ELTRA ELEMENTRAC CS-i User manual

© Eltra GmbH, 42781 Haan, Retsch-Allee 1-5, Germany | 10.12.2020 Version 0005
Operating Manual
ELEMENTRAC CS-i
Translation

Information about the Manual
2
Urheberrecht
© Copyright by
Eltra GmbH
Retsch-Allee 1-5
42781 Haan
Germany

Information about the Manual
3

Information about the Manual
4
Table of contents
1Information about the Manual.............................................................................................................. 6
1.1 Explanation of signs and symbols ..................................................................................................... 6
1.2 Disclaimer.......................................................................................................................................... 6
1.3 Copyright............................................................................................................................................ 6
2Safety...................................................................................................................................................... 7
2.1 Explanation of the safety instructions................................................................................................ 8
2.2 General safety instructions ................................................................................................................ 9
2.3 Repairs............................................................................................................................................. 10
2.4 Intended use.................................................................................................................................... 10
2.5 Improper use.................................................................................................................................... 10
2.6 Safety symbols on the machine....................................................................................................... 11
2.7 Emergency stop............................................................................................................................... 12
2.8 Residual risks................................................................................................................................... 12
3Description........................................................................................................................................... 18
3.1 Front................................................................................................................................................. 18
3.2 Back of the analyzer ........................................................................................................................ 19
4Installation............................................................................................................................................ 21
4.1 Setting up......................................................................................................................................... 22
4.2 Filling the reagent tubes .................................................................................................................. 23
4.3 Establishing the gas supply ............................................................................................................. 23
4.4Connecting the machine to the PC.................................................................................................. 24
4.5 Establishing the power supply......................................................................................................... 24
5Commissioning.................................................................................................................................... 25
6Operation of the analyzer ................................................................................................................... 26
7Technical data...................................................................................................................................... 29
7.1 Technical data for the analyzer........................................................................................................ 29
7.2 Type plate on the analyzer .............................................................................................................. 30
7.3Standards for inorganic materials.................................................................................................... 31
8Troubleshooting on the analyzer....................................................................................................... 32
8.1 Troubleshooting on the analyzer. .................................................................................................... 32
9Cleaning ............................................................................................................................................... 32
10 Maintenance......................................................................................................................................... 33
10.1 Maintenance the analyzer................................................................................................................ 33
10.1.1 Overview of maintenance work for the analyzer...................................................................... 33
10.1.2 Removing the reagent tubes.................................................................................................... 34
10.1.3 Filling reagent tubes ................................................................................................................ 37
10.1.3.1 Filling the reagent tube on the SO3 filter.......................................................................... 38
10.1.3.2 Filling the reagent tube on the inlet gas purification ........................................................ 39
10.1.3.3 Filling the reagent tube on the moisture filter .................................................................. 40
10.1.4 Inserting reagent tubes............................................................................................................ 41
10.1.5 Replacing the dust filter cartridge on the analyzer .................................................................. 43
10.1.6 Filling the reagent tube on the catalyst furnace....................................................................... 44
10.1.7 Cleaning the dust box.............................................................................................................. 47
10.1.7.1 Quick cleaning of the dust box......................................................................................... 48
10.1.7.2 Thorough cleaning of the dust box .................................................................................. 49
10.1.8 Maintenance in the furnace area............................................................................................. 50
10.1.8.1 Replacing the furnace cleaning brush and thermal shield............................................... 50
10.1.8.2 Replacing the combustion tube ....................................................................................... 54
10.1.8.3 Removing the crucible tray .............................................................................................. 56
10.1.9 Replacing the O-rings.............................................................................................................. 57

Information about the Manual
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10.1.9.1 Replacing the O-ring at the top of the combustion tube .................................................. 57
10.1.9.2 Replacing the O-rings at the bottom and in the bottom furnace locking device.............. 58
10.1.9.3 Replacing the O-rings on the furnace seal ...................................................................... 60
10.1.10 Cleaning the connecting hose between the furnace and metal filter....................................... 62
11 Spare parts........................................................................................................................................... 63
11.1 Spare parts for the analyzer ............................................................................................................ 63
11.1.1 Front of the machine................................................................................................................ 63
11.1.2 Front (interior view).................................................................................................................. 64
11.1.2.1 Catalyst furnace............................................................................................................... 66
11.1.2.2 Complete dust filter housing with heating element.......................................................... 67
11.1.2.3 Complete dust filter.......................................................................................................... 68
11.1.3 Furnace.................................................................................................................................... 69
11.1.4 Furnace cleaning mechanism.................................................................................................. 72
11.1.5 Back of the machine ................................................................................................................ 73
11.1.6 Left-hand side of the machine ................................................................................................. 74
11.1.6.1 Left side, Dev Gate.......................................................................................................... 75
11.1.6.2 Valve block, compressed air control system ................................................................... 76
11.1.7 Top mounting plate.................................................................................................................. 78
11.2 Gas purification furnace, optional.................................................................................................... 80
11.3 Fuses............................................................................................................................................... 81
11.4 Consumables................................................................................................................................... 81
12 Decommissioning................................................................................................................................ 82
13 Storage ................................................................................................................................................. 82
14 Disposal................................................................................................................................................ 83
15 Index ..................................................................................................................................................... 84

Information about the Manual
6
1 Information about the Manual
This Manual provides technical guidelines on the safe operation of the machine. Read the
Manual through carefully prior to installing, commissioning and operating the machine. Reading
and understanding this Manual is a requirement for the safe and correct use of the machine.
This Manual does not contain any repair instructions . Please contact your supplier or Eltra
GmbH directly in the event of any queries or questions concerning this Manual or the machine,
or in the case of any faults or necessary repairs.
Further information about your machine can be found at http://www.eltra.com/de on the pages
relating specifically to the machine.
Revision status
Document revision 0005 of the "ELEMENTRAC CS-i" Manual has been prepared in accordance
with the Machinery Directive 2006/42/EC.
1.1 Explanation of signs and symbols
The following signs and symbols are used in this Manual:
Sign
Meaning
Additional or further information is
shown here.
Further or additional information.
1. First instruction.
2. Next instruction.
Result.
Numbered paragraphs contain a series of
instructions. An instruction can end with a result.
Tab 1: Signs and symbols used
1.2 Disclaimer
Diev orliegende Bedi enungsanleitung wurd ewi th größter Sorgfalt ers tellt. Technisch eÄn derungen sind vorbe halten.F ür Personensc häden, die aus der Nichtb efolgung der Sich erheits- and Warnhinweis ei ndi eser Bedienungs anleitung resultiere n, wirdk eine Haftung übernommen. Für Sachsc häden, die aus der Nichtb efolgung der Hinweis ei n dieser Bedienungs anleitung resultieren, wir dk eine Haftung übernommen.
This Manual has been produced with the greatest care. We reserve the right to make technical
modifications. We shall accept no liability for any personal injuries resulting from the failure to
comply with the safety information and warnings in this Manual. We shall accept no liability for
damage to property resulting from the failure to comply with the instructions in this Manual.
1.3 Copyright
This Manual or parts of it may not be duplicated, distributed, edited or copied in any form
without the prior written consent of Eltra GmbH. Damage claims will be asserted in the event of
infringement.

Safety
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2 Safety
Safety officer
The operating company itself must ensure that persons authorised to work on the machine
comply with the following points:
−they have noted and understood all regulations regarding the area of safety;
−they are aware before they start work of all instructions and regulations relating to their
target group;
−they have easy access to the Manual for this machine at all times;
−they have been familiarised with the safe and correct handling of the machine before
starting work on it, either by means of a verbal introduction by a competent person
and/or with the help of this Manual.
Incorrect operation may lead to personal injuries. The operating company itself is
responsible for its safety and that of its staff. The operating company itself must ensure that no
unauthorised personnel have access to the machine.
Target group
This covers everybody who operates, cleans or works on the machine.
This machine is a modern, efficient, state-of-the-art product from Eltra GmbH. Reliability is
guaranteed when it is used correctly and when this Manual is complied with.
Persons under the influence of intoxicating substances (medications, drugs, alcohol) or who
are overtired are not allowed to operate or work on the machine.

Safety
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2.1 Explanation of the safety instructions
The following warnings in this Manual alert to potential hazards and damage:
DANGER
D1.0000
Risk of fatal injuries
Source of the danger
−Possible consequences of failure to heed the danger.
•Instructions and advice on how to avoid the risk.
Fatal or serious injuries may ensue if the “Danger” warnings “ are not complied with. There is
a very high risk of a life-threatening accident or lasting personal injury. The signal word
DANGER is also used in the running text or instructions
WARNING
W1.0000
Risk of life-threatening or serious injuries
Source of the danger
−Possible consequences of failure to heed the risk.
•Instructions and advice on how to avoid the risk.
Life-threatening or serious injuries may ensue if the “Warning“ signs are not complied with.
There is an increased risk of a serious accident or potentially fatal injury. The signal word
WARNING is also used in the running text or instructions.
CAUTION
C1.0000
Risk of injuries
Source of the danger
−Possible consequences of failure to heed the risk.
•Instructions and advice on how to avoid the risk.
Moderate or minor injuries may ensue if the “Caution” warnings are not complied with. There
is a moderate or slight risk of an accident or personal injury. The signal word CAUTION is
also used in the running text or instructions.
NOTICE
N1.0000
Nature of the damage to equipment
Source of the damage to equipment
−Possible consequences of failure to comply with the warnings.
•Instructions and advice on how to avoid the damage to equipment.
Damage to equipment may ensue if the notice is not complied with. The signal word NOTICE
is also used in the running text or instructions.

Safety
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2.2 General safety instructions
CAUTION
C2.0002
Risk of injury
Unfamiliarity with the Manual
−The Manual contains all safety-related information. Failure to comply
with the Manual can therefore lead to injuries.
•Read the Manual carefully before using the machine.
CAUTION
C3.0015
Risk of injury
Improper modifications to the machine
−Improper modifications to the machine can lead to injuries.
•Do not make any unauthorised changes to the machine.
•Only use spare parts and accessories that have been approved by
Eltra GmbH.
NOTICE
N2.0012
Changes to the machine
Improper modification
−As a result of improper modification, the conformity with European
directives as specified by Eltra GmbH will no longer be valid. All warranty
claims will be invalidated.
•Do not make any modifications to the machine.
•Only use spare parts and accessories that have been approved by
Eltra GmbH.

Safety
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2.3 Repairs
This Manual does not contain any repair instructions. For reasons of safety, repairs may only
be carried out by Eltra GmbH, by an authorised agency, or by qualified service technicians.
Please notify the following in the event of a repair …
…the agent representing Eltra GmbH in your country;
…your supplier; or
…Eltra GmbH directly.
Service address :
Eltra GmbH
Retsch-Allee 1-5
42781 Haan
Germany
[phone]
[email protected]
www.eltra.com
2.4 Intended use
The ELEMENTRAC CS-i has been developed for the analysis of carbon and sulphur in various
materials. The induction furnace permits the analysis of typically inorganic materials such as
metals, alloys, ceramics and cement.
2.5 Improper use
Use is prohibited in the private domain and for purposes other than those set out in the
“Intended use”chapter. Repairs and modifications may only be carried out by Eltra GmbH, by
an authorized agency, or by qualified service technicians.

Safety
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2.6 Safety symbols on the machine
Safety symbols on the ELEMENTRAC CS-i provide warnings about risks when using the
machine.
The following safety symbols can be found on the analyzer:
Fig. 1: Safety symbols on the analyzer
Position
Component
Description
1
The warning signs at the top on the back
and on the right-hand side warn that the
covers may only be opened by qualified
personnel.
2
3
The warning signs on the furnace opening
warn of a risk of burns and crushing on
fingers or hands.
4
5
The warning sign on the dust filter housing
warns of burns.
2
1
4
5
3

Safety
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2.7 Emergency stop
An emergency stop is initiated using the relevant main switch on the machines.
Turn the analyzer off in an emergency as follows:
1. Turn the main switch on the analyzer to Position 0.
2.8 Residual risks
DANGER
D2.0000
Risk to life caused by an electric shock
Exposed power contacts
−Contact with exposed power contacts can cause life-threatening injuries
or death.
•Turn the main switch to Position 0 and pull out the power plug prior
to maintenance work on the analyzer.
WARNING
W2.0015
Risk to life caused by an electric shock
Connection to a socket without protective conductor
−Connecting the machine to sockets without protective conductor can lead
to life-threatening injuries caused by an electric shock.
•Only operate the machine on sockets with a protective conductor
(PE).
WARNING
W3.0002
Risk to life caused by an electric shock
Damaged mains lead
−Operating the machine with a damaged mains lead or plug can result in
life-threatening injuries caused by an electric shock.
•Check the mains lead and plug for damage before operating the
machine.
•Never operate the machine with a damaged mains lead or plug!

Safety
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WARNING
W4.0000
Risk to life caused by an electric shock
Uninsulated part of the sample insertion tool
−The metal part of the sample insertion tool is not insulated. Contact with
the metal part of the sample insertion tool when inserting it into the
furnace can result in an electric shock and cause serious or life-
threatening injuries.
•Never grasp the sample insertion tool by the metal part when
inserting the tool into the furnace.
•Only ever grasp the sample insertion tool by the plastic handle when
inserting it into the furnace.
WARNING
W5.0017
Risk of injury
Dangerous chemicals
−Dangerous chemicals can cause fatal poisoning or serious chemical burns
to the skin when working on the machine.
•Comply with the safety data sheet for the substances used.
•Wear personal protective equipment.
•Never eat or drink near chemicals.
WARNING
W6.0022
Chemical burns to skin, eyes and mucous membranes
Caustic substances
−Acids can cause chemical burns to skin, eyes and mucous membranes.
•Comply with the safety data sheet for the acids used.
•Always wear suitable work clothing including protective gloves and
eyewear.

Safety
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WARNING
W7.0021
Risk of fire / burns
Hot parts (crucibles, reagents etc.) can fall down
−Hot parts may fall onto benches, floors or other surfaces and catch fire.
−Clothing and other materials may catch fire.
•Erect the analyzer in a fireproof environment. Pay special attention
to the bench, the floor and other surfaces close to the analyzer.
•Always wear suitable work clothes.
•Keep the work environment free from all materials that could catch
fire.
WARNING
W8.0000
Risk of poisoning
Toxic combustion gases
−Samples are exposed to high temperatures during the analysis. Harmful
gaseous fission products can be released or formed from reaction
processes here. These gases can escape from the gas outlet and cause
serious poisoning.
•Connect the exhaust air outlet on the machine to a suitable
ventilation system.
•Wear your personal protective equipment.
•Comply with the safety data sheet for the substances used.
•Carry out a risk analysis on the potential hazards of your samples
and implement protective measures.
WARNING
W9.0000
Risk of life-threatening injuries
Falling loads
−The analyzer may only be transported or lifted using suitable lifting gear
such as a forklift or crane. Loads can fall down causing life-threatening
injuries.
•Only lift and transport the analyzer with the help of suitable lifting
gear such as a forklift or crane.
•Secure the analyzer with suitable safety belts (supplied straps)
during transport.
•Pay attention to the centre of gravity of the analyzer (on the right-
hand side of the machine).
•Keep a safe distance from the machine while transporting it.
•Never step underneath raised loads.

Safety
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CAUTION
C4.0000
Risk of injuries
Moving parts
−The furnace closes automatically. Hands in the area of the opening can
get crushed when the furnace closes.
•Never reach into the closing furnace.
•Uses crucible tongs when positioning ceramic crucibles.
CAUTION
C5.0092
Machine falling down
Incorrect installation or insufficient working space
–Due to its weight, the machine can cause injuries if it falls down.
•Only operate the machine in a sufficiently large, robust, non-slip and
stable working area.
•Ensure that all machine bases are placed securely on the surface.
CAUTION
C6.0000
Risk of cuts
Glass splinters
−Sample vials and reagent tubes are made of glass and can break. Glass
splinters can cause cuts.
•Inspect reagent tubes and sample vials for damage prior to use.
•Wear protective gloves and goggles when handling reagent tubes
and sample vials.
•Replace damaged reagent tubes and sample vials.
•Do not touch glass splinters with unprotected hands.
CAUTION
C7.0000
Risk of burns
Hot machine parts
−Parts of the machine can get very hot and cause burns during
maintenance work if the waiting time to ensure cooling is not complied
with.
•Before maintenance work, wait until the temperature of the furnace
is < 40 °C.
•Check the furnace temperature in the ELEMENTS software.

Safety
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CAUTION
C8.0076
Risk of burns
Hot machine parts
−Some parts of the machine can get very hot and cause burns when
touched without wearing protective gloves.
•Wear heat-resistant protective gloves when working with hot
machine parts.
•Never touch hot parts of the machine without suitable protective
gloves.
CAUTION
C9.0096
Risk of eye injury
Very bright combustion tube
−The combustion tube shines very brightly when it is hot and can cause
eye injuries if you look directly into the furnace due to visible light and
invisible infrared light.
•Wear suitable goggles when working on the furnace.
•To protect your eyes, slide the glass guard in front of the furnace
entrance.
•Never look directly into the furnace.
CAUTION
C10.0093a
Risk of burns
Hot sample carriers
−The sample carrier may be very hot after the analysis and can cause fires
and therefore injuries if in contact with flammable surfaces.
•Always use suitable crucible tongs to transport used crucibles and
dishes.
•Ensure there are no combustible materials beneath the furnace
opening.
•Only open the furnace once the appropriate waiting time has expired.
•Adapt the waiting time in the program where necessary to enable the
sample carrier to cool down sufficiently.

Safety
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CAUTION
C11.0090
Risk of eye injury
Chemicals
−When changing the chemicals, minute particles of chemicals may be
suspended in the air and cause burns to eyes.
•Always wear protective goggles when working with chemicals.
•Comply with the safety data sheets for the chemicals used.
CAUTION
C12.0000
Risk of injury
Pressurised system
−The machine is pressurised during operation. The removal of the reagent
tube during operation results in an explosive escape of chemicals or
sample material and can cause injuries.
•Never remove reagent tubes during operation.
CAUTION
C13.0094
Risk of burns
Hot catalyst furnace
−The furnace temperature of the catalyst furnace can be up to 800 °C
during operation and cause burns.
•Wear heat-resistant protective gloves when working with the catalyst
furnace .
•Only replace the catalyst furnace filling after a sufficiently long
cooling period.

Description
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3 Description
The ELEMENTRAC CS-i is a combustion analyzer. The machine determines the concentration
of carbon and sulphur in inorganic and organic samples through the combustion in the induction
furnace or resistance furnace. The gaseous products of combustion CO2and SO2are
measured by infrared measurement cells.
3.1 Front
The following figure shows the front of the machine:
Fig. 2: Front of the ELEMENTRAC CS-i
Position
Component
Description
1
Analyzer
Analyzer with induction furnace
2
Crucible holder
Holder for ceramic crucibles with sample material
and furnace opening
3
Main switch on the analyzer
Switches the analyzer on and off
4
Analyzer door
Behind the machine door are the paper filter, dust
box, carrier gas preliminary cleaning, particle filter
and moisture filter
5
Feet
The inner feet secure the tether (supplied for
transport).
1
4
2
3
5

Description
19
3.2 Back of the analyzer
The following figure shows the back of the analyzer:
Fig. 3: Back of the analyzer
Position
Component
Description
1
Fan
Fan on the analyzer
2
USB cable (internally already
connected)
Cable for connecting to the PC
3
CAN connector
For connecting to the HTFr
4
USB connector
For connecting to the PC
5
Compressed air inlet
Compressed air connector
6
Gas outlet
For discharging the analysis gas
7
Carrier gas connector
Connector with pressure reducer for the carrier gas
oxygen
8
Inlet for analysis gas from the HTFr
Return of the analysis gas from the HTFr for analysis
9
Connector for carrier gas supply to
the HTFr
Carrier gas supply for the HTFr
10
Connector for vacuum cleaner
Connector for a vacuum cleaner to clean the furnace
after every analysis
11
Power connection
Connector for the machine’s power supply
1
2
3
4
6
7
8
5
9
11
10
13
14
12

Description
20
Position
Component
Description
12
Circuit breaker
Automatic shutting down of the power circuit in the
event of an overload or short circuit
13
Power connection for the vacuum
cleaner
Switched power socket to connect a vacuum cleaner
The vacuum cleaner can be switched on
automatically on opening the furnace after every
analysis.
14
Power connection for equipment
with low output
Socket for connecting equipment with low output
such as a PC and monitor.