 12-SMC-001 B5C Instrument Air Filter Pack B5C Instrument Air Filter Pack Elements 19-KIT-123 19-B5C-026 B5C 6 Month Service Kit B5C Cooler Kit 19-BS5-001 19-BS5-002 B5C Acid Dip Tube B5C Base Dip Tube Page 157 Section 12 General Information 12.1 Declaration of Conformity and Certification Declaration of Conformity Manufacturer: BioTector Analytical Systems Ltd. Address: Raffeen House, Ringaskiddy, Co. Cork, Ireland. Declares that the following models:  BioTector System-C  BioTector B3500C are in conformity with the following directives: EMC Directive Machinery Directive Pressure Equipment Directive 2004/108/EC 2006/42/EC 97/23/EC Conformity to the Essential Health and Safety Requirements for Machinery contained in the Machinery Directive 2006/42/EC, Annex I is assessed under EN61010-1. EN 61000-6-2: 2005 EN 61000-6-4:2007 EN-61010-1:2001 Martin Horan Managing Director BioTector Analytical Systems Ltd. 21 November 2012. Page 158 12.2 Declaration of Compliance Declaration of Compliance Manufacturer: BioTector Analytical Systems Ltd. Address: Raffeen House, Ringaskiddy, Co. Cork, Ireland. Declares that the BioTector TOC Analyzer is in compliance with the following European/Irish Standard: I.S. EN 1484:1998 Water Analysis – Guidelines for the Determination of Total Organic Carbon (TOC) and Dissolved Organic Carbon (DOC) Martin Horan Managing Director BioTector Analytical Systems Ltd. 27 March 2010. Page 159 12.3 Warranty and Exclusions Coverage of BioTector Warranty The BioTector comes with a standard 1 year warranty for agreed applications. The BioTector warranty is against manufacturing defects only. The warranty does not cover service/consumable items and consequential damage. Validity of Warranty th For the warranty to be valid, regular 6 Month servicing must be carried out using the Service Kit supplied by the manufacturer. The recommendations on Maintenance and Service given in the manual should, as a general rule, be followed. However, service needs will vary from site to site and difficult applications may require additional service checks and/or service items not normally supplied with the BioTector Service Kit. Exclusions The following standard service items are not covered under the BioTector warranty:  EMPP tubing  Peristaltic pumps if the lifetime of the DC motor has been exceeded.  PP Y connectors  Filter mats in fan and vent housing  Viton tubing in ozone generator  Catalyst in ozone destructor  CO2 filter  Reactor Valve  Exhaust Valve  Diaphragm in Mixer Reactor  50 micron filters used in acid and base reagents Limitations The manufacturer liability with respect to certain moving parts (e.g. peristaltic pumps, rotary valve, sample valve) will be limited to the manufacturer's specified lifetimes. Agreed Applications It is important that the Pre-Installation Questionnaire be filled in for each new application as the manufacturer cannot guarantee the BioTector without knowing what chemicals/substances it is being exposed to. Procedure for Warranty Repair/Replacement Prior to returning any item under warranty, a Returned Merchandise Authorization (R.M.A.) number must first be requested from the manufacturer. The R.M.A. number must be quoted on all correspondence. Shipping Costs The cost of transporting the parts to be repaired or replaced under warranty from the end-user to the manufacturer shall be borne by the end-user. The transport costs from the manufacturer back to the distributor shall be borne by the manufacturer. Method of delivery shall be at the sender’s discretion. The manufacturer will use the lowest cost service (including regular post) available. If the distributor requires goods returned on an urgent basis, the distributor may nominate his preferred means of transport but shall then be liable for shipping costs. BioTector Software BioTector analyzers operate using BioTector proprietary software “BioTector OS3” (BioTector Operating System 3). This software and all associated copyright is the sole property of BioTector Analytical Systems Ltd. Purchase of the BioTector analyzer licenses the user to use the BioTector OS3 software as configured and for the purpose of operating the BioTector during the life of the analyzer. Page 160 Section 13 Appendices Appendix 1 Glossary of Terms and Abbreviations --4-20mA CHNG A A1 – A3 ALLDAT Amp ATM BOD C-276 CAL MUX CAL SIGNAL CAL CE CNFG CO2 CO2p CO2z COD CSA CTFE DegC DIAG DIN DIW EMPP EN ETL F FARCH FFKM FKM FRP H H2SO4 HCl HDPE HS Hz ID kPa L l/h M M1 – M3 mA MAINT SIGNAL MAN MODE TRIG mbar MCB MCR mg No function is programmed 4-20mA Change signal Amperes 24 hours average for stream 1 – 3 All Data Amperes Atmospheric pressure Biochemical Oxygen Demand Hastelloy Calibration multiplexer Calibration signal Calibration reactions European Conformity (Conformité Européene) Configuration Carbon dioxide CO2 peak CO2 analyzer zero Chemical Oxygen Demand Cross Sectional Area Chloro-tri-fluoro-ethylene Degrees Celsius (°C) Diagnostics German Institute for Standardization (Deutsches Institut für Normung e.V.) Deionized Water Elastomer-modified-poly-propylene European Norm Electrical Testing Laboratories Fuse Fault Archive Kalrez, perfluoro-elastomer Viton, fluoro-elastomer Fiberglass Reinforced Polyester High Interrupt Sulphuric acid Hydrochloric acid High Density Poly-Ethylene High Speed Hertz Internal Diameter, Identification Kilo Pascal Liters / Low Interrupt Liters per hour Molar Manual stream 1 - 3 Milli-amperes Maintenance signal Manual Mode Trigger Millibar Miniature Circuit Breaker Multi-Component Reactor milligram Page 161 ml ml/min MMC/SD N N/A N/D N/E NaOH NBR NDIR NOTE NPOC O2 O3 OD OS3 PCB PEEK PFA POC PP ppb ppm PTFE PVC PVDF RARCH RS RW S S1 – S3 SC SK SM SMPL sparge SS-316 STD STM ALARM SYNC T TC TCmgC/l TIC TICmgc TICmgC/l TICmgu TOC TOCmgc TOCmgC/l TOCmgu V VOC VOCmgC/l W Z ZC Milliliter Milliliters per minute Multi Media Card/Secure Digital Card Normal Not Applicable Normally de-energized Normally Energized Sodium Hydroxide Nitrile Butadiene Rubber Nondispersive Infrared Notification Non-purgeable Organic Carbon Oxygen Ozone Outside Diameter Operating System 3 Printed Circuit Board Poly-ether-ether-ketone Per-fluoro-alkoxy Purgeable Organic Carbon Poly-propylene Parts per billion (g/l) Parts per million (mg/l) Poly-tetra-fluoro-ethylene Poly-vinyl-chloride Poly-vinylidene-flouride Reaction Archive Remote standby reaction Reactor wash reaction Span Stream 1 - 3 Span calibration Span check Manually input span adjust Sample Removal of a chemical by purging a gas through a liquid Stainless Steel 316 Standard Stream alarm Synchronization Time Lag (Time Delay) Total Carbon Total Carbon value in mgC/l Total Inorganic Carbon Calibrated Total Inorganic Carbon value in mgC/l Total Inorganic Carbon value in mgC/l Un-calibrated Total Inorganic Carbon value in mgC/l Total Organic Carbon Calibrated Total Organic Carbon value in mgC/l Total Organic Carbon value in mgC/l Un-calibrated, atmospheric pressure uncompensated TOC in mgC/l Volts Volatile Organic Carbon Volatile Organic Carbon value in mgC/l Watts Zero Zero calibration Page 162 ZK ZM ZS Zero check Manually input zero adjust Zero and Span Page 163 Appendix 2 Contact Information HACH Company World Headquarters Repair Service in the United States: P.O. Box 389 Loveland, Colorado 80539-0389 U.S.A. Tel (800) 227-HACH (800) -227-4224 (U.S.A. only) Fax (970) 669-2932 orders@hach.com www.hach.com HACH Company Ames Service 100 Dayton Avenue Ames, Iowa 50010 Tel (800) 227-4224 (U.S.A. only) Fax (515) 232-3835 Hach Sales & Service Canada Ltd. 1313 Border Street, Unit 34 Winnipeg, Manitoba R3H 0X4 Tel (800) 665-7635 (Canada only) Tel (204) 632-5598 Fax (204) 694-5134 canada@hach.com HACH LANGE GMBH HACH LANGE LTD HACH LANGE LTD Willstätterstraße 11 D-40549 Düsseldorf Tel. +49 (0)2 11 52 88-320 Fax +49 (0)2 11 52 88-210 info@hach-lange.de www.hach-lange.de Pacific Way Salford GB-Manchester, M50 1DL Tel. +44 (0)161 872 14 87 Fax +44 (0)161 848 73 24 info@hach-lange.co.uk www.hach-lange.co.uk Unit 1, Chestnut Road Western Industrial Estate IRL-Dublin 12 Tel. +353(0)1 46 02 5 22 Fax +353(0)1 4 50 93 37 info@hach-lange.ie www.hach-lange.ie Hütteldorferstr. 299/Top 6 A-1140 Wien Tel. +43 (0)1 9 12 16 92 Fax +43 (0)1 9 12 16 92-99 info@hach-lange.at www.hach-lange.at HACH LANGE HACH LANGE FRANCE S.A.S. HACH LANGE SA DR. LANGE NEDERLAND B.V. Rorschacherstrasse 30 a CH-9424 Rheineck Tel. +41 (0)71 886 91 11 Fax +41 (0)71 886 91 66 info@hach-lange.ch www.hach-lange.ch 8, mail Barthélémy Thimonnier Lognes F-77437 Marne-La-Vallée cedex 2 Tél. +33 (0)8 20 20 14 14 Fax +33 (0)1 69 67 34 99 info@hach-lange.fr www.hach-lange.fr Repair Service in Canada: Motstraat 54 B-2800 Mechelen Tél. +32 (0)15 42 35 00 Fax +32 (0)15 41 61 20 info@hach-lange.be www.hach-lange.be HACH LANGE S.R.L. Repair Service in Latin America, the Caribbean, the Far East, Indian Subcontinent, Africa, Europe, or the Middle East: Hach Company World Headquarters, P.O. Box 389 Loveland, Colorado, 80539-0389 U.S.A. Tel +001 (970) 669-3050 Fax +001 (970) 669-2932 intl@hach.com HACH LANGE GMBH Laan van Westroijen 2a NL-4003 AZ Tiel Tel. +31(0)344 63 11 30 Fax +31(0)344 63 11 50 info@hach-lange.nl www.hach-lange.nl HACH LANGE S.L.U. HACH LANGE APS HACH LANGE AB Åkandevej 21 DK-2700 Brønshøj Tel. +45 36 77 29 11 Fax +45 36 77 49 11 info@hach-lange.dk www.hach-lange.dk Vinthundsvägen 159A SE-128 62 Sköndal Tel. +46 (0)8 7 98 05 00 Fax +46 (0)8 7 98 05 30 info@hach-lange.se www.hach-lange.se Via Riccione, 14 I-20156 Milano Tel. +39 02 39 23 14-1 Fax +39 02 39 23 14-39 info@hach-lange.it www.hach-lange.it Edif. Arteaga Centrum C/Larrauri, 1C- 2ª Pl. E-48160 Derio/Vizcaya Tel. +34 94 657 33 88 Fax +34 94 657 33 97 info@hach-lange.es www.hach-lange.es HACH LANGE LDA HACH LANGE SP.ZO.O. HACH LANGE S.R.O. HACH LANGE S.R.O. Av. do Forte nº8 Fracção M P-2790-072 Carnaxide Tel. +351 214 253 420 Fax +351 214 253 429 info@hach-lange.pt www.hach-lange.pt ul. 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